description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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CROSS-REFERENCE TO RELATED U.S. APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
[0004] REFERENCE TO AN APPENDIX SUBMITTED ON COMPACT DISC
[0005] Not applicable.
BACKGROUND OF THE INVENTION
[0006] 1. Field of the Invention
[0007] The present invention relates to a method for manufacturing an antibacterial synthetic fiber. More particularly, the present invention relates to an antibacterial synthetic fiber comprising a plant extract, and a method for manufacturing the same.
[0008] 2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98.
[0009] A variety of attempts have been made to provide synthetic fibers with antibacterial activity. Prevalent among them is the inclusion of antibacterial inorganic substances into the synthetic fibers. Barleystone, jade, mica, and silver nanoparticles are representative of such inorganic substances. However, because they interfere with the manufacturing process of fibers, the inorganic substances are used in trace amounts which are not sufficient to guarantee the desired extent of antibacterial activity. Particularly, silver nanoparticles, known for their good antibacterial activity, additionally suffer from the drawback of having a negative influence on the light fastness of fibers following dyeing process, which is likely to cause a color change in the product.
[0010] In addition, conventional antibacterial synthetic fibers, although employing a trace amount of such an inorganic substance, are inferior in physical property to ordinary synthetic fibers.
[0011] In order to overcome these problems, extensive attention has been given to plant extracts or vegetable essential oils having antibacterial activity.
[0012] Exemplary are the disclosure of Korean Patent Nos. 10-0726409 and 10-0515808, which describe the direct coating and fixation of synthetic fibers with antibacterial plant extracts. The synthetic fibers coated with plant extracts do not persistently exhibit antibacterial activity because the extracts bleed out of the fibers upon washing.
[0013] The incorporation of plant extracts or vegetable essential oils into synthetic fibers arose as an alternative to coating, and methods therefor have been continuously studied.
[0014] As disclosed in Korean Patent Laid-Open Publication No. 2000-0058680 to the present inventors, efforts were made to elicit a deodorization effect by absorbing pyroligneous acid (wood vinegar) into porous mineral particles which were then used to prepare master batch chips. However, wood vinegar is viscous so that the mineral particles significantly aggregate when they are mixed with wood vinegar, resulting in plugging the filter of the mast batch facility. In addition, the aqueous liquid causes the degradation of the polymer, thus reducing the viscosity of the polymer. For these different reasons, the use of wood vinegar made it impossible to prepare master batch chips.
[0015] In the presence of water, mineral particles aggregate and once this aggregation of mineral particles has begun, it is fundamentally impossible to prevent. After a drying process, the aggregated mineral particles appear as solidified lumps which cannot be used in the manufacture of synthetic fibers. To be used, the aggregated mineral particles should be finely pulverized to the desired particle size, which may be achieved by repeating the milling process over time in, for example, a pin mill or a jet mill, followed by disintegration to prevent re-aggregation.
[0016] Although the mineral particles can be used after fine pulverization and disintegration, these processes are too expensive and increase the production cost.
[0017] Moreover, the fibers, even though obtained after the above-mentioned complex processes, still have the problem of having inferior physical properties because mineral substances act as a negative factor on physical properties as stated above.
[0018] Typical melting points for synthetic fibers are on the order of 200˜300° C. at which plant extracts or vegetable oils, if used in advance of melt spinning, may undergo evaporation, degradation and/or denaturation and thus cannot be incorporated into fibers or will not exhibit sufficient functionally even if incorporated.
[0019] In an effort to solve this problem, Korean Patent No. 10-0910241 teaches an electrospinning method by which fine fibers can be drawn at low temperatures from a solution of (a) at least one component selected from among plant extracts and vegetable essential oils and (b) at least one fiber-formable polymer in (c) a solvent.
[0020] In electrospinning, a solution is erupted from a nozzle by the electrical force existing between a collector and the nozzle and becomes a jet stream which is then dried into nanofibers as the solvent evaporates when it reaches an incomplete region. Electrospinning is considered to be a solution to most of the problems associated with conventional spinning methods. However, electrospun fibers show poor mechanical properties because they are not accompanied by the strength enhancement imparted by the molecular orientation of the polymer. For this reason, electrospun fibers are not used for clothes, but are limited to special industrial purposes.
[0021] In addition, electrospinning further suffers from the disadvantage of its process being unstable, increasing the production cost, and having a low production yield.
[0022] The method disclosed in US 2010/0221969 A1 is suggested as a solution to these problems. In the method, microcapsules containing vegetable essential oils are mixed with a polymeric material prior to spinning so as to provide the fibers with perfume. However, the microcapsules degrade the physical properties of the fibers. Particularly, the vegetable essential oils entrapped within the microcapsules may be released under the high pressure and temperature conditions that the polymeric materials are put through until they are melted and spun upon melt spinning. In this case, the released oils may have a negative influence on the physical properties of the polymeric materials, thus incurring unbeneficial results in the manufacturing processes.
TECHNICAL PROBLEM
[0023] It is an object of the present invention to provide an antibacterial synthetic fiber incorporated with an antibacterial plant extract.
[0024] It is another object of the present invention to provide a synthetic fiber with persistent antibacterial activity.
[0025] It is a further object of the present invention to provide a synthetic fiber with excellent antibacterial reproducibility.
[0026] It is still a further object of the present invention to provide an antibacterial synthetic fiber useful as a material for clothes.
BRIEF SUMMARY OF THE INVENTION
[0027] In accordance with an aspect thereof, the present invention provides a method for manufacturing a synthetic fiber, comprising: incorporating an extract of an antibacterial plant in an amount of from 0.01 to 10 wt % into a fiber-formable polymer: and melt-spinning the plant extract-incorporated polymer. Incorporating the antibacterial plant extract into the fiber-formable polymer may be carried out by (i) coating synthetic resin chips with the antibacterial plant extract and melt spinning the coated chips, (ii) preparing a master batch chip in the presence of the antibacterial plant extract and melt spinning the master batch chip alone or in combination with another typical synthetic chip, or (iii) adding the antibacterial plant extract during the polymerisation of the fiber-formable polymer.
[0028] A detailed description will be given of the present invention, infra. There are a variety of plants that have antibacterial activity. In fact, most plants exhibit antibacterial activity although its extent and kind differs from one species to another.
[0029] Illustrative examples of antibacterial plants are given below. It should be understood that so long as it has antibacterial activity, any plant, although not exemplified below, can be used in the present invention.
[0030] Extracts from the leaves, stems, flowers, fruits or seeds of plants belonging to Lauraceae, Cupressaceae, Pinaceae, Taxodiaceae, Araliaceae, Theaceae, Jumiperaceae, Rosaceae, Herbaceae, Oleaceae, Gingkoaceae, Caprifoliaceae, Linaceae, Poaceae, Rutaceae, Liliaceae, Nelumbonaceae, Lamiaceae, Asteraceae, Fagaceae, and Anacardiaceae, or sap from the plants are known to have excellent antibacterial activity.
[0031] In order to prevent the pyrolysis or thermal degradation of active gradients of these extracts, various methods including electrospinning have been suggested, as described above.
[0032] However, the present inventors found that active ingredients of the plant extracts are not thermally lyzed or degraded completely even during typical melt spinning. It is very useful when manufacturing antibacterial synthetic fibers for even a part of the active ingredients of plant extracts to remain antibacterially active after melt spinning in which they are thermally treated at the risk of pyrolysis or thermal degradation. This was revealed clearly in the present invention.
[0033] In the context of the present invention, the term “a part of the active ingredients remains antibacterially active” is intended to include “some of active ingredients exhibit full antibacterial activity” and “active ingredients lose their antibacterial activity to some degree.” For example, after being dried for a long period of time at a high temperature and then undergoing a melt spinning process at high temperature and a dyeing process, the resulting fibers lack the characteristic fragrance of plants, hut exhibit antibacterial activity.
[0034] As used herein, the term “plant extract” means an extract produced when the leaves, flowers, stems, roots, fruits or seeds of a plant are boiled in water or an extract obtained by cooling and condensing the smoke generated when plants are heated.
[0035] The extract, whether obtained by boiling in water or condensing the smoke, is dried in a drying process or a master batch preparation process, so that the water is evaporated while the active ingredients remain within the fibers. Impurities such as solids are removed by filtration. The extract should be concentrated sufficiently. Concentration by heating may be continued until the weight of the extract reaches 25˜60% of the total weight of the material (antibacterial plant) and water used, and more preferably 30˜50%. For example, when the extract is insufficiently concentrated, a large content of combustible volatile matter is left, making it difficult to conduct the processes in series and degrading the physical properties of the fibers. On the other hand, an excessively concentrated extract increases the viscosity too much, leading to a decrease in workability. In addition, the excessive concentration may cause the degradation of the active ingredients. Extraction may be performed preferably at a temperature of 110˜150° C. and more preferably at a temperature of 120˜130° C. When the temperature used is too low, the extract is produced in an insufficient yield. On the other hand, no additional increase in extraction efficiency is obtained at a temperature exceeding the upper limit. In addition, high pressure is generated during extraction at too high of a temperature, increasing the risk of explosion.
[0036] The weight ratio of the material (antibacterial plant) to added water is on the order of 1:2˜5, which is usually used for a decoction.
[0037] In the present invention, the plant extract in the form of a powder, which may be obtained by drying the liquid extract and pulverizing the dried residue or by drying and pulverizing the plant, cannot be used, not only because it is difficult to produce as fine a powder as desirable, but also because the powder is apt to undergo significant thermal degradation or burn during a pre-drying process or a melt spinning process. If the plant powder is burned, the synthetic resin rapidly decreases in viscosity, making spinning itself impossible.
[0038] The content of the plant extract in the fiber may be on the order of 0.01˜10.0 wt %, preferably on the order of 0.05˜6.0 wt %, and more preferably on the order of 0.1˜3.0 wt %. At too low a content, only an insufficient effect is obtained from the plant extract. A content exceeding the upper limit does not guarantee additional effects, but has a negative influence on the physical properties of the fiber.
[0039] The method of the present invention comprises incorporating an extract of an antibacterial plant in an amount of from 0.01 to 10 wt %, preferably in an amount of 0.05˜6.0 wt %, and more preferably in an amount of from 0.1 to 3.0 wt % into a fiber-formable polymer, and melt-spinning the plant extract-incorporated polymer.
[0040] Incorporation of the extract of the antibacterial plant into the fiber-formable polymer may be achieved using a coating method, a master batch method or a polymerisation method, as stated above.
[0041] In the coating method, preferably, a low temperature dryer or a rotary hot-air dryer is employed in order to prevent the degradation of the plant extract.
[0042] The synthetic fiber manufactured according to the method of the present invention comprises an antibacterial plant extract or wood vinegar in an amount of from 0.01 to 3.0 wt %, and exhibits excellent antibacterial activity with an inhibition rate of 90% or higher against bacteria at 18 hours after inoculation.
ADVANTAGEOUS EFFECTS
[0043] As described hitherto, the antibacterial synthetic fibers of the present invention exhibit excellent and persistent antibacterial activity. Superior in physical property to conventional antibacterial fibers, the fibers of the present invention are also suitable for use in clothes, non-woven or industrial materials. In addition, their antibacterial activity is maintained after repetitive laundering, and shows therapeutic activity for dermal diseases and allergies, so that the fibers may be effectively used as materials of diapers for babies or patients. On the other hand, the fibers may be applied to antibacterial toothbrushes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] FIG. 1 is a photograph showing a comparison of antibacterial activity between a test sample and a control 18 hours after inoculation.
DETAILED DESCRIPTION OF THE INVENTION
[0045] A better understanding of the present invention may be obtained through the following examples which are set forth to illustrate, but are not to be construed as limiting the present invention.
Preparation Example 1
Preparation of Extract from Forsythia suspensa Vahl
[0046] Four P.P. non-woven sacks, each containing 2 kg of pulverized powder of Forsythia suspensa Vahl, were put into a pressure decoction machine, and 20 kg of water was added. After boiling at 130° C. for 3 hours, the decoction was pressurised in a hydraulic linkage to produce 15 kg of an extract. This was concentrated into 5 kg by two rounds of filtration through a 5-micron filter.
[0047] The procedure was continued until 65 kg of a concentrated extract was obtained.
Preparation Examples 2 to 4
Preparation of Extracts from Lonicerae Flos, Ginkgo Leaves and Cinnamon Barks
[0048] Respective concentrated extracts from Lonicerae Flos, Ginkgo leaves, and cinnamon bark were prepared in a manner similar to that of Preparation Example 1.
Preparation Examples 5 to 8
[0049] Each of the extracts prepared in Preparation Examples 1 to 4 was mixed in an amount of 2 wt % with polypropylene chips, followed by drying at 60° C. for 2 hours in a rotary hot-air drier to afford coated chips.
[0050] Using a pilot spinning machine, 2 kg of the coating chips was spun at 225° C. in a typical manner to produce 150 denier/28 fila filaments.
Preparation Example 9
[0051] The extract obtained in Preparation Example 1 was mixed in an amount of 3 wt % with nylon chips and dried at 60° C. for 3 hours in a rotary hot-air drier to afford 50 kg of coated chips. The coated chips were mixed at a ratio of 1:1 with general nylon chips and dried before spinning at 235° C. in a pilot spinning machine to produce 150 denier/28 fila nylon filaments.
Preparation Example 10
[0052] Filtered quercus wood vinegar was mixed in an amount of 2 wt % with polypropylene chips and dried at 60° C. for 3 hours in a rotary hot-air drier to afford 50 kg of wood vinegar-coated chips. Two kilograms of the coated chips alone were spun at 225° C. in a typical manner to produce 150 denier/28 fila filaments.
Preparation Example 11
[0053] 65 Kg of the concentrated Forsythia suspensa Vahl extract prepared in Preparation Example 1 was mixed with 700 kg of polyester chips and dried before melt extrusion at 285° C. in a master batch extruder (twin screw, W&P, Germany) to produce 620 kg of master batch chips. The master batch chips were mixed at a weight ratio of 1:7 with typical polyester chips having an average intrinsic viscosity of 0.64 and spun to produce 4,080 kg of 1.4 D/38 mm staple fibers.
[0054] 40 S/1 raw yarns (spun yarns) produced from the fibers were S/J knitted, and then subjected to scouring, dyeing and souping processes in a high-pressure dyeing machine, followed by treatment with a softener and a tentering process. A test sample was obtained using a general method.
Examples 1 to 8
[0055] The filaments prepared in Preparation Examples 5 to 10 were knitted into socks. These knitted goods and the test sample were assayed for antibacterial activity. Both were found to inhibit the growth of bacteria at a rate of 90% or higher 18 hours after inoculation thereinto, as shown in Table 1, below. The assay was conducted as follows.
[0056] Test method: KS K 0693-2006
[0057] The test sample prepared in Preparation Example 11 was also tested for antibacterial activity against superbacteria MRSA. The results are summarized in Table 2, below. The test was conducted under the following conditions. The test sample was photographed, together with a control, 18 hours after inoculation, as shown in FIG. 1 .
Test Bacteria: Staphylococcus aureus (MRSA) ATCC 33591 Density of Inoculum: 1.2×105 CFU/mL CFU Control: standard cotton fabric Non-ionic surfactant: Tween80, added in an amount of 0.05% to the inoculum
[0000]
TABLE 1
Material
Bacteria
% Inhibition
Preparation Example 5
Staphylococcus aureus ATCC.
≧99.9%
(Forsythia suspensa Vahl)
6538
Klebsiella pneumonia ATCC
≧99.9%
4352
Preparation Example 6
Staphylococcus aureus ATCC
99.7%
(Lonicerae Flos)
6538
Klebsiella pneumonia ATCC
99.1%
4352
Preparation Example 7
Staphylococcus aureus ATCC
98.3%
(Ginkgo leaves)
6538
Klebsiella pneumonia ATCC
92.1%
4352
Preparation Example 8
Staphylococcus aureus ATCC
≧99.9%
(Cinnamon)
6538
Klebsiella pneumonia ATCC
≧99.9%
4352
Preparation Example 9
Staphylococcus aureus ATCC
99.4%
(Forsythia suspensa Vahl)
6538
Klebsiella pneumonia ATCC
≧99.9%
4352
Preparation Example 10
Staphylococcus aureus ATCC
≧99.9%
(Wood vinegar)
6538
Klebsiella pneumonia ATCC
≧99.9%
4357
Preparation Example 11
Staphylococcus aureus ATCC
≧99.99%
(Forsythia suspensa Vahl)
6538
Klebsiella pneumonia ATCC
≧99.9%
4352
Staphylococcus
≧99.9%
aureus (MRSA) ATCC 33591
[0000]
TABLE 2
Test Result
Test Item
Sample 1
Antibacterial Activity: Tested according to KS K0693: 2006
Bacteria
CFU/mL
No. of Bacteria
% Reduction
Early Stage (0 h)
1,150
2.4E+04
1,220
1,230
Control (18 h)
2,280,000
43E4+07
2,100,000
2,090,000
S# 1 (18 h)
450
93 + 03
99.9%
500
450
Comparative Example 1
[0062] A single jersey fabric knitted from polyester 40 s/1 spun yarns was subjected to scouring, dyeing and souping processes in a high-pressure dyeing machine and then dewatered. The Forsythia suspensa Vahl extract was mixed in an amount of 5 wt % with softener-containing water (95 wt %), and the mixture was allowed to go through a mangle roller and subjected to a tenter process to afford a sample.
[0063] The sample showed an antibacterial activity of 99.9% before washing, but it was significantly decreased to 34% after five washes.
Comparative Example 2
[0064] To 20 L of wood vinegar was added 5 kg of porous mineral particles. Upon the addition, the mineral particles aggregated. The wood vinegar-absorbed mineral particles were mixed in an amount of 2 wt % with polyester chips and dried at 130˜160° C. for 6 hours. Thereafter, the aggregated mineral particles were solidified into lumps which could not be further processed.
[0065] Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. | Disclosed are an antibacterial synthetic fiber, and a method for manufacturing the same, characterized in that one or more antibacterial plant extracts are mixed with a fiber-formable polymer and the mixture is melt spun at 200˜300° C. The antibacterial synthetic fiber exhibits excellent and persistent antibacterial activity. In addition, the antibacterial synthetic fiber is superior in physical property to conventional antibacterial fibers and is suitable for use as a material for clothes. | 3 |
FIELD OF THE INVENTION AND RELATED ART
[0001] This invention relates to anti-vibration technique particularly effectively usable in exposure apparatuses, for example.
[0002] In semiconductor exposure apparatuses, generally, an X-Y stage is mounted on an anti-vibration system. Such anti-vibration system includes a type in which vibration is attenuated by use of vibration absorbing means such as air spring, coiled spring or vibration isolating rubber, and a type wherein vibration is actively cancelled by driving an actuator such as a voice coil motor. In recent years, in order to avoid deterioration of the positioning precision of the X-Y stage to meet further reduction in size of circuit patterns, active vibration cancellation has been used widely. The anti-vibration system based on active vibration cancellation uses acceleration sensors as sensor means for detecting the vibration.
[0003] As regards such acceleration sensors, it is possible that the offset voltage (offset component in an output signal, and hereinafter this will be referred to “offset” or “offset value”) may change with time for a while after the anti-vibration system is assembled or installed in the factory. If such offset voltage is present, an unwanted input as well will be applied to the actuator, and in some cases the offset voltage becomes large and the acceleration value grows beyond the reproducible range of an A/D converter. In consideration of it, conventionally, the offset is checked again before shipment. Alternatively, an average of time-series signals concerning acceleration signals may be detected and the difference between a latest acceleration signal and the average may be calculated to remove a DC component (Japanese Laid-Open Patent Application, Publication No. 6-137371). As a further alternative, whether a low-frequency driving signal for driving a pneumatic actuator has reached a predetermined level or more may be detected to thereby detect malfunction of an acceleration sensor (Japanese Laid-Open Patent Application, Publication No. 10-281215).
[0004] However, even if adjustment for checking the offset again is carried out before shipment, this could not meet the possibility that the offset voltage is variable after installment. Further, the offset removing method based on detection of an average of time-series signals of acceleration signals described above is not easy to perform because acceleration of a base table can be produced in various patterns due to the reaction force of the stage driving force. On the other hand, the acceleration sensor malfunction detecting method based on detecting whether the low-frequency driving signal reaches a predetermined level described above is suitable only to a system having two types of actuators, that is, electromagnetic actuator and pneumatic actuator.
SUMMARY OF THE INVENTION
[0005] It is accordingly an object of the present invention to provide an anti-vibration technique by which at least one of the inconveniences described above can be removed or reduced.
[0006] It is another object of the present invention to make it possible to appropriately renew offset data of an acceleration sensor that detects acceleration of a supporting member for supporting a driving mechanism.
[0007] In accordance with an aspect of the present invention, to achieve at least one of the objects described above, there is provided an anti-vibration system, comprising: a supporting member for supporting a driving mechanism; an acceleration sensor for detecting acceleration of said supporting member; a driving unit for driving said supporting member; a storing unit for memorizing offset data to be used for offsetting an output of said acceleration sensor; an offset unit for offsetting an output of said acceleration sensor in accordance with the offset data memorized in said storing unit; a control unit for producing a driving signal in relation to said driving unit, on the basis of an output of said offset unit; and a renewing unit for renewing the offset data during a non-driving period of the driving mechanism, on the basis of an output of said acceleration sensor.
[0008] In accordance with another aspect of the present invention, there is provided an offset data renewing method to be used with an anti-vibration system that includes (i) a supporting member for supporting a driving mechanism, (ii) an acceleration sensor for detecting acceleration of the supporting member, (iii) a driving unit for driving the supporting member, (iv) a storing unit for memorizing offset data to be used for offsetting an output of the acceleration sensor, (v) an offset unit for offsetting an output of the acceleration sensor in accordance with the offset data memorized in the storing unit, and (vi) a control unit for producing a driving signal in relation to the driving unit, on the basis of an output of the offset unit, the improvements residing in the steps of: discriminating whether the offset data should be renewed or not, during the non-driving period of the driving mechanism, on the basis of an output of the acceleration sensor; and renewing the offset data during a non-driving period of the driving mechanism, on the basis of an affirmative discrimination result obtained in said discriminating step.
[0009] These and other objects, features and advantages of the present invention will become more apparent upon a consideration of the following description of the preferred embodiments of the present invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a block diagram for explaining the structure of an anti-vibration system according to an embodiment of the present invention.
[0011] FIG. 2 is a block diagram for explaining offset adjusting means in the anti-vibration system of FIG. 1 .
[0012] FIGS. 3A and 3B are waveform views, respectively, each illustrating a waveform of acceleration value at the time of floating start of a base table.
[0013] FIG. 4 is a flow chart for explaining offset value renewing procedure in the anti-vibration system of FIG. 1 .
[0014] FIG. 5 is a block diagram for explaining the structure of an anti-vibration system according to another embodiment of the present invention.
[0015] FIG. 6 is a flow chart for explaining offset value renewing procedure in the anti-vibration system of FIG. 5 .
[0016] FIG. 7 is a schematic view of an exposure apparatus to which the present invention can be applied.
[0017] FIG. 8 is a flow chart for explaining the procedure of device manufacturing processes.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] Preferred embodiments of the present invention will now be described with reference to the attached drawings.
[0019] FIG. 1 illustrates the structure of an anti-vibration system according to an embodiment of the present invention. Denoted in the drawing at 1 is a base table on which an X-Y stage for positioning a substrate to be exposed, in a semiconductor exposure apparatus, is mounted. Denoted at 2 is a position sensor for measuring the position of the base table 1 , and denoted at 3 is a position controller for producing a driving signal on the basis of the measurement result of the position sensor 2 . Denoted at 4 is an acceleration sensor for measuring acceleration of the base table 1 , and denoted at 5 is a vibration controller for producing a driving signal on the basis of an acceleration value to be obtained by subtracting an offset value from the output of said acceleration sensor 4 . Denoted at 6 is an adder for adding outputs of the position controller 3 and the vibration controller 5 , and outputting a drive command on the basis of it. Denoted at 7 is an actuator for driving the base table 1 on the basis of the drive command from the adding circuit 6 .
[0020] The position controller 3 operates to calculate a position drive command necessary for the base table 1 to follow a target position, on the basis of the result of position measurement made by the position sensor 2 . The position controller then outputs a corresponding drive signal for the actuator 7 . Generally, in many cases, the position controller 3 is provided by a PI controller. The vibration controller 5 calculates a vibration drive command (a command for attenuating the vibration) effective to avoid vibration of the base table 1 , on the basis of an acceleration value that can be obtained by subtracting an offset value from the measured acceleration of the base table 1 , measured by the acceleration sensor 4 . The vibration controller then outputs a corresponding drive signal for the actuator 7 . Since the actuator 7 has an integration characteristic, as regards the vibration controller 5 , generally and in many cases, one that can apply a proportional gain is used. The calculation of a drive command in the position controller 3 and the vibration controller 5 may be carried out by use of predetermined software, in a CPU 9 of FIG. 2 to be described below.
[0021] FIG. 2 illustrates the structure of offset adjusting means for canceling offset voltage of the acceleration sensor 4 . Denoted in FIG. 2 at 9 is a CPU, and denoted at 10 is a D/A converter for converting an output of the CPU 9 into an analog value. Denoted at 11 is an adder for subtracting an output of the D/A converter 10 from an output of the acceleration sensor 4 and for outputting the result. Denoted at 12 is an A/D converter for converting an output of the adder 11 into a digital value and for applying the same to the CPU 9 . Denoted at 13 is a memory to which the CUP 9 is accessible. Denoted at 14 is an offset table prepared inside the memory 13 .
[0022] The offset table 14 stores therein offset set value for canceling an offset attributable to a mounting error or the like of the acceleration sensor 4 . The CPU 9 reads out the offset set value from the offset table 14 , and it produces and outputs an offset voltage through the D/A converter 10 . The adder 11 has a function for providing an output corresponding to a difference between this offset voltage and an acceleration measured value from the acceleration sensor 4 . This output of the adder is applied as an acceleration value to the CUP 9 through the A/D converter 12 .
[0023] With this circuitry, the offset of the acceleration sensor which is attributable to the mount error or the like thereof and which is variable with time, can be cancelled by the offset set value in the offset table 14 . As regards the offset set value, the initial value thereof may be set at zero or any other appropriate value, and it may be determined by calculating an average value of measured values of the acceleration sensor 4 in a predetermined period.
[0024] FIG. 3A illustrates a waveform of an acceleration value as the base table 1 is just floated in the state in which the offset of the acceleration sensor 4 is cancelled correctly. However, in some acceleration sensors, it is possible that the offset voltage thereof varies for a while after being assembled into an anti-vibration system or after being installed in the factory. For example, if the offset voltage becomes large and the acceleration value growth to exceed the reproducible range (“-thm” to “thm”) of the A/D converter 12 , as shown in FIG. 3B , accurate acceleration value is no more obtainable.
[0025] FIG. 4 illustrates the procedure of offset renewal, being effective to solve this problem. The offset renewing process is carried out as the base table 1 is floated, by means of vibration controller 5 or CPU 9 . As the process starts, first at step 41 the waveform of an acceleration signal outputted from the adder 11 is observed while the base table 11 is being floated, and discrimination is made as to whether the time period in which the acceleration value is equal to the upper limit “thm” or the lower limit “-thm” of the reproducible range is longer than a predetermined time period or not. If the result of discrimination shows that the time period is not longer than the predetermined time, since it means that offset cancellation has been made correctly, offset renewing process is finished. If on the other hand the time period is discriminated as being longer than the predetermined time, since it means that offset cancellation has not been made correctly and the acceleration value is not correct, at step 42 the base table is seated. Then, at step 43 , an average of acceleration values in a predetermined period is calculated.
[0026] Subsequently, at step 44 , on the basis of the thus calculated average value, a new offset set value is stored into the offset table 14 . Then, at step 45 , the base table floating is initiated again, and the sequence goes back to step 41 . The above-described procedure is repeated until abnormality of acceleration value is extinguished. However, if the number of repetitions reaches a predetermined number, occurrence of hardware disorder may be displayed and notified to an operator, and the offset renewing process may be discontinued.
[0027] FIG. 5 illustrates the structure of an anti-vibration system according to another embodiment of the present invention. Elements corresponding to those of FIG. 1 are denoted by like numerals. In FIG. 5 , denoted at 8 is an electromagnetic actuator for driving a base table 1 . The offset voltage of an acceleration sensor 4 can be cancelled by similar offset adjusting means such as shown in FIG. 2 . In this embodiment, vibration of the base table 1 is suppressed by means of electromagnetic actuator 8 . More specifically, acceleration of the base table 1 is measured by the acceleration sensor 4 , and it is applied to a vibration controller 5 . The vibration controller 5 calculates a vibration drive command (a command for attenuating the vibration) effective to avoid vibration of the base table 1 , and it applies that vibration drive command to the electromagnetic actuator 8 .
[0028] Here, for applying damping to the control characteristic of the base table 1 , generally and in many cases an integrator or a pseudo integrator is used as the vibration controller 5 . The calculation of a drive command in the position controller 3 and the vibration controller 5 may be carried out by use of predetermined software, in the CPU 9 of FIG. 2 , for example.
[0029] FIG. 6 is a flow chart for explaining an offset renewing process according to this embodiment, which should be carried out each time the base table 1 is going to be floated (before the floating). This offset renewing process is carried out by means of vibration controller 5 or CPU 9 . As the process starts, first at step 61 a current output value of the acceleration sensor 4 is measured. Subsequently, at step 62 , the measured output value is compared with an offset set value in the offset table 14 , and discrimination is made as to whether the difference between them is within a predetermined allowable range or not. If the discrimination result shows that the difference is within the allowable range, the sequence goes to step 64 where the floating of the stage 1 is initiated and the offset renewing process is finished. If the discrimination result shows that the difference is beyond the allowable range, the sequence goes to step 65 , and an average of acceleration values in a predetermined period is calculated.
[0030] Subsequently, at step 66 , on the basis of the thus calculated average value, a new offset set value is stored into the offset table 14 . Then, the sequence goes back to step 61 . The above-described procedure is repeated until the acceleration value comes into the allowable range. However, if the number of repetitions reaches a predetermined number, occurrence of hardware disorder may be displayed and notified to an operator, and the offset renewing process may be discontinued.
[0031] In this embodiment, the offset renewing process is carried out before starting the float of base table 1 . In place of this, as in the preceding embodiment, the process may be carried out in the state that the base table 1 is being floated at a steady position and the stage supported by the base table 1 is held stationary (i.e. not being driven).
[0032] The present invention is not limited to the embodiments described above, and it can be modified appropriately. For example, the criteria for discriminating whether the offset renewing process should be initiated or not is not limited to the one described above. It may be one that includes at least the former of the output of the acceleration sensor 4 and the offset set value. Furthermore, while the offset measuring and renewing process is carried out while the base table is being seated, it may be carried out while the base table is being floated. Moreover, although in the embodiments described above, the number of actuators is not specified, it may be one or more. Generally, actuators are mounted on a supporting leg of the base table. If there are three supporting legs extending in a vertical direction, regarding the base-table position control system, a three-axis control system including Z-axis (vertical driving axis) translational control system, rotational control system about X-axis, and rotational control system about Y-axis. This is also the case with the vibration control system.
[0033] As regards the supporting legs for supporting the base table, they are not limited to vertical ones. Supporting legs adapted to drive the base table in a horizontal direction may be mounted. For example, by providing an air spring in a horizontal direction, swinging motion of the base table in the horizontal direction can be suppressed effectively. Alternatively, electromagnetic actuators for driving the base table in a horizontal direction may be mounted.
[0034] Furthermore, the present invention is effectively applicable even to a case where a plurality of stage are mounted on a base table or to a case where there is canceling means (called “countermass”) for canceling a drive reaction force of a stage on the base table by applying a drive in a direction opposite to the movement direction of the stage.
[0035] FIG. 7 shows an exposure apparatus for device manufacture, into which an anti-vibration system such as described above is incorporated.
[0036] This exposure apparatus is to be used for manufacture of microdevices having a fine pattern formed thereon, such as semiconductor devices (semiconductor integrated circuits, for example), micromachines, or thin-film magnetic heads, for example. In this exposure apparatus, exposure light (which may include visible light, ultraviolet light, EUV light, X-ray, electron beam, and charged particle beam, for example) as an exposure energy supplied from a light source 161 illuminates a reticle R (original), and light from the reticle R is projected onto a semiconductor wafer W (substrate) through a projection system having a projection lens 162 (which may include refractive lens, reflective lens, catadioptric lens system, and charged particle lens, for example), whereby a desired pattern is produced on the substrate.
[0037] The exposure apparatus includes a base table 151 having a guide 152 and a linear motor stator 121 fixed thereto. The linear motor stator 121 has a multiple-phase electromagnetic coil, while a linear motor movable element 111 includes a permanent magnet group. The linear motor movable portion 111 is connected as a movable portion 153 to a movable guide 154 (stage), and through the drive of the linear motor M 1 , the movable guide 154 can be moved in a direction of a normal to the sheet of the drawing. The movable portion 153 is supported by a static bearing 155 , taking the upper surface of the base table 151 as a reference, and also by a static bearing 156 , taking the side surface of the guide 152 as a reference.
[0038] A movable stage 157 which is a stage member disposed to straddle the movable guide 154 is supported by a static bearing 158 . This movable stage 157 is driven by a similar linear motor M 2 , so that the movable stage 157 moves leftwardly and rightwardly as viewed in the drawing, while taking the movable guide 154 as a reference. The motion of the movable stage 157 is measured by means of an interferometer 160 and a mirror 159 which is fixed to the movable stage 159 .
[0039] A wafer (substrate) W is held on a chuck which is mounted on the movable stage 157 , and a pattern of the reticle R is transferred in a reduced scale onto different regions on the wafer W by means of the light source 61 and the projection optical system 162 , in accordance with a step-and-repeat method or a step-and-scan method.
[0040] It should be noted that the substrate attracting device described hereinbefore can be similarly applied also to an exposure apparatus in which, without using a mask, a circuit pattern is directly drawn on a semiconductor wafer to expose a resist thereon.
[0041] Next, an embodiment of a device manufacturing method which uses an exposure apparatus described above, will be explained.
[0042] FIG. 8 is a flow chart for explaining the overall procedure for semiconductor manufacture. Step 1 is a design process for designing a circuit of a semiconductor device. Step 2 is a process for making a mask on the basis of the circuit pattern design. Step 3 is a process for preparing a wafer by using a material such as silicon. Step 4 is a wafer process which is called a pre-process wherein, by using the thus prepared mask and wafer, a circuit is formed on the wafer in practice, in accordance with lithography. Step 5 subsequent to this is an assembling step which is called a post-process wherein the wafer having been processed at step 4 is formed into semiconductor chips. This step includes an assembling (dicing and bonding) process and a packaging (chip sealing) process. Step 6 is an inspection step wherein an operation check, a durability check an so on, for the semiconductor devices produced by step 5 , are carried out. With these processes, semiconductor devices are produced, and they are shipped (step 7 ).
[0043] More specifically, the wafer process at step 4 described above includes: (i) an oxidation process for oxidizing the surface of a wafer; (ii) a CVD process for forming an insulating film on the wafer surface; (iii) an electrode forming process for forming electrodes upon the wafer by vapor deposition; (iv) an ion implanting process for implanting ions to the wafer; (v) a resist process for applying a resist (photosensitive material) to the wafer; (vi) an exposure process for printing, by exposure, the circuit pattern of the mask on the wafer through the exposure apparatus described above; (vii) a developing process for developing the exposed wafer; (viii) an etching process for removing portions other than the developed resist image; and (ix) a resist separation process for separating the resist material remaining on the wafer after being subjected to the etching process. By repeating these processes, circuit patterns are superposedly formed on the wafer.
[0044] While the invention has been described with reference to the structures disclosed herein, it is not confined to the details set forth and this application is intended to cover such modifications or changes as may come within the purposes of the improvements or the scope of the following claims.
[0045] This application claims priority from Japanese Patent Application No. 2003-386349 filed Nov. 17, 2003, for which is hereby incorporated by reference. | Disclosed is an anti-vibration technique and, specifically, an anti-vibration system and an offset data renewing method. The anti-vibration system according to an aspect of the present invention includes a supporting member for supporting a driving mechanism, an acceleration sensor for detecting acceleration of the supporting member, a driving unit for driving the supporting member, a storing unit for memorizing offset data to be used for offsetting an output of the acceleration sensor, an offset unit for offsetting an output of the acceleration sensor in accordance with the offset data memorized in the storing unit, a control unit for producing a driving signal in relation to the driving unit, on the basis of an output of the offset unit, and a renewing unit for renewing the offset data during a non-driving period of the driving mechanism, on the basis of an output of the acceleration sensor. | 5 |
[0001] This application claims the benefit of U.S. Provisional Application No. 61/445,801, filed Feb. 23, 2011, which is incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to a process for purifying TiCl 4 produced via a chloride process.
BACKGROUND OF THE INVENTION
[0003] Pigmentary TiO 2 is commercially produced through the sulfate or the chloride process. The chloride process is also used to produce TiCl 4 for titanium metal production. In the chloride process, titanoferrous ore is carbochlorinated to produce TiCl 4 and a range of other metal chlorides from the ore impurities. The crude TiCl 4 produced in the carbochlorination is processed with a series of physical separation steps to produce a usable TiCl 4 product. One contaminating element found in titanoferrous ore is arsenic. The chlorination of the arsenic species present in the ore produces AsCl 3 . AsCl 3 has a boiling point very similar to that of TiCl 4 , making removal more problematic.
[0004] Different ores can contain significantly different levels of arsenic ranging from non-detectible to greater than 100 ppm. Standard purification methods for the chloride process involve first removing solids chlorides and then removing vanadium in a separate step. AsCl 3 is a liquid, so it is not removed by the solids removal steps. Known vanadium removal steps such as organic treating agents, like plant and animal oils, soaps, fats and waxes, do not react with AsCl 3 . Another known commercial process is using elemental copper to remove vanadium from crude TiCl 4 . Copper also shows no reactivity to AsCl 3 . As a result, all of the AsCl 3 that forms from chlorination is present in the pure TiCl 4 sent to oxidation and can end up in the TiO 2 product. High levels of arsenic are undesirable in TiO 2 pigment. Pigmentary TiO 2 used in FDA products such as cosmetics require <1 ppm arsenic by the FDA method. Low levels are also desired in other pigmentary application such as some plastics and coatings products. Arsenic levels in TiCl 4 used to produce titanium metal must also be kept low to avoid deformations in the final metal pieces. Typical levels for TiCl 4 for titanium metal are <10 ppm arsenic.
[0005] Since AsCl 3 passes through all the known vanadium removal processes, such as organic treatment or copper metal, all the AsCl 3 will end up in the purified TiCl 4 . If high concentrations of arsenic were present in the ore, elevated levels of AsCl 3 will also be present. Two technologies are known to remove AsCl 3 from pure TiCl 4 . If a partial reduction of the concentration from, for example, 100 ppm to 10 ppm is all that is required, distillation can be used with effective production of the desired product, but a significant yield loss of TiCl 4 is also required. Lower concentrations can also be achieved at greater penalties for energy consumption and equipment sizing. AsCl 3 has little commercial value. Arsenic is currently only used in a few specific applications, and each of these requires a high purity level, such as gallium arsenide production. As a result, using distillation of produce a highly concentrated AsCl 3 product would reduce the yield loss of TiCl 4 but would not yield a useful product. The AsCl 3 /TiCl 4 stream would need disposal in a proper manner. Since the boiling points of AsCl 3 and TiCl 4 are so close, only 6° C. apart, a large amount of energy would be required to produce this waste stream.
[0006] Another potential method for removing AsCl 3 from purified TiCl 4 is to use carbon adsorption. This method does not work on crude TiCl 4 . Carbon adsorption can remove the AsCl 3 to very low levels that would be suitable for all applications including cosmetics. However, the carbon adsorption is not selective for only AsCl 3 . Many other species are present in the pure TiCl 4 such as the sulfur gases produced from the carbochlorination, like SO 2 , COS, and CS 2 . These species will adsorb competitively on to the carbon, limiting the capacity. As a result, this method is not commercially viable for large scale production such as pigmentary TiO 2 for large markets like plastics and coatings.
[0007] Thus, the problem to be solved is removal of AsCl 3 from TiCl 4 produced via the chloride process in an economical, efficient, and safe manner.
SUMMARY OF THE INVENTION
[0008] Applicants have solved the aforementioned problems by using tin metal to remove arsenic from crude TiCl 4 produced via the chloride process.
[0009] One aspect is for a process for the purification of TiCl 4 comprising contacting arsenic-containing crude TiCl 4 with tin to produce purified TiCl 4 , SnCl 4 , and solid arsenic and separating the solid arsenic from the purified TiCl 4 and SnCl 4 . In some aspects, the contacting and separating steps are performed by a two stage process comprising reducing the arsenic content in the arsenic-containing crude TiCl 4 by contacting the arsenic-containing crude TiCl 4 with a less than excess amount of tin to produce partially purified TiCl 4 , SnCl 4 , and solid arsenic; separating the solid arsenic from the partially purified TiCl 4 and SnCl 4 ; further reducing the arsenic content in the partially purified TiCl 4 by contacting the partially purified TiCl 4 with an excess of tin to produce purified TiCl 4 , SnCl 4 , solid arsenic, and excess tin; and separating the solid arsenic and excess tin from the purified TiCl 4 and SnCl 4 .
[0010] Another aspect is for a process for the purification of TiCl 4 comprising contacting arsenic- and vanadium-containing crude TiCl 4 with tin to produce purified TiCl 4 , SnCl 4 , solid arsenic, and solid vanadium and separating the solid arsenic and solid vanadium from the purified TiCl 4 and SnCl 4 . In some aspects, the contacting and separating steps are performed by a two stage process comprising reducing the arsenic and vanadium content in the arsenic- and vanadium-containing crude TiCl 4 by contacting the arsenic- and vanadium-containing crude TiCl 4 with a less than excess amount of tin to produce partially purified TiCl 4 , SnCl 4 , solid arsenic, and solid vanadium; separating the solid arsenic and the solid vanadium from the partially purified TiCl 4 and SnCl 4 ; further reducing the arsenic and vanadium content in the partially purified TiCl 4 by contacting the partially purified TiCl 4 with an excess of tin to produce purified TiCl 4 , SnCl 4 , solid arsenic, solid vanadium, and excess tin; and separating the solid arsenic and the solid vanadium and excess tin from the purified TiCl 4 and SnCl 4 .
[0011] Other objects and advantages will become apparent to those skilled in the art upon reference to the detailed description that hereinafter follows.
DETAILED DESCRIPTION
[0012] Applicants specifically incorporate the entire contents of all cited references in this disclosure. Further, when an amount, concentration, or other value or parameter is given as either a range, preferred range, or a list of upper preferable values and lower preferable values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper range limit or preferred value and any lower range limit or preferred value, regardless of whether ranges are separately disclosed. Where a range of numerical values is recited herein, unless otherwise stated, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the scope of the invention be limited to the specific values recited when defining a range.
[0013] When tin metal is reacted with the arsenic in the crude TiCl 4 (i.e., titanium tetrachloride produced by a chloride process, which has been subjected to partial purification procedures to remove some metal chlorides), a solid arsenic product is produced along with SnCl 4 . This treatment process works with all ranges of arsenic seen in the variety of ores available with levels from 10 ppm to 100 ppm arsenic but has not been seen to have any limitations either with lower or higher concentrations. SnCl 4 is a liquid, not a solid like copper chloride. As a result, the SnCl 4 does not contaminate the arsenic solid. Tin metal, being a milder reducing agent, also does not appear to react with TiCl 4 , unlike copper metal. As a result, a simple two stage reactor system can be used with tin powder with essentially no extra yield loss of TiCl 4 or tin through reaction with the purified TiCl 4 . By the term “purified TiCl 4 ” it is meant that the concentration of the arsenic in the TiCl 4 is at least significantly lowered if not reduced to a level below that which can be detected by known analytical techniques. The product TiCl 4 has arsenic removed to a level suitable for use in the production of TiO 2 or titanium metal. The TiO 2 may be suitable for use in applications where lower arsenic concentrations are desired.
[0014] In the step of contacting the crude TiCl 4 with the tin material, the tin can be added to the TiCl 4 by any suitable addition or mixing method. The tin can be added as a fine powder using known engineering methods such as a star valve or screw feeder with appropriate consideration made for controlling TiCl 4 vapors back flowing into the system. Mixing of the tin powder with the crude TiCl 4 may be done with agitation such as paddle mixer, sparging, or other engineering methods appropriate for the difficulties associated with handling TiCl 4 . In some embodiments, the amount of tin added to the crude TiCl 4 is an excess amount. For a given equipment size and temperature, the rate of the reaction will be adjusted by the amount of excess tin added. When a single stage configuration is used, excess amounts could be very high, such as 20 times excess. A two stage configuration allows less excess to be used in the final stage, and lower amounts such as eight times excess can be used. The excess used in the final stage is also utilized later in the first stage.
[0015] SnCl 4 can be separated from the resulting pure TiCl 4 through, for example, distillation. SnCl 4 is a valuable product used as a catalyst and the starting material for the production of organometallic tin compounds that are used in a wide variety of applications. So, in this process, a valuable co-product is produced, and many other technical problems are eliminated.
[0016] First, by converting liquid AsCl 3 into a solid, disposal of the arsenic atoms becomes much easier. Liquid AsCl 3 is a water reactive, corrosive material that releases HCl upon contact with atmospheric moisture. As such, it cannot be disposed of directly. If it was removed from the product TiCl 4 stream through distillation, it would be mixed with larger concentrations of TiCl 4 , which is also a water reactive, corrosive material that releases HCl upon contact with atmospheric moisture, and both liquids would need to be converted into a different product before disposal. By converting the AsCl 3 into a solid as part of the removal process and then separating all of the TiCl 4 from the solid, a less hazardous material is produced. The residual solid is not contaminated with treating agent such as copper chloride or organic residue that must be separated since SnCl 4 was formed and already separated. This separation also produces a much small stream to handle. This stream might be much easier to convert into an acceptable form for landfill or other appropriate disposal.
[0017] Second, while a distillation step would still be required to recover SnCl 4 , the energy intensity would be lower to produce the TiCl 4 product. For TiO 2 production in the chloride process, significantly higher concentrations of SnCl 4 are allowed in the TiCl 4 since the Sn does not end up incorporated into the final TiO 2 product. So, the initial separation where a lower SnCl 4 - and much lower AsCl 3 -containing TiCl 4 product is produced from the bottom of the distillation column, would experience two benefits: (1) an increase in the separation of the boiling points of the two species being separated and (2) an increase in the amount of tolerated contamination in the product TiCl 4 . So, for example, a starting crude TiCl 4 with 100 ppm As might have to be distilled to reduce the arsenic level to 10 ppm As. With a 6° C. difference in the boiling points, 130° C. for AsCl 3 and 136° C. for TiCl 4 , a large column with many trays and considerable energy input would be required. If this process were used on the crude TiCl 4 to reduce the AsCl 3 from 100 ppm to 10 ppm As, then the only extra energy input required would be to reduce the SnCl 4 concentration. Some SnCl 4 is present in crude TiCl 4 to start due to the ore composition. As a result, the SnCl 4 concentration might need to be reduced from 2000 ppm to 1000 ppm in the product TiCl 4 ; however, that reduction is much easier to achieve, plus a 22° C. difference in the boiling points exists between the 114° C. for SnCl 4 and 136° C. for TiCl 4 . Now the extra energy can be applied to converting the high SnCl 4 material into a suitable product.
[0018] Third, a valuable product is produced in the reaction instead of material with disposal issues. SnCl 4 is typically made through the reaction of tin metal and chlorine at elevated temperatures. In this reaction, instead of using virgin chlorine, the chloride ligand is obtained in the purification process. These chlorine ligands would be lost, for example through the copper chloride disposal in other systems. In this case, the chloride, an expensive and energy intensive reagent, is conserved instead of lost.
[0019] Fourth, no opportunity for undesirable production of Persistent Bio-accumulative and Toxic (PBT) organic compounds exists because no carbon is introduced into the system. When organic treating agents are used, the combination of heat, chlorine and carbon can under some conditions produce PBTs such as chlorinated dioxins and furans.
[0020] Finally, tin provides an opportunity to simultaneously remove both vanadium and arsenic in one unit operation. Using carbon adsorption to remove the arsenic would first require a traditional purification step such as organic treating agents, followed by a separate unit operation for the arsenic removal. If very low AsCl 3 levels were required, such as <1 ppm As, and low levels of SnCl 4 were also required, a distillation column might also be required to meet the final product specifications.
[0021] In some embodiments, the SnCl 4 is subsequently recovered from the TiCl 4 . This separation can be accomplished through, for example, distillation. All of the SnCl 4 does not need to be removed from the TiCl 4 for the TiCl 4 to be used for TiO 2 production. Most of the SnCl 4 could be recovered in this process and recycled to produce a more concentrated SnCl 4 stream. The concentration of SnCl 4 does not impact the rate of the arsenic removal step One example of the separation of TiCl 4 and SnCl 4 would involve two separate distillation columns. The first column would be fed the product from the vanadium removal stage to the upper portion of the column. TiCl 4 suitable for commercial use would be collected from the bottom of the first column. The purity requirements for TiCl 4 used for TiO 2 or titanium metal manufacture would determine the configuration of this column, typically set using Aspen modeling conditions or similar engineering principles. The stream collected from the top of the first column would provide the reflux flow to the first column and feed a second column. The second column would be used to produce a finished SnCl 4 product from the top of the column. The material from the bottom of the second column would be high in TiCl 4 and lower in SnCl 4 . The bottom material would be recycled to the tank used to provide the reflux to the first column. In this manner, no TiCl 4 would be lost while conserving energy. The size of the columns and number of trays would be related to the total purification strategy for the crude TiCl 4 since that will determine the amount of SnCl 4 present. SnCl 4 can also be present in crude TiCl 4 due to tin oxide in the ores. The SnCl 4 from the crude TiCl 4 will also be accounted for in the distillation.
[0022] One embodiment is for crude TiCl 4 to be purified in two stages. In the first stage, the arsenic concentration is only partially reduced so that the tin metal reaction can be driven to completion. The solid arsenic product is separated from this stage and a liquid (or vapor) TiCl 4 stream containing arsenic is transferred to a second stage. This step preferably occurs at least at 100° C. More preferably, this step occurs under pressure at temperatures elevated above the boiling point of TiCl 4 (about 150° C. to about 200° C. range). The arsenic solids can be collected in a drying chamber, for example a drying chamber found after a purge separation (see, e.g., U.S. Pat. No. 7,368,096, incorporated herein by reference). Alternatively, they may be collected by other known engineering methods such as, for example, filtration.
[0023] In the second stage, the arsenic is removed to the desired low levels and excess tin metal is present. The excess tin metal stream (containing some arsenic solid) is removed and can be sent to the first stage for further reaction. The TiCl 4 /SnCl 4 with no arsenic is then separated, in one embodiment in a distillation column.
[0024] Distillation may be operated in different methods depending on the end use of the TiCl 4 . In one embodiment, the initial TiCl 4 /SnCl 4 mixture is sent to a rough distillation column where a stream containing low enough amounts of SnCl 4 in TiCl 4 is produced from the bottom of the column and a high SnCl 4 stream is produced from the top of the column. The bottom stream of TiCl 4 can be used to produce TiO 2 . The top stream can be sent to a polishing distillation column which is used to produce a pure SnCl 4 stream from the top and a rough TiCl 4 /SnCl 4 stream from the bottom. The bottom stream from this column can be recycled back to the start of the first distillation column. Through the use of multiple distillation columns, essentially no TiCl 4 yield loss occurs and both a TiCl 4 product and SnCl 4 product can be produced. A third distillation column (or batch operation of the second distillation column) can be used in some embodiments to produce a TiCl 4 product ideal for titanium metal production. The benefit of using elemental tin compared to organic treating agents is no organic residue is present in the TiCl 4 , which is highly detrimental to the titanium metal.
[0025] In some embodiments, the contaminant vanadium is also removed by a process described herein. The vanadium chlorination products, VOCl 3 or VCl 4 , have boiling points close to that of TiCl 4 , which makes removal problematic. When tin metal is reacted with the vanadium in the crude TiCl 4 , a solid vanadium product is produced along with SnCl 4 . This treatment process works with all ranges of vanadium seen in the variety of ores available with levels from 100 ppm V to 3000 ppm V but has not been seen to have any limitations either with lower or higher concentrations. As with arsenic noted above, the SnCl 4 does not contaminate the vanadium solid.
[0026] The product TiCl 4 has vanadium removed to a level suitable for use in the production of TiO 2 or titanium metal Additionally, vanadium can be lowered to an operator specified concentration.
[0027] Vanadium can be removed using either the one stage or two stage process described above for arsenic. The solid vanadium product that is produced by a process described herein is suitable to become a feedstock into other processes such as the production of steel.
[0028] The TiCl 4 product of the process described herein can be used in any application for which titanium tetrachloride is useful. The TiCl 4 can be used as a starting material for making titanium dioxide and derivatives thereof especially as a feedstream for the well-known chlorination and oxidation processes for making titanium dioxide.
[0029] Titanium dioxide can be suitable for use as a pigment. The majority of TiO 2 produced is used for this property. Common applications are in paints, paper and plastics. The TiCl 4 produced in this process is suitable for use in production of TiO 2 for all of these applications.
[0030] Titanium dioxide is useful in, for example, compounding; extrusion of sheets, films and shapes; pultrusion; coextrusion; ram extrusion; spinning; blown film; injection molding; insert molding; isostatic molding; compression molding; rotomolding; thermoforming; sputter coating; lamination; wire coating; calendaring; welding; powder coating; sintering; cosmetics; and catalysts.
[0031] Alternatively, titanium dioxide can be in the nano-size range (average particle diameter less than 100 nm), which is usually translucent or transparent. TiO 2 of this particle size range is typically used for non-optical properties such as photo-protection.
[0032] The TiCl 4 from this process is also suitable for use to produce titanium metal through any of the known commercial pathways such as the Kroll and Hunter processes. The TiCl 4 is also suitable for use in the production of titanium based catalysts such as organo-titanates or Ziegler-Natta type catalysts.
EXAMPLES
[0033] The present invention is further defined in the following Examples. It should be understood that these Examples, while indicating preferred embodiments of the invention, are given by way of illustration only. From the above discussion and these Examples, one skilled in the art can ascertain the preferred features of this invention, and without departing from the spirit and scope thereof, can make various changes and modification of the invention to adapt it to various uses and conditions.
Example 1
Crude TiCl 4 and One Stage Removal with Elemental Sn
[0034] A 100 mL aliquot of commercial crude TiCl 4 was added into a 250 mL reaction flask equipped with a magnetic stirrer, heating mantle, powder addition funnel and Dean Stark trap for condensate collection. The crude TiCl 4 contained a range of impurities including vanadium, iron and other elements including SnCl 4 plus 36 ppm arsenic as AsCl 3 . The dark yellow TiCl 4 was mixed with 2.0 g of powdered elemental Sn (<45 micron size, Aldrich, 98.8%) and the heated to reflux. The TiCl 4 and Sn were refluxed together for 3 hours. All of the color was removed from the distillate. The TiCl 4 was then distilled from the solids. The overheads were measured to contain <1 ppm V and <5 ppm As. They also contained 2000 ppm of Sn which includes the SnCl 4 which was present in the crude TiCl 4 .
Example 2
Crude TiCl 4 and Two Stage Removal with Elemental Sn
[0035] A 100 mL aliquot of commercial crude TiCl 4 was added into a 250 mL reaction flask equipped with a magnetic stirrer, heating mantle, powder addition funnel and Dean Stark trap for condensate collection. The crude TiCl 4 contained a range of impurities including vanadium, iron and other elements including SnCl 4 plus 40 ppm arsenic as AsCl 3 . The dark yellow TiCl 4 was heated to 100° C. and mixed with 1.2 g of powdered elemental Sn. The TiCl 4 and Sn were refluxed together for 12 hours to ensure that an endpoint had been achieved. The distillate was still a strong yellow color indicating that only a portion of the vanadium was removed. Another 1.1 g of Sn was then added. The slurry was refluxed for 1 more hour. All of the color was removed from the distillate. The TiCl 4 was then distilled from the solids. The overheads were measured to contain <1 ppm V and <5 ppm As. They also contained 2000 ppm of Sn which includes the SnCl 4 which was present in the crude TiCl 4 . | The present disclosure relates to reacting tin metal with crude TiCl 4 containing arsenic to produce pure TiCl 4 , SnCl 4 , and an arsenic solid co-product. In some embodiments, the contaminant vanadium is removed as well. The reaction is preferably done in a continuous fashion in two stages for maximum through-put and utility at an elevated temperature. Distillation can be used to purify the TiCl 4 produced and simultaneously yield a purified SnCl 4 product. The synthesis of SnCl 4 in this method utilizes waste chloride to save virgin chlorine which would otherwise be used. | 2 |
FIELD OF THE INVENTION
The invention generally relates to the field of computer communication systems in client-server architectures. More specifically, the invention relates to providing a user with desired, remotely-stored information. The invention has particular applicability to the World Wide Web.
BACKGROUND OF THE INVENTION
The Internet, and its multimedia counterpart, the World Wide Web, have become a popular medium of communication. Information on a wide variety of topics is available with just a few clicks of a mouse. As the Internet expands its boundaries by increasing the number of servers and networks which it supports, and as more and more people utilize the Internet to search for data, the way in which information is presented is undergoing evolution. Two important evolutionary factors, which have become increasingly apparent, are discussed herein.
THE FIRST FACTOR--"PUSH" TECHNOLOGY
The first important evolutionary factor is that the burden of obtaining information desired by a user no longer falls squarely on the shoulders of the user. Rather, an active technology, called "Push" technology, is making it possible for the system to provide the user with desired information automatically, as information, defined by a class of criteria as being "desired," becomes available. Push technology has been pioneered by PointCast, Inc., in Sunnyvale, Calif.
For example, automated agent machines, such as "web crawlers", search the Web for data collection, indexing and filtering. As another example, a single access to a server might be made by a "proxy server", which then saves the content and re-distributes it to a user community.
Also, push technology has been explored, with particular reference to issues relating to providing compensation to content providers, on co-pending, co-assigned United States Patent Application 08/819,345, filed Mar, 18, 1997, Lotspiech et al., "Persona-Based Client/Server Communications." The disclosed invention provides a system and method for client/server communications on the World Wide Web, which represents one possible approach for allowing the user to control information that is revealed to a server and that is delivered from a server.
A client system is communicatively coupled to a server. User information about a user on the client system is stored on the client system. A user information request is received from the server. The requested user information is compared with the stored user information, at the client. User information is transmitted from the client to the server based on the comparison between the requested user information and the stored user information. Information is received from the server that is based on the user information transmitted from the client to the server.
The PointCast and Lotspiech systems have used Push technology to make desired information available to users. However, the user then faces the prospect of being overwhelmed by the volume of information received.
THE SECOND FACTOR--HIGHLIGHTS
The second important evolutionary factor is that the explosive growth of the amount of information available in cyberspace makes presenting highlights a more valuable approach.
A user interface technology, commonly called "Ticker" technology, has recently emerged as one of the dominant user interfaces, used by Internet information systems, for displaying dynamically changing data.
"Ticker" is a metaphor, referring to the old-style hard-copy stock tickers which printed information, such as stock quotes and news bulletins, on a thin strip of paper tape. In a graphical user interface (GUI), the ticker manifests itself as a strip, typically along the bottom of a GUI display, within which information is displayed. Text either runs, or "crawls," horizontally along the length of the ticker display strip, or rolls vertically, in the fashion of a line of just-typewritten text coming into view as the platen of a typewriter rolls upward one line.
Conventional visual and text-based ticker interfaces have had many drawbacks. First, one must always pay close attention to the ticker's display, or otherwise he/she has no way of getting the information content.
Second, a ticker requires a display device with sufficient capabilities to realize its value. This means that it is not appropriate for devices with very limited displaying capabilities such as a mobile phone. A ticker, however small and compact it is, occupies some screen space that could otherwise be used by other applications. For example, a user filling out a financial spreadsheet must constantly close an application window in order to see the ticker's content.
Third, the visual display ties up user's eye sights thus diverting one's attention from performing some other important tasks. Finally, one has to be near the screen to get the information.
Therefore, there is an unfilled need for a method and system, usable in client/server or remote networked systems such as the Internet, for making desired information available to the user in a way that the user is optimally able to receive the information without being unduly distracted from his/her work.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide desired information to a user in a way which is less distracting to the user than conventional ways are.
It is a further object of the invention to provide the desired information to a user in a way which requires less video display real estate than conventional ways are.
To achieve these and other objects, there is provided, in accordance with the invention, a system, for use with an information processing system which is coupled to an information source, for providing a user of the information processing system with desired information while the user is otherwise occupied using the information processing system.
The system of the invention comprises the following components:
A user interface unit is provided, the unit including a video display mechanism and an audio play mechanism.
Means are provided for displaying first information, using the video display mechanism, responsive to user commands for accessing the first information. This generally includes a known computer graphical user interface (GUI) system, having a pixel display, such as a video display, for displaying the familiar GUI paradigm of a desktop, icons representing user-selectable application programs, and windows representing active application programs and including functional features usable by the user through manipulation of a keyboard and of a mouse or other pointing device.
Finally, in accordance with the invention, means are provided for playing second information, responsive to a predetermined system condition, using the audio play mechanism.
Advantages of the system and method according to the invention will be evident from the detailed description which follows. First, since most of the functionality of the system remains within the GUI, audio information played for the user, in accordance with the invention, does not take up "bandwidth" of the user's visual perception. Rather, the user's hearing, which is conventionally utilized less fully than the user's vision, is available for absorbing the information in audio form. Thus, information conveyed by a system according to the invention does not monopolize the user's attention from his/her work at hand. Also, the information conveyed does not require display screen real estate.
It is believed that the system according to the invention is inexpensive to implement on conventional GUI computer systems, and can be an easy add-on to existing systems.
While the invention is primarily disclosed as a system, it will be understood by a person of ordinary skill in the art that an apparatus, such as a conventional data processor, including a CPU, memory, I/O, program storage, a connecting bus, and other appropriate components, could be programmed or otherwise designed to facilitate the practice of the method of the invention. Such a processor would include appropriate program means for executing the method of the invention.
Also, an article of manufacture, such as a pre-recorded disk or other similar computer program product, for use with a data processing system, could include a storage medium and program means recorded thereon for directing the data processing system to facilitate the practice of the method of the invention. It will be understood that such apparatus and articles of manufacture also fall within the spirit and scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of an environment in which the invention is advantageously employed.
FIG. 2 is a high-level block diagram, showing the architecture of a system according to the invention.
FIG. 3 is a more detailed block diagram, showing additional details of a system according to the invention, particularly with reference to the process of distributing new information to users.
FIG. 4 is a flowchart showing operation of the system of FIG. 3.
FIG. 5 is a more detailed block diagram, showing additional details of a system according to the invention, particularly with reference to the process of determining which information is to be provided to which users.
FIG. 6 is a flowchart showing operation of the system of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In accordance with the invention, information is automatically provided, in audio form, to a user. The description which follows will include a description of the environment in which the invention is to be used, the system architecture of a server supporting the invention and a client system for allowing a user to utilize the invention, and a procedure for allowing the user to request the service and specify the sort of information which is desired.
THE ENVIRONMENT OF THE INVENTION
FIG. 1 is a diagram, showing an environment in which the invention is advantageously practiced. Various sources of information are shown collectively as 2. The information sources may include a remote information processing system, a time clock, an on-line database of information such as legal information or financial information, broadcast radio or television signals, etc.
A communication network 3 couples the information from the information sources 2 to a push server 4. Many noteworthy aspects of the invention are preferably embodied within the push server 4, and its structure and function will be described in detail below.
The push server 4 processes the information, and produces formatted information 6, which is provided to a user at an information processing system 8 which serves as a push client. In accordance with the invention, the formatted information 6 is formatted as audio information, such as a sequence of pre-recorded voice clips chosen from a library, based on the information coupled to the push server 4.
The push server 4 distributes the information among registered clients (one or more users at information processing systems 8) according to their requests. The process by which a user subscribes to the service will be described in detail below.
THE USE OF INFORMATION TOKENS: FIRST EMBODIMENT--FIG. 2
In accordance with the invention, information is quantified in the form of "tokens," or discrete units, and the push client 8 receives information consisting of sets of the tokens. Here, the term "token" is taken as broadly meaning data in any suitable form, packetized or otherwise, for storage and/or transmission. The nature of the tokens is dependent on the type of information being provided, and numerous different types, which would be understood by persons skilled in the art, fall within the spirit and scope of the invention. Preferred implementations of the invention accommodate such token formats as are already in existence and in use with existing systems.
FIG. 2 is a diagram showing the sequence, within the environment of the invention, whereby information tokens are provided to the user. When a system according to the invention provides information to a user, the information goes through a mapping process, which will be explained in detail below.
While some or all of the functionality of the mapping process can reside at the server 4, the mapping process preferably is performed at the push client 8, for two reasons. In general, the mapping process maps received tokens (relatively small-size data packets) to audio clips (relatively large data objects). Transmission throughput, then, is optimized by doing the greatest possible amount of transmission using the tokens, and keeping the need for transmission of audio clips to a minimum.
The second reason for preferably keeping the mapping function at the client 8 is that information resources, in the form of a library of audio clips, are maintained at the venue where the mapping takes place. If the mapping takes place at the user's client system 8, the required on-site information resources may be kept small, to accommodate only the needs of that particular user.
Information originates in a repository, or from a remote source such as a news service, a stock exchange, etc. It is contemplated that the information is dynamically updated over time, and new information updates are provided to the server 4 at random times. Some of these new information updates will be considered likely to be of interest to users. Accordingly, means are provided for noting changes to the stored information, new incoming information, etc. Responsive to these changes, the new information is made available by the server 4 as an information token.
The new information is made available, preferably over a link 12 to the client 8. The information, received in the form of tokens 13, is provided to a mapper 14. The mapper 14 includes, or operates cooperatively with, a library 16 of clips of information, in a format suitable for use by the client 8. The library 16 is also preferably resident within the push client 8, but may alternatively include an external database, file system, etc.
In accordance with the invention, the library 16 includes audio clips. The audio clips are preferably such as can be assembled in a sequence to convey the meaning of the information to the user, through an audio player 18. In one preferred embodiment, the library 16 includes a dictionary of audio clips of individual spoken words. Alternatively, phrases may also be included. Where the information is likely to relate to a specialized area of subject matter, audio clips of phrases relating to that subject matter are particularly advantageous.
In many foreseeable applications of the invention, the information dealt with is limited in its vocabulary. The vast majority of push channels are dealing with such subjects as stock prices, traffic reports, weather conditions, sports scores, etc. For all these areas of interest, a limited vocabulary can be designed so as to facilitate the translation from any text containing information to that subject matter to the sequence of predefined sounds.
The mapper 14 parses the information within the token, and identifies individual words, phrases, etc. By referencing the audio clip database 16, the mapper 14 accesses corresponding pre-recorded audio clips for the tokens. The mapper 14 then assembles these clips into a cohesive structure. While a skeleton structure of key words may be sufficient to convey the meaning of the information item, additional processing may be employed to produce linguistically correct and natural sentences.
Note that a speech synthesizer, which generates voice from text, may be used in place of an audio clip library. However, it is believed that, because of the relatively low level of maturity in present-day speech synthesis technology, of the difficulty in generating synthesized voice with natural sounding tone, inflections, etc., and of the advantages of using audio clips for specialized areas of vocabulary, audio clip libraries are deemed to be the preferred mode of operation of the invention.
SECOND EMBODIMENT--FIGS. 3 AND 4
Next, a detailed description of a second preferred system architecture, and of the operation responsive to receipt of a new information item, will be given.
FIG. 3 is a block diagram of a system including a client 8, substantially as given in FIG. 2, and a server 20, having functionality in addition to that described in connection with the embodiment of FIG. 2.
Again, the preferred location for most of the functionality is in the server 8. However, additional capability is provided in the server 20, for situations in which the mapper 14 is unable to map a portion of the information item to any audio clips existing in the clip library 16, residing on the client 8.
Where a portion of the text in a token cannot be mapped to any audio clip in the database 16, it is possible simply to omit that part of the text from the audio sequence, or to insert an audio warning indicating that a portion of the message is missing from the audio sequence. However, preferred embodiments of the invention provide ways for dealing with such situations.
An additional audio clip database 22 is provided at the server 20. It is anticipated that the database 22 will be more comprehensive than those found in the clients, such as the database 16 in the client 8. Thus, where the client 8 fails to match a portion of the token with its own audio clips, it sends a message back to the server 20, requesting a consultation with the database 22. If the database 22 contains a matching audio clip, it sends that audio clip to the client 8. While this solution has the drawback that a fairly sizeable audio clip is sent between the server 20 and the client 8, it is anticipated that this will not need to happen very frequently.
Yet another possible solution is to provide the client 8 or the server 20 with a thesaurus database, which contains synonyms for words, and sets of equivalent phrases. Thus, if a word or phrase cannot be matched up with a literally equivalent audio clip, it may nevertheless be matched up with an audio clip for a synonym or equivalent phrase.
Additional functionality is shown in the server 20, including a profile engine 24 and a user profile database 26. These will be discussed in connection with FIGS. 5 and 6, below.
PREFERRED FUNCTIONALITY--FIG. 4
FIG. 4 is a flowchart showing the preferred operation of the system of FIG. 3. Initially, some of the terminology used in FIG. 4 will be defined.
"Channel C": an information source, generally characterized in terms of content. For instance, one channel might be stock market information, while another channel might be sporting event results. User preferences as to desired information will be expressed in terms of channels of information.
"Token t": a unit of information, associated with a particular channel, and deemed of interest to the user.
"Table T": a table, used in the mapping process, which contains audio clips, and which uses a suitable indexing or addressing scheme for allowing the mapper 14 to access an appropriate audio clip for a parsed word or phrase from the token.
"Audio Clip a": an audio clip from within the table T, corresponding with part of the content of the token t.
"Audio Sequence S": a sequence of audio clips, assembled from the clips in the table T, for correspondence with the content of a token t.
Referring now to FIG. 4, the process executed by a system according to the invention will be described in detail.
The input is a token t, such as a text token, provided from channel C.
First, a token mapping table is accessed (steps 28, 30). the table is essentially equivalent to the database 16 of FIG. 3, but is specific to the subject matter likely to arise in messages from channel C. It will be understood, then, that the client 8 also includes other similar tables for other channels.
If a match for a word or phrase in the token t is found in the table T, then processing proceeds to steps 32 and 34, in which an audio clip is accessed from the table T, and used to build an audio sequence.
If step 30 failed to find a match, then, in the preferred embodiment of FIG. 3, a request for a consultation with the database 22 is made (step 36). If a matching clip is found there, then step 38 retrieves the matching clip, and sends it back to the client 8. Processing passes to step 34, where the clip is used in the building of the audio sequence.
If step 36 also fails to find a match, then a suitable response is sent back to the client 8. The client 8 either consults a thesaurus, or uses a default "unknown" audio clip (step 40).
The processing up through step 34 is executed iteratively, for tokens containing a sequence of segmentable words or phrases. When the last word or phrase is processed, the final result of step 36 is a completed audio sequence S (step 42).
Optionally, prelude and postlude sounds, such as fanfares, chimes, etc., are added, and background sound, such as music, is superimposed (step 44). Finally, in step 46, the entire audio sequence is played back through a suitable audio system in, or coupled to, the client system 8.
USER PREFERENCE CONFIGURATION--FIGS. 5 AND 6
Next, a discussion will be provided of the process of configuring the system for a given user's preferences and interests.
In the block diagram of FIG. 5, the server 20 and the client 8, substantially as per those of FIG. 3, are shown.
As discussed above, sources of various particular types of subject matter are referred to as "channels." Thus, a user will express his/her desired information by specifying channels.
In FIG. 5, the server 20 includes a channel administration tool 48, which operates, in conjunction with a user's input, to subscribe a user to a desired channel. The server 20 also includes a library 50 of channels to which a given user has already subscribed. When a user adds or deletes a subscribed channel (by means of a process to be described below), the administrator 48 makes suitable changes to the entries in the library 50.
The client 8 includes means for providing a user interface that allows the user to make channel selections. Preferably, the means includes a profile editor 52, which displays a menu 54 of possible channels, including an indication of which channels are currently subscribed to. Since the information about available channels and channels currently subscribed to is typically resident on the server 20, the means further includes a communication arrangement for allowing the profile editor 52 to access and update the library 50 of pre-defined channels. It will be understood that consistency is required between the record of subscribed channels in the library 50 and the information 54 displayed at the client.
Also in accordance with the invention, a further refinement in the user's ability to specify desired information is preferably provided. This further refinement is called "filtering."
The user filters desired information by specifying subsets of the information within a given channel which is desired. For a channel devoted to stock market information, the user can filter the information by subscribing only for information about IBM Corp. stock. For a channel devoted to sports information, the user can filter the information by subscribing only for information about baseball, or more specifically for information about the Cleveland Indians.
The mechanisms by which desired channel information is identified, and by which particular filtered information within a given channel is identified, are not necessarily identical. Channel information is likely to be easily identifiable by the server 20 because of its transmission point of origin, or because of a header on the token, the header identifying the origin of the token, or giving information that classifies the token's content.
Where more specific filtering of information is to be performed, a more elaborate test may be required. For instance, where Cleveland Indians information is to be filtered out of information from a sports channel, the system identifies the information by its channel as being sports information, and then runs a content check, for instance by using "Cleveland Indians" as a keyword or keyphrase. Information from the sports channel that contains this keyphrase is considered as having been identified by the filtering.
Where less specific filtering of information is to be performed, the test may be modified to include a set of keywords or keyphrases. That is, where the more general category of baseball information is to be filtered out of a sports channel, a set of keyphrases might include {baseball, spring training, World Series, Little League, Minor League} or other related terms. An information item containing any one of these keyphrases would satisfy the filtering, and be provided to the user.
FIG. 6 is a flowchart showing a process by which a user, operating the client 8, changes the user's desired information. In step 56, the user operates the client 8 by entering a command to invoke the profile editor 52. a suitable user interface, such as an application window, opens on the client 8's display. Also, a message is sent to the server 20, requesting a download of the user's current desired information from the library 50 of pre-defined, subscribed information.
The client 8 receives this information (step 58) and displays it to the user, through the client 8's user interface (step 60).
The user then subscribes (step 62) to new channels, in which he/she is interested, or deletes channels which had been subscribed to, but which are no longer of interest. Preferably, the user interface supports a convenient, userintuitive way of doing this. For instance, a menu of channels is listed, and a user clicks a mouse on one of the channels to subscribe to it. A channel already subscribed to is marked accordingly, such as by an adjacent checkmark or other symbol. When the user clicks on a channel already subscribed to, the subscription symbol disappears, indicating that the channel is no longer to be subscribed to.
The profile editor 52 also provides the user with the ability to specify a filter associated with a subscribed channel. This functionality is invoked (step 64) in a suitable manner, such as by selecting a subscribed channel and clicking on a "filter definition" button.
As discussed above, a filter is preferably defined in terms of a set of one or more keywords or keyphrases. Initially, the system displays any filter already in existence for the channel. Preferably, the defined filter is given in an edit window, or the like, so that the user can edit the filter as desired.
Optionally, the channel menu may contain a default filter, or a list of suggested keywords and keyphrases, associated with a given channel. A user, selecting that channel, may invoke the default filter or select keywords or keyphrases from the list, as well as type in his/her own desired keywords or keyphrases. The editor may also include a spell checker for the keywords, or a "wildcard" capability, so that a user can type in the root of a desired keyword, and use the wildcard to catch all possible inflections, suffixes, or variations on that root.
Also, the filter may be specified in terms of more sophisticated logical combinations of keywords, as are commonly used with other keyword-based search engines. Examples are "a and (B or C)", "D and not (E)", "F (adjacent to) G," "H (within (a specified number of words) of) I," etc.
When the user has completed the desired subscriptions and filters, he/she indicates completion (step 66), such as by clicking on an Enter button in the user interface. The information entered, including all changes, is then sent (step 68) back to the server 20, for entry into the library 50 of subscribed channels and filters. Thereafter, that information is used to identify information items to be sent to the client 8.
USER INTERFACE FEATURES RELATING TO SOUND PLAYBACK
1. SOUND PLAYBACK FEATURES
In addition to those aspects of the user interface according to the invention discussed above, related to subscribing to channels and filtering, a preferred implementation of the invention includes an interface defined in terms of a commonly known interface paradigm usually applied to audio devices such as compact disc players or tape recorders. Play, pause, rewind, fast-forward and other similar tasks are provided, preferably by means of mouse click buttons in a graphical user interface. Also, a set of new features is introduced. A user can play the clips in reverse or repeat them more than once.
2. MAPPING DIFFERENT SOUNDS TO DIFFERENT INFORMATION
As discussed above, audio clips being played may be headed and ended with Prelude and Postlude sounds, such as fanfares, chimes, etc. Also a background sound, played concurrently with the information, is provided and can be changed or turned off. Preferably, a plurality of such sounds are available, and a flexible triggering mechanism is supplied, which plays back such sounds based on the content of the information items. The user maps sounds to information by channel or filter, preferably during the process of FIG. 6.
Accordingly, when an information item occurs, which has been suitably flagged by the user, the user is notified by an audio icon he/she has chosen for that information, and which he/she recognizes as such. For instance, if a specified stock suddenly drops its value by a specified amount, the user hears a warning sound of a siren selected for use when an information item occurs from the stock channel, filtered by the stock name and the amount of the price drop.
3. SOUND PLAYBACK MODES FOR REPETITIVE MESSAGES
It will often be the case that a particular desired information item is an item which will, from time to time, be updated in value, status, etc. For instance, desired information might include changes in the price of a stock. Such changes will only occur during a time interval while the stock market is open. While the market is open, however, a series of price fluctuations may take place. Then, a final price will stand at the close of the stock market's session.
For another example, messages might be desired regarding the score of a baseball game in progress. A first message is given when the first team scores. Subsequent messages will be given as further scoring takes place. Then, when the game ends, a final score will be given.
In either instance, a succession of messages, all using the same prelude, postlude, or background might become undesirably repetitive to the user. To give the user an opportunity to accommodate his/her particular tasks in such situations, an audio ticker playing mode selection is provided. Two modes are as follows:
(a) Play once: some users do not like to hear the audio get repeatedly played, so a "play once" option may be selected. The audio gets played only once when the information is received from the push server. For instance, the first stock price quote of the day might be accompanied by the familiar bell ringing used to open and close sessions of the New York Stock Exchange. Once the first price quote has been given, with the bell sound, subsequent stock price quotes omit the bell.
In the baseball example, the opening score could be accompanied by, for instance, a segment of "Take Me Out To The Ball Game," to draw the user's attention to the fact that the item pertains to a baseball game which is beginning. Subsequent scores could omit the tune. The same tune, or a different sound, could be used to signal the final score. An additional option could be that different sounds are used depending on the content of the token. For example, different sounds could be used for the report of the final score, depending on the outcome of the game. For instance, if the user's home team wins, the final score could be accompanied by a clip chosen to convey victory, such as a clip of "Happy Days Are Here Again."
(b) Play when updated: some users want to hear a ticker item whenever its content is updated from its last value. For example, if the user listens to the stock channel of the audio ticker and there are 20 stocks in the channel. The ticker will play the stock whose value have been updated since the last time the value was received from the push server.
4. VOICE OTHER THAN A TRANSCRIPT OF THE INFORMATION ITEM
The discussion above has focused on providing a substantially word-for-word voice representation of the content of an information token. For instance, if an information token from a weather channel indicates that it will rain later that day, the voice clips played for the user give merely a statement that rain is coming.
However, it is also possible to include audio clips in the library 16 (or the server library 22) which give other information which, in some suitable way, follows from the information in the token. For instance, if an information token from a weather channel indicates that it will rain later that day, the voice clips played for the user could include a directive to the user to take an umbrella and a raincoat, in addition to (or in place of) the statement that rain is coming.
5. SOUND CONTENT OTHER THAN VOICE
Where the information items include text tokens such as stock quotes received from the push server, voice is sufficient to communicate the message to the user. Other sounds, such as preludes, postludes, and background, as described above, are used to attract the user's attention, rather than to convey additional content.
However, with the current trend of fast growing amount of audio data on the cyberspace, the audio ticker design is also extended to take advantage of such information resources. Therefore, an audio ticker channel can contain audio clips such as sports highlights, speeches, music, etc.
6. USING THE USER'S CLIENT SYSTEM AS AN INFORMATION SOURCE
Information resources may originate, not only from the push server, but also from the user's personal computer. Where the client 8 is supported by a platform of a general purpose computer, or the like, the computer may also concurrently run another application program which handles information that can be conveyed to the user as audio signals. That application program may then be treated as another information channel, in a manner generally equivalent to the way in which the system of the invention treats the external or remote information channels.
For example, the audio ticker can have a reminder channel that plays the entries of the user's calendar. A meeting scheduled on the user's on-line calendar utility generates an information token which is provided to the mapper 14, the message saying "you have a meeting at 10 o'clock", "your phone bill is due today", etc.
7. "PERSONAL RADIO": COMBINING INFORMATION MESSAGES WITH ONGOING BACKGROUND SOUNDS
Conventional machines which can serve as the client system 8, such as IBM Corporation's Dock II docking station for use with a ThinkPad laptop computer, provide audio playback capability, such as a CD-ROM drive with an audio CD driver application. Other systems have the capability of playing back broadcast audio, such as music from radio stations.
Such a novel user interface may be characterized as a "personal radio." Thus, business-related information, such as the audio clips discussed above, may be integrated with entertainment, such as one's favorite music. Alternatively, a company or product theme song or jingle may be used as a background while stock quotes are being played, thus providing an integrated advertising sound presentation.
8. USE WITH PORTABLE DEVICES
A class of portable information tools has appeared on the market in recent years. These tools include cordless cellular telephones, laptop computers, "personal digital assistant" devices, etc. Many of such devices have interfaces for accepting downloaded information for later, stand-alone use by the user. An increasing number of such devices also have audio playback capabilities.
A system according to the invention may advantageously be used with such portable devices. Audio information produced by a system according to the invention, such as voice messages with preludes, etc., may be downloaded onto these portable devices.
Using the foregoing specification, the invention may be implemented using standard programming and/or engineering techniques using computer programming software, firmware, hardware or any combination or subcombination thereof. Any such resulting program(s), having computer readable program code means, may be embodied or provided within one or more computer readable or usable media such as fixed (hard) drives, disk, diskettes, optical disks, magnetic tape, semiconductor memories such as read-only memory (ROM), etc., or any transmitting/receiving medium such as the Internet or other communication network or link, thereby making a computer program product, i.e., an article of manufacture, according to the invention. The article of manufacture containing the computer programming code may be made and/or used by executing the code directly from one medium, by copying the code from one medium to another medium, or by transmitting the code over a network.
An apparatus for making, using, or selling the invention may be one or more processing systems including, but not limited to, a central processing unit (CPU), memory, storage devices, communication links, communication devices, servers, I/O devices, or any subcomponents or individual parts of one or more processing systems, including software, firmware, hardware or any combination or subcombination thereof, which embody the invention as set forth in the claims.
User input may be received from the keyboard, mouse, pen, voice, touch screen, or any other means by which a human can input data to a computer, including through other programs such as application programs.
One skilled in the art of computer science will easily be able to combine the software created as described with appropriate general purpose or special purpose computer hardware to create a computer system and/or computer subcomponents embodying the invention and to create a computer system and/or computer subcomponents for carrying out the method of the invention. While the preferred embodiment of the present invention has been illustrated in detail, it should be apparent that modifications and adaptations to that embodiment may occur to one skilled in the art without departing from the spirit or scope of the present invention as set forth in the following claims.
While the preferred embodiments of the present invention have been illustrated in detail, it should be apparent that modifications and adaptations to those embodiments may occur to one skilled in the art without departing from the scope of the present invention as set forth in the following claims. | For use with client/server or network communication and processing systems, such as the Internet, a "push" information system is provided, for automatically providing information to a user. The information is provided in audio form. The system includes a library of prerecorded sounds, including a dictionary of words and phrases. When information appears, for instance in text format, a mapper produces a sequence of audio clips from the library, to convey information substantially identical to that in the information. This sequence of audio clips is played at the user's terminal. Thus the user is exposed to the information, while the user continues to use an application on the terminal. The information does not require screen real estate, and the user need not look away from his/her work in order to receive the information. | 7 |
This application is a request for U.S. examination under 35 U.S.C. §371 of International application No. PCT/JP93/00331 filed on Mar. 22, 1993.
TECHNICAL FIELD
The present invention relates to a chelating agent, a complex compound of said chelating agent and a metallic atom and a diagnostic agent containing said complex compound. More particularly, the present invention relates to a novel metallic chelating agent capable of forming a complex compound with a metallic atom, a complex compound of said chelating agent and a metallic atom which is useful for medical diagnosis, and a diagnostic agent containing said complex compound.
BACKGROUND ART
An image diagnosis which is based on images conveying the information of a lesion is an indispensable method for clinical diagnosis. In addition to an X-ray CT which is one of the image diagnoses currently in wide use, new distinguished techniques for image diagnosis such as Magnetic Resonance Imaging (MRI) have been developed for the last decade or so, and are making great contribution to the development of image diagnosis.
MRI has been recently introduced into the medical field and rapidly improved to be widely used ever since. MRI is advantageously characterized in that it is free of exposure since it does not involve radiation. that optional cross section can be put into an image and that it is free of hindrance by bones, and these characteristics make MRI distinct from conventional X-ray CT. MRI shows magnetic resonance phenomena [usually a relaxation time (T 1 , T 2 ) of hydrogen atomic nucleus] of internal substances with different signal intensities. A paramagnetic substance promotes relaxation of proton (proton of water) and acts as a contrast medium capable of enhancing contrast of images. In particular, rare earth Gd (trivalent) has 7 unpaired electrons on the 4f orbit and has many coordinations (9 or 10), which results in a strong relaxation effect to provide a powerful contrast medium [R. B. Lauffer, Chem. Rev., 87, 901 (1987)]. However, Gd (trivalent) is not discharged from the body and poses toxicity problem.
For this reason, Gd is administered as a complex compound (Gd-DTPA) with a known chelating agent DTPA (diethylenetriaminepentaacetic acid).
Gd-DTPA has been acknowledged to be useful for clinical diagnosis. However, there are many problems to be resolved with respect to Gd-DTPA. For example, the drug per se has a short half-life in blood and poor tissue selectivity and shows a high osmotic pressure since it is present as a bivalent anion complex under physiological conditions. While various approaches have been taken to overcome these problems (Japanese Patent Unexamined Publication Nos. 93758/1988, 1395/1989), they have not necessarily achieved satisfactory results.
Accordingly, research and development of new complex compounds, particularly of a ehelating agent, is significantly important.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a novel chelating agent capable of forming a complex compound characterized in that it exhibits superior contrast enhancement, tissue selectivity, stability and duration in blood, and it does not show high osmotic pressure, a complex compound comprising said chelating agent and a metallic atom, and a diagnostic agent containing said complex compound.
With the aim of solving the aforementioned problems, the present inventors have made intensive studies and found that a complex compound of a compound of the following formula (I) and a metallic atom shows superior contrast enhancement, tissue selectivity, stability and duration in blood and does not show high osmotic pressure, which resulted in the completion of the invention. That is, the present invention relates to a compound of the following formula (I) [hereinafter sometimes referred to as Compound (I) or merely as a chelating agent], its salt, a complex compound of the Compound (I) and a metallic atom, its salt and a diagnostic containing said complex compound or its salt. ##STR3## wherein: is an integer of 1 to 3;
R 1 and R 2 are the same or different and each is hydrogen atom or lower alkyl; and
R 3 , R 4 , R 5 and R 6 are the same or different and each is hydroxy or a group of the formula ##STR4## wherein: n is 0 or 1;
X is --NH-- or --O--;
Y is alkylene;
A is hydrogen atom, lower alkyl, lower alkoxy, halogen atom or trifluoromethyl; and
B is alkyl or alkenyl,
with the proviso that two or three of R 3 , R 4 , R 5 and R 6 are hydroxyl groups and that when two of them are hydroxyl groups, the cases where R 3 and R 5 are hydroxy, and R 4 and R 6 are hydroxy are excluded.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows accumulation, in an organ (liver, kidney or spleen), of the complex compound of the present invention comprising a chelating agent and a metallic atom when administered to rats.
DETAILED DESCRIPTION OF THE INVENTION
In the compounds of the above-depicted formula, lower alkyl may be straight- or branched chain and preferably has 1 to 4 carbon atoms, which is exemplified by methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl and tert-butyl.
Alkylene may be straight- or branched chain and preferably has 1 to 10 carbon atoms, which is exemplified by methylene, ethylene, trimethylene, propylene, tetramethylene, pentamethylene, 1-methylethylene, 1-methyltetramethylene, hexamethylenc, octamethylene and decamethylene.
Lower alkoxy may be straight- or branched chain and preferably has 1 to 4 carbon atoms, which is exemplified by methoxy, ethoxy, propoxy, butoxy and tert-butoxy.
Alkyl may be straight- or branched chain and preferably has 1 to 20 carbon atoms, which is exemplified by methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl, tert-butyl, pentyl, hexyl, octyl, decyl, dodecyl, tetradecyl and octadecyl.
Alkenyl may be straight- or branched chain and preferably has 2 to 20 carbon atoms, which is exemplified by hexenyl, octenyl, 3,7-dimethyl-2,6-dioctadienyl and 9-octadecenyl, with no limitation on the position and the number of double bond.
Halogen atom is exemplified by chlorine atom and bromine atom.
Of the compounds of the formula (I), preferred are those having a total carbon number of Y and B of 5 or more, more preferably 8-12. While there is no limitation on the bonding site of A and B which are the substituents on phenyl, B is preferably bonded at the meta- or para position relative to Y.
Preferably, the salts of the compound of the present invention are pharmaceutically acceptable ones and are exemplified by salts with metal such as sodium and potassium, salts with organic base such as ethanolamine, morpholine and meglumine (N-methylglucamine), and salts with amino acid such as arginine and ornithine.
The compounds of the present invention can be produced by various methods and they are obtainable, for example, by the method shown by the following reaction formulas. ##STR5## wherein m, n, R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , Y, A and B are as defined above and X, is --NH 2 or --OH.
In the reaction step as described, Compound (III) which is an acid anhydride can be obtained by, for example, subjecting a Compound (II) to a known dehydration using acetic anhydride, dicyclohexylcarbodiimide, 1,1'-carbonyldiimidazole or the like.
The reaction proceeds in a solvent which does not adversely affect the reaction at about 50°-100° C. for about 3 hours to 3 days.
Compound (I) is obtained by reacting a compound (III) and a compound (IV). The reaction between the compound (III) and the compound (IV) can be carried out according to a conventional method including reaction of an acid anhydride and an amino compound or a hydroxyl compound. For example, a compound (III) is dissolved in an organic solvent such as N,N-dimethylformamide (DMF) and a compound (IV) is added thereto upon dissolution in an organic solvent such as methylene chloride or chloroform on demand, followed by reaction at about room temperature to 90° C. for about 30 minutes to 5 days. During this reaction, a basic compound such as pyridine, triethylamine or N,N-dimethylaniline may be added.
When a Compound (I) wherein two of R 3 -R 6 are hydroxyl groups is desired, a compound (IV) is used in 2.0 to 2.3 equivalents relative to a compound (III). When a compound having three hydroxyl groups is desired, a compound (IV) is used in 1.0 to 1.3 equivalents relative to a compound (III). In the latter case wherein hydroxyl groups are three, water (about 1.0 equivalent) is added after the reaction and a reaction under the same reaction conditions as above is carried out, thereby to hydrate the unreacted anhydrous carboxylic acid moiety to introduce same into a Compound (I). The addition of water to the anhydrous carboxylic acid moiety may be performed with the compound (III) prior to the reaction between the compound (III) and the compound (IV).
The salts of the Compound (I) can be prepared according to conventional methods.
The Compound (I) and its salt thus obtained are isolated and purified by a conventional method such as recrystallization, reprecipitation and column chromatography.
The complex compound of the present invention comprises the aforementioned Compound (I) and a metallic atom and preparation of the complex compound can be done by a method known in the pertinent field. For example, an oxide or halide compound of a metal is added to water and treated with an equimolar amount of the Compound (I) or its salt. The Compound (I) and its salt can be added as an aqueous solution. When solubility in water may be low, an organic solvent such as methanol, ethanol, acetone or dimethylsulfoxide may be added. Where necessary, a dilute acid or a dilute base is added for pH control. Heating and cooling involved when preparing a complex compound may be done as appropriate. Pharmaceutically acceptable salts of the complex compound of the present invention are prepared by neutralizing the complex compound with an acid such as an organic acid or an inorganic acid, or a base such as alkali metal hydroxide or basic amino acid, while the complex compound is still in a dissolution state.
The diagnostic agent of the present invention comprises the aforementioned complex compound or its salt and can be used as an MRI diagnostic, X-ray diagnostic, nuclear medicine diagnostic or ultrasonic diagnostic, according to metallic atom selected as appropriate. Particularly preferably, it is used as an MRI diagnostic. In this case, preferable metallic atoms for the complex compound are the elements of atomic number 21-29, 42, 44, and 57-70. The central metallic ion of the complex compound needs to be paramagnetic and bivalent, and trivalent ions of the aforementioned metallic atoms are preferable. Examples of suitable ion include chromium (III), manganese (II), iron (III), cobalt (II), nickel (II), copper (II), praseodymium (III), neodymium (III), samarium (III), gadolinium (III), terbium (III), dysprosium (III), holmium (III), erbium (III) and ytterbium (III) ions, with particular preference given to gadolinium (III), terbium (III), dysprosium (III), holmium (III), erbium (III) and iron (III) ions.
When used as a nuclear medicine diagnostic, the metallic atom of the complex compound needs to be radioactive and, for example, a radioisotope of an element such as gallium, technetium, indium or yttrium is used.
When used as an X-ray diagnostic, the metallic atom of the complex compound needs to absorb X-rays and, for example, a metal of lanthanum series, tantalum or the like is used. These complex compounds are usable as ultrasonic diagnostics.
The diagnostic agent of the present invention is provided in the form of an aqueous solution, emulsion, liposome preparation or a lyophilized preparation thereof, which are prepared by conventional means for producing pharmaceutical preparations from an aqueous solution of the aforementioned complex compound. When in use, the lyophilized preparation is dissolved or dispersed in a suitable diluent. The diagnostic agent of the present invention may contain physiologically acceptable buffer such as tris(hydroxymethyl)aminomethane or other physiologically acceptable additives such as stabilizer (e.g. p-hydroxybenzoate esters). The diagnostic agent of the present invention can be used in the same manner as when using other conventional diagnostic-agents and, for example, a liquid preparation is orally or parenterally administered to mammals inclusive of human. The dose is substantially the same as that of the conventional diagnostic agents and is about 0.001-5 mmol/kg, usually about 0.005-0.5 mmol/kg.
The complex compound composed of the compound of the present invention and a metallic atom exhibits superior contrast enhancement, tissue selectivity, stability and duration in blood and does not show high osmotic pressure. Accordingly, it is useful for medical diagnosis, in particular, for MRI diagnosis. The complex compound of the present invention is advantageously used for imaging various organs such as liver and spleen, tumor, blood vessels etc. and is also useful as a diagnostic agent for arterial sclerosis. The complex compound specifically shows high accumulation in the lesions of atherosclerosis and is useful for the diagnosis of atherosclerosis. Also, the complex compound is useful for the diagnosis of liver tumor. In addition, the compound of the present invention has a benzene ring in the molecule. Therefore, tracing and analysis of internal kinetics and concentration in blood of the complex compound can be easily done using UV absorption (e.g. at 254 nm) as an index. Furthermore, the compound of the present invention is appropriately liposoluble and has affinity for lipids. For this reason, the complex compound of the present invention is easily prepared into a lipid emulsion or liposome by a known method, thus enabling further improvement in tissue selectivity. The preferable compounds are N-(4 -octylphenylcarbamoylmethyl) diethylenetriamine-N,N',N",N"-tetraacetic acid (DTPA-OA, Example 4 to be mentioned later); N-(4-hexylphenylcarbamoylmethyl) diethylenetriamine-N,N',N",N"-tetraacetic acid (DTPA-HA, Example 5 to be mentioned later); N-(4-decylphenylcarbamoylmethyl) diethylenetriamine-N,N',N",N"-tetraacetic acid (DTPA-DeA, Example 6 to be mentioned later); and N-(4-dodecylphenylcarbanoylmethyl)diethylenetriamine-N,N',N",N"-tetraacetic acid (DTPA-DoA, Example 7 to be mentioned later).
While the present invention is explained in detail by illustration of Examples and Experimental Examples in the following, the present invention is not limited to them.
EXAMPLE 1
Synthesis of diethylenetriaminepentaacetic acid dianides--1 [A Compound (I) wherein m=1, R 1 =R 2 =H, R 3 =R 4 =p-C 8 H 17 C 6 H 4 NH, R 5 =R 6 =OH, DTPA-DIOA]
Diethylenetriaminepentaacetic acid dianhydride (2.05 g, 5.7 mmol) was dissolved in dry DMF (100 ml). A solution of 4-octylaniline (2.36 g, 11.4 mmol) in methylene chloride (10 ml) was added thereto and the mixture was stirred at room temperature for 15 hours. The resultant crystals were collected by filtration, washed with ether and recrystallized (ethanol: methanol:benzene=6:1:1) to give 3.64 g of the object compound (white amorphous, mp 207.0°-208.5° C.), yield 82.7%.
1 H-NMR (CDCl 3 +CF 3 COOD) δ: 0.88 (6H, t, J=6.4Hz ), 1.2-1.4 (20H, m ), 1.5-1.7 (4H, m), 2.57 (4H, t, J=7.6Hz), 3.2-3.4 (4H, m), 3.6-3.9 (6H, m), 4.33 (4H, s), 4.43 (4H, s), 7.16 (8H, s)
IR (KBr): 3350, 1680, 1620 cm -1
EXAMPLE 2
Synthesis of diethylenetriaminepentaacetic acid dianides--2 [A Compound (I) wherein m=1, R 1 =R 2 =H, R 3 =R 4 =p-C 6 H 13 C 6 H 4 NH, R 5 =R 6 =OH, DTPA-DIIIA]
Diethylenetriaminepentaacetic acid dianhydride (2.02 g, 5.7 mmol) was dissolved in dry DMF (100 ml). A solution of 4-hexylaniline (2.02 g, 11.4 mmol) in methylene chloride (10 ml) was added thereto and the mixture was stirred at room temperature for 15 hours. The solvent was distilled away and the residue was crystallized with ether and recrystallized (THF: methanol=3:1) to give 3.36 g of the object compound (white amorphous, mp 207.5°-209.0° C.), yield 82.8%.
1 H-NMR (CDCl 3 +CF 3 COOD) δ: 0.88 (6H, t, J=6.2Hz), 1.2-1.4 (12H, m), 1.5-1.7 (4H, m), 2.58 (4H, t, J=7.7Hz), 3.2-3.4 (4H, m), 3.7-3.9 (6H, m), 4.34 (4H, s), 4.44 (4H, s), 7.17 (8H, s)
IR (KBr): 3330, 1680, 1620 cm -1
EXAMPLE 3
Synthesis of triethylenetetraminehexaacetic acid diamides [A Compound (I) wherein m=2, R 1 =R 2 =H, R 3 =R 4 =p-C 8 H 17 C 6 H 4 NH, R 5 =R 6 =OH, TTHA-DIOA]
Triethylenetetraaminehexaacetic acid dianhydride (1.20 g, 2.6 mmol, obtained from triethylenetetraaminehexaacetic acid by conventional dehydration using acetic anhydride and anhydrous pyridine) was dissolved in dry DMF (120 ml). A solution of 4-octylaniline (1.04 g, 5.1 mmol) in methylene chloride (10 ml) was added thereto and the mixture was stirred at room temperature for 4 days. The resultant crystals were collected by filtration, washed with ether and then with ethanol and recrystallized (THF:methanol=3:1) to give 1.55 g of the object compound (white amorphous, mp 212.5°-214.0° C.), yield 68.0%.
1 H-NMR (CDCl 3 +CF 3 COOD) δ:0.88 (6H, t, J=6.4Hz), 1.2-1.4 (20H, m), 1.5-1.7 (4H, m), 2.59 (4H, t, J=7.7Hz), 3.4-3.8 (8H, m), 3.8-4.1 (8H, m), 4.36 (4H, m), 4.50 (4H, m), 7.19 (8H, s)
IR (KBr): 3600-3200, 1720, 1670 cm -1
EXAMPLE 4
Synthesis of diethylenetriaminepentaacetic acid monoamides--1 [A Compound (I) wherein m=1, R 1 =R 2 =H, R 3 =p-C 8 H 17 C 6 H 4 NH, R 4 =R 5 =R 6 =OH, DTPA-OA]
Diethylenetriaminepentaacetic acid dianhydride (3.00 g, 8.4 mmol) was dissolved in dry DMF (45 ml) at 75° C. Water (0.15 ml, 8.3 mmol) was dropwise added thereto and the mixture was stirred at said temperature for 1 hour to produce diethylenetriaminepentaacetic acid monoanhydride. 4-Octylaniline (1.75 g, 8.3 mmol) was dropwise added thereto and the mixture was stirred at said temperature for 1 hour. The mixture was purified by column chromatography (eluate: 40% aqueous methanol) to give 1.48 g of the object compound (white amorphous, mp 164.0°-167.0° C.), yield 30.0%.
1 H-NMR (CD 3 OD+CF 3 COOD) δ: 0.89 (3H, t, J=6.4Hz ), 1.1-1.5 (10H, m), 1.5-1.7 (2H, m), 2.56 (2H, t, J=7.5Hz ), 3.1-3.4 (4H, m), 3.4-3.6 (4H, m), 3.6-3.9 (8H, m), 4.36 (2H, s), 7.13 (2H, d, J=8.4Hz), 7.49 (2H, d, J=8.4Hz)
IR (KBr): 3400-3000, 1680, 1610 cm -1
EXAMPLE 5
Synthesis of diethylenetriaminepentaacetic acid monoamides--2 [A Compound (I) wherein m=1, R 1 =R 2 =H, R 3 =p-C 6 H 13 C 6 H 4 NH, R 4 =R 5 =R 6 =OH, DTPA-HA]
Diethylenetriaminepentaacetic acid dianhydride (3.00 g, 8.4 mmol) was dissolved in dry DMF (45 ml) at 75° C. Water (0.15 ml, 8.3 mmol) was dropwise added thereto and the mixture was stirred at said temperature for 1 hour to produce diethylenetriaminepentaacetic acid monoanhydride. 4-Hexylaniline (1.47 g, 8.3 mmol) was dropwise added thereto and the mixture was stirred at said temperature for 1 hour. The mixture was purified by column chromatography (eluate: 20% aqueous methanol) to give 1.74 g of the object compound (slightly yellow amorphous, mp 159.0°-160.0° C.), yield 38.0%.
1 H-NMR (CD 3 OD) δ: 0.89 (3H, t, J=6.5Hz), 1.2-1.5 (6H, m), 1.5-1.8 (2H, m), 2.55 (2H, t, J=7.5Hz), 3.1-3.5 (8H, m), 3.60 (2H, brs), 3.68 (6H, brs), 3.79 (2H, brs), 7.11 (2H, d, J=8.4Hz), 7.53 (2H, d, J=8.4Hz)
IR (KBr): 3380-3000, 1680, 1610 cm -1
EXAMPLE 6
Synthesis of diethylenetriaminepentaacetic acid monoamides--3 [A Compound (I) wherein m=1, R 1 =R 2 =H, R 3 =p-C 10 H 21 C 6 H 4 NH, R 4 =R 5 =R 6 =OH, DTPA-DeA]
Diethylenetriaminepentaacetic acid dianhydride (3.97 g, 11.1 mmol) was dissolved in dry DMF (60 ml) at 75° C. Water (0.20 ml, 11.1 mmol) was dropwise added thereto and the mixture was stirred at said temperature for I hour to produce diethylenetriaminepentaacetic acid monoanhydride. A solution of 4-decylaniline (2.59 g, 11.1 mmol) in dry methylene chloride (5 ml) was dropwise added thereto and the mixture was stirred at said temperature for 1 hour. The mixture was purified by column chromatography (eluate: 40% aqueous methanol) to give 3.06 g of the object compound (white amorphous, mp 169.0°-172.0° C.), yield 45.3%.
1 H-NMR (CD 3 OD) δ: 0.89 (3H, t, J=6.3Hz), 1.2-1.4 (14H, m), 1.5-1.7 (2H, m), 2.56 (2H, t, J=7.5Hz), 3.1-3.4 (8H, m), 3.59 (2H, s), 3.63 (4H, s), 3.71 (2H, s), 3.73 (2H, s), 7.12 (2H, d, J=8.3Hz), 7.53 (2H, d, J=8.3Hz)
IR (KBr): 3500-3000, 1680, 1620 cm -1
EXAMPLE 7
Synthesis of diethylenetriaminepentaacetic acid monoamides--4 [A Compound (I) wherein m=1, R 1 =R 2 =H, R 3 =p-C 12 H 25 C 6 H 4 NH, R 4 =R 5 =R 6 =OH, DTPA-DoA]
Diethylenetriaminepentaacetic acid dianhydride (3.97 g, 11.1 mmol) was dissolved in dry DMF (60 ml) at 75° C. Water (0.20 ml, 11.1 mmol) was dropwise added thereto and the mixture was stirred at said temperature for 1 hour to produce diethylenetriaminepentaacetic acid monoanhydride. A solution of 4-dodecylaniline (2.91 g, 11.1 mmol) in dry methylene chloride (5 ml) was dropwise added thereto and the mixture was stirred at said temperature for 1 hour. The mixture was purified by column chromatography (eluate: 40% aqueous methanol) to give 2.60 g of the object compound (white amorphous, mp 171.0°-173.5° C.), yield 36.7%.
1 H-NMR (CD 3 OD) δ: 0.89 (3H, t, J=6.4Hz), 1.2-1.4 (16H, m), 1.5-1.7 (2H, m), 2.56 (2H, t, J=7.5Hz), 3.1-3.4 (8H, m), 3.50 (2H, s), 3.61 (2H, s), 3.66 (4H, s), 3.71 (2H, s), 7.11 (2H, d, J=8.4Hz), 7.54 (2H, d, J=8.4Hz)
IR (KBr): 3500-3000, 1680, 1620 cm -1
EXAMPLE 8
Synthesis of triethylenetetraaminehexaacetic acid monoamides--1 [A Compound (I) wherein m=2, R 1 =R 2 =H, R 3 =p-C 8 H 17 C 6 H 4 NH, R 4 =R 5 =R 6 =OH, TTHA-OA]
Triethylenetetraaminehexaacetic acid dianhydride (4.63 g, 10.1 mmol) was dissolved in dry DMF (55 ml) at 80° C. Water (0.18 ml, 10 mmol) was dropwise added thereto and the mixture was stirred at said temperature for 30 minutes to produce triethylenetetraaminehexaacetic acid monoanhydride. 4-Octylaniline (2.3 ml, 10.1 mmol) was dropwise added thereto and the mixture was stirred at said temperature for 1 hour. The mixture was purified by HPLC (eluate: 35% aqueous methanol) to give 2.28 g of the object compound (brown amorphous, mp 182°-184° C.), yield 33%.
1 H-NMR (CD 3 OD) δ:0.89 (3H, t, J=6.4Hz), 1.1-1.45 (10H, m), 1.45-1.7 (2H, m), 2.56 (2H, t, J=7.5Hz), 2.9-3.25 (6H, m), 3.25-3.55 (10H, m), 3.57 (2H, s), 3.65-3.9 (6H, m), 7.11 (2H, d, J=8.4Hz), 7.55 (2H, d, J=8.4Hz)
IR (KBr): 3400, 1620 cm -1
EXAMPLE 9
Synthesis of triethylenetetraaminehexaacetic acid monoamides--2 A Compound (I) wherein m=2, R 1 =R 2 =H, R 3 =p-C 6 H 13 C 6 H 4 NH, R 4 =R 5 =R 6 =OH, TTHA-HA]
Triethylenetetraaminehexaacetic acid dianhydride (500 mg, 1.1 mmol) was dissolved in dry DMF (10 ml) at 80° C. Water (0.02 ml, 1.1 mmol) was dropwise added thereto and the mixture was stirred at said temperature for 1 hour to produce triethylenetetraaminehexaacetic acid monoanhydride. 4-Hexylaniline (0.18 g, 1.0 mmol) was dropwise added thereto and the mixture was stirred at said temperature for 1 hour. The mixture was purified by column chromatography (eluate: 20% aqueous methanol) to give 119 mg of the object compound (colorless amorphous, mp 168.0°-170.0° C.), yield 18.0%.
1 H-NMR (CD 3 OD) δ: 0.89 (3H, t, J=6.4Hz), 1.2-1.5 (6H, m), 1.5-1.7 (2H, m), 2.57 (2H, t, J=7.5Hz), 3.0-3.3 (6H, m), 3.3-3.5 (6H, m), 3.5-3.6 (4H, m), 3.61 (2H, s), 3.7-3.9 (6H, m), 7.11 (2H, d, J=8.4Hz), 7.54 (2H, d, J=8.4Hz )
IR (KBr): 3380-3000, 1680, 1610 cm -1
EXAMPLE 10
Synthesis of diethylenetriaminepentaacetic acid diesters--1 [A Compound (I) wherein m=1, R 1 =R 2 =H, R 3 =R 4 =p-C 4 H 9 C 6 H 4 CH 2 O, R 5 =R 6 =OH]
Diethylenetriaminepentaacetic acid dianhydride (1.43 g, 4.00 mmol) was dissolved in dry DMF (24 ml) at 80° C. A solution of 4-butylbenzyl alcohol (1.32 g, 8.00 mmol) in dry DMF (12 ml) was added thereto and the mixture was stirred at said temperature for 16 hours. The solvent was distilled away and the residue was recrystallized (chloroform-hexane) to give 2.04 g of the object compound (white amorphous, mp 61.5°-63.5° C.), yield 74.5%.
1 H-NMR (CDCl 3 ) δ:0.90 (6H, t, J=7.2Hz), 1.2-1.4 (4H, m), 1.5-1.6 (4H, m), 2.56 (4H, t, J=7.6Hz ), 3.0-3.2 (4H, m), 3.3-3.7 (12H, m), 4.0-4.2 (2H, m), 5.02 (4H, s), 7.10 (4H, d, J=8.1Hz ), 7.19 (4H, d, J=8.1Hz)
IR (KBr): 3400, 1730, 1620 cm -1
EXAMPLE 11
Synthesis of diethylenetriaminepentaacetic acid diesters--2 [A Compound (I) wherein m=1, R 1 =R 2 =H, R 3 =R 4 =p-C 13 H 27 C 6 H 4 CH 2 O, R 5 =R 6 =OH]
In the same manner as in Example 10 except that 4-tridecylbenzyl alcohol (synthesized by conventional method) was used in place of 4-butylbenzyl alcohol, the object compound (pale yellow amorphous, mp 157.0°-161.0° C.) was obtained.
1 -NMR (CDCl 3 +CF 3 COOD) δ:0.87 (6H, t, J=6.3Hz), 1.2-1.4 (40H, m), 1.5-1.7 (4H, m), 2.56 (4H, t, J=7.4Hz ), 3.1-3.9 (10H, m), 4.0-4.3 (8H, m), 5.12 (4H, brs), 7.15 (8H, t)
IR (KBr): 3400, 1730, 1700, 1620 cm -1
EXAMPLE 12
Synthesis of diethylenetriaminepentaacetic acid monoesters
A Compound (I) wherein m=1, R 1 =R 2 =H, R 3 =p-C 13 H 27 C 6 H 4 CH 2 O, R 4 =R 5 =R 6 =OH, DTPA-TBE]
In the same manner as in Example 4 except that 4-tridecylbenzyl alcohol was used in place of 4-octylaniline, the object compound (pale yellow amorphous, mp 194.0°-197.0° C.) was obtained.
1 H-NMR (CDCl 3 +CF 3 COOD) δ:0.88 (3H, t, J=6.6Hz), 1.2-1.4 (20H, m), 1.5-1.7 (2H, m), 2.61 (2H, t, J=7.8Hz), 3.3-3.4 (4H, m), 3.6-3.8 (4H, m), 3.80 (2H, s), 4.26 (6H, s), 4.31 (2H, s), 5.22 (2H, s), 7.21 (4H, s)
IR (KBr): 3400, 1720, 1700, 1630 cm -1
EXAMPLE 13
Preparation of Gd·DTPA-OA complex compound
To an aqueous solution of DTPA-OA (5.8 g) obtained by the method of Example 4 in distilled water (800 ml) was gradually added a 0.05M GdCl 3 solution (200 ml) and the mixture was stirred while adjusting its pH to about 7.0 with 0.1N aqueous solution of NaOH, followed by reaction at room temperature for about 1 hour. After the reaction, the reaction mixture was lyophilized to give 7.92 g of Gd·DTPA-OA complex compound.
EXAMPLE 14
Preparation of Gd·DTPA-DeA complex compound
In the same manner as in Example 13 except that DTPA-DeA obtained by the method of Example 6 was used in place of DTPA-OA, the object complex compound was obtained.
EXAMPLE 15
Preparation of lipid-emulsified complex compound
Purified egg yolk phospholipid (60 g) and Gd·DTPA-DeA complex compound (40 g) were added to purified soybean oil (100 g) and mixed. Distilled water (1750 ml) and glycerin (20.0 g) were added thereto and the mixture was homogenized in a homomixer. The mixture was subjected to high-pressure emulsification in a Manton-Gaulin high pressure homogenizer to give a homogenized highly fine Gd·DTPA-DeA lipid emulsion having an average particle size of not more than 1 μm. The osmotic pressure of the obtained Gd·DTPA-DeA lipid emulsion to physiological saline was about 1.0.
Experimental Example 1
Diagnosis of atherosclerosis using complex compound of the invention
Rabbit models with arterial sclerosis were fixed at the dorsal position without anesthetizing and an aqueous solution of Gd·DTPA-OA as obtained in Example 13 was continuously administered to the rabbits at 2 ml/min from the auricular vein at a dose of 200 μmol/kg. The rabbits were poisoned to death at 5 min, 30 min or 6 hours after the administration and the thoracica aorta was removed. The fat adhered to the outside of the aorta was carefully removed and the blood vessel was incised to remove the sclerosis lesion. The lesion was placed in an NMR test tube and subjected to MRI imaging. The MRI system was Siemens Magnetom 1.5T and the coil used was an eye coil. Image pickup was done at time of repetition (TR)=500 msec, echo time (TE)=22 msec, slice thickness=1 mm, accumulation=8 times and matrix=128×256.
The obtained image clearly showed the sclerosis lesion in the blood vessel with distinct contrast between the sclerosis lesion and where not, thus proving its usefulness as a contrast medium for MRI diagnosis.
Experimental Example 2
Measurement of internal distribution in rat organs
An aqueous solution of Gd. DTPA-DoA as obtained by the procedure similar to that in Example 13 was bolus-administered at 0.02 mmol/kg from the tail vein. The test animal was slaughtered with CO 2 gas at 30 min, 1 hour, 2 hours, 4 hours, 6 hours or 24 hours after the administration and dehematized. Organs (liver, kidney and spleen) were removed. After homogenizing each organ, ethanol was added thereto and the mixture was centrifuged to give a supernatant. The supernatant was subjected to HPLC (65% methanol, 1% triethylamine, pH 7.0, C18 column) to measure the amount of the complex compound and the percentage thereof to the dose was calculated. The results are shown in FIG. 1. As shown in FIG. 1, a superior accumulation in liver was found. | A compound of the following formula ##STR1## wherein m is an integer of 1 to 3, R 1 and R 2 are the same or different and each is hydrogen atom or lower alkyl, and R 3 , R 4 , R 5 and R 6 are the same or different and each is hydroxy or a ##STR2## (wherein n is 0 or 1, X is --NH-- or --O--, Y is alkylene, A is hydrogen atom, lower alkyl, lower alkoxy, halogen atom or trifluoromethyl, and B is alkyl or alkenyl), with the proviso that two or three of R 3 , R 4 , R 5 and R 6 are hydroxyl groups and that when two of them are hydroxyl groups, the cases where R 3 and R 5 are hydroxy, and R 4 and R 6 are hydroxy are excluded; a complex compound comprising said compound and a metallic atom; and a diagnostic agent containing said complex compound. The above compound is useful as a chelating agent and the complex compound comprising said compound and a metallic atom exhibits superior characteristics as a contrast medium for image diagnosis. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to high gas barrier, delamination-resistant polyamide compositions suitable for extended shelf-life packaging applications. The invention also pertains to polyamide compositions exhibiting high oxygen scavenging capability. The polyamide products are particularly suited for producing barrier packaging articles such as monolayer or multi-layer films, sheets, thermoformed containers and molded bottles. Such articles are useful in a variety of oxygen-sensitive food, beverage, pharmaceutical, and health care product packaging applications.
[0003] 2. Description of the Related Art
[0004] It is well known in the art to polyamide based packaging articles such as films, bottles and containers, which are useful for food packaging. In order to enhance freshness preservation, it is well known to package food and beverage products within a packaging structure composed of multiple layers of two or more different plastics. For example, U.S. Pat. Nos. 5,055,355 and 5,547,765 teach laminates of polyamides and ethylene vinyl alcohol copolymers which have good oxygen barrier properties. Such packaging structures generally include a barrier plastic layer which has low permeation to oxygen and/or carbon dioxide.
[0005] In order to enhance freshness preservation, it is standard practice to package food and other materials within a laminated packaging material that generally includes a barrier layer having a low permeability to oxygen. The material can be thin, allowing it to be wrapped around the material being packaged, or it can be sufficiently thick to form a shaped container body. It is further known to include an oxygen scavenger in polymeric packaging materials. The oxygen scavenger reacts with oxygen that is trapped in the package or that permeates into the package. This is described, for instance, in U.S. Pat. Nos. 4,536,409 and 6,423,776.
[0006] Various types of oxygen scavengers have been proposed for this purpose. U.S. Pat. No. 4,536,409 recommends potassium sulfite as an oxygen scavenger. U.S. Pat. No. 5,211,875 discloses, the use of unsaturated hydrocarbons as oxygen scavengers in packaging films. It is also known in the art that ascorbic acid derivatives as well as sulfites, bisulfites, and phenolics, can be oxidized by molecular oxygen, and can thus serve as an oxygen scavenging material. U.S. Pat. Nos. 5,202,052 and 5,364,555 describe polymeric material carriers containing oxygen scavenging material. These polymeric carriers for the oxygen scavenging material include polyolefin, PVC, polyurethanes, EVA and PET.
[0007] There is an ongoing need in the art for a high barrier polymeric material which can provide low permeation of gaseous permeates through the material, as well as high oxygen scavenging capability. The present invention provides new polymeric compositions and structures formed therefrom that show such excellent gas barrier performance as well as high oxygen scavenging capacity, resulting in extended shelf lives of packaged foods or beverages.
[0008] More particularly, polymeric compositions of the invention are slow crystallizing blends including a first polyamide comprising a crystallizable polyamide homopolymer, copolymer or polyamide nanocomposite, or a blend thereof, and a second polyamide comprising a m-xylylene diamine moiety, an isophthalic acid moiety and at least one additional moiety comprising a polyamide monomeric precursor. Also provided are direct blends of the above polyamide compositions with other polymeric materials, for example, polyethylene terephthalate (PET), and articles formed therefrom. Each of the above compositions show good melt processability, good miscibility and slow crystallization to give a barrier layer with a high clarity and good adhesion to other polymer layers in multilayer structures. The compositions also exhibit good recyclability. The composition can also be used for applications of gas barrier films requiring oxygen scavenging capabilities.
SUMMARY OF THE INVENTION
[0009] The invention provides a polyamide composition comprising a slow crystallizing blend comprising:
[0000] (i) a first polyamide comprising a crystallizable polyamide homopolymer, a crystallizable polyamide copolymer, a crystallizable polyamide nanocomposite, or a blend thereof; and
[0000] (ii) a second polyamide comprising a polyamide copolymer comprising a m-xylylene diamine moiety, an isophthalic acid moiety, and at least one additional moiety comprising a polyamide monomeric precursor, and an optional clay.
[0010] The invention also provides a polyamide composition comprising a slow crystallizing blend comprising:
[0000] (i) a first polyamide comprising a crystallizable polyamide homopolymer, a crystallizable polyamide copolymer, a crystallizable polyamide nanocomposite, or a blend thereof;
[0000] (ii) a second polyamide comprising a polyamide copolymer comprising a m-xylylene diamine moiety, an isophthalic acid moiety, and at least one additional moiety comprising a polyamide monomeric precursor, and an optional clay;
[0000] (iii) at least one polyamide-compatible, oxidizable polydiene; and
[0000] (iv) at least one oxidation promoting metal salt catalyst.
[0011] The invention further provides a process for forming a polyamide composition comprising combining:
[0000] (i) a first polyamide comprising a crystallizable polyamide homopolymer, a crystallizable polyamide copolymer, a crystallizable polyamide nanocomposite, or a blend thereof; and
[0000] (ii) a second polyamide comprising a polyamide copolymer comprising a m-xylylene diamine moiety, an isophthalic acid moiety, and at least one additional moiety comprising a polyamide monomeric precursor, and an optional clay.
[0012] The invention still further provides a polymeric composition comprising:
[0000] (a) polyamide composition component comprising:
[0000]
(i) a first polyamide comprising a crystallizable polyamide homopolymer, a crystallizable polyamide copolymer, a crystallizable polyamide nanocomposite, or a blend thereof; and
(ii) a second polyamide comprising a polyamide copolymer comprising a m-xylylene diamine moiety, an isophthalic acid moiety, and at least one additional moiety comprising a polyamide monomeric precursor, and an optional clay; and
(b) at least one polymer component blended with said polyamide composition component.
[0015] The invention also provides a process for forming a polymeric composition comprising combining at least one polymer component with a polyamide composition component, the polyamide composition component comprising:
[0000] (i) a first polyamide comprising a crystallizable polyamide homopolymer, a crystallizable polyamide copolymer, a crystallizable polyamide nanocomposite, or a blend thereof; and
[0000] (ii) a second polyamide comprising a polyamide copolymer comprising a m-xylylene diamine moiety, an isophthalic acid moiety, and at least one additional moiety comprising a polyamide monomeric precursor, and an optional clay.
[0016] Also provided are films, bottles and other articles and containers formed from the polymeric compositions of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] In the first embodiment of the present invention, an improved polyamide composition is prepared by combining at least two polyamides. The first polyamide is a crystallizable polyamide homopolymer, crystallizable polyamide copolymer, a crystallizable polyamide nanocomposite or a blend thereof. The second polyamide is a polyamide copolymer comprising a m-xylylene diamine moiety, an isophthalic acid moiety, and at least one additional moiety comprising a polyamide monomeric precursor, and an optional clay.
[0018] Suitable nylons within the scope of the invention for forming the first polyamide of this embodiment non-exclusively include homopolymers or copolymers selected from aliphatic polyamides and aliphatic/aromatic polyamides having a molecular weight of from about 10,000 to about 100,000. General procedures useful for the preparation of polyamides are well known to the art. Such include the reaction products of diacids with diamines. Useful diacids for making polyamides include dicarboxylic acids which are represented by the general formula:
HOOC-Z-COOH
wherein Z is representative of a divalent aliphatic radical containing at least 2 carbon atoms, such as adipic acid, sebacic acid, octadecanedioic acid, pimelic acid, suberic acid, azelaic acid, dodecanedioic acid, and glutaric acid. The dicarboxylic acids may be aliphatic acids, or aromatic acids such as isophthalic acid and terephthalic acid. Suitable diamines for making polyamides include those having the formula:
H 2 N(CH 2 ) n NH 2
wherein n has an integer value of 1-16, and includes such compounds as trimethylenediamine, tetramethylenediamine, pentamethylenediamine, hexamethylenediamine, octamethylenediamine, decamethylenediamine, dodecamethylenediamine, hexadecamethylenediamine, aromatic diamines such as p-phenylenediamine, 4,4′-diaminodiphenyl ether, 4,4′-diaminodiphenyl sulphone, 4,4′-diaminodiphenylmethane, alkylated diamines such as 2,2-dimethylpentamethylenediamine, 2,2,4-trimethylhexamethylenediamine, and 2,4,4 trimethylpentamethylenediamine, as well as cycloaliphatic diamines, such as diaminodicyclohexylmethane, and other compounds. Other useful diamines include heptamethylenediamine, nonamethylenediamine, and the like.
[0019] Useful polyamide homopolymers and copolymers include poly(4-aminobutyric acid) (nylon 4), poly(6-aminohexanoic acid) (nylon 6, also known as poly(caprolactam)), poly(7-aminoheptanoic acid) (nylon 7), poly(8-aminooctanoic acid)(nylon 8), poly(9-aminononanoic acid) (nylon 9), poly(10-aminodecanoic acid) (nylon 10), poly(11-aminoundecanoic acid) (nylon 11), poly(12-aminododecanoic acid) (nylon 12), nylon 4,6, poly(hexamethylene adipamide) (nylon 6,6), poly(hexamethylene sebacamide) (nylon 6,10), poly(heptamethylene pimelamide) (nylon 7,7), poly(octamethylene suberamide) (nylon 8,8), poly(hexamethylene azelamide) (nylon 6,9), poly(nonamethylene azelamide) (nylon 9,9), poly(decamethylene azelamide) (nylon 10,9), poly(tetramethylenediamine-co-oxalic acid) (nylon 4,2), the polyamide of n-dodecanedioic acid and hexamethylenediamine (nylon 6,12), the polyamide of dodecamethylenediamine and n-dodecanedioic acid (nylon 12,12) and the like. Useful aliphatic polyamide copolymers include caprolactam/hexamethylene adipamide copolymer (nylon 6,6/6), hexamethylene adipamide/caprolactam copolymer (nylon 6/6,6), trimethylene adipamide/hexamethylene azelaiamide copolymer (nylon trimethyl 6,2/6,2), hexamethylene adipamide-hexamethylene-azelaiamide caprolactam copolymer (nylon 6,6/6,9/6) and the like. Also included are other nylons which are not particularly delineated here.
[0020] Of these polyamides, preferred polyamides include nylon 6, nylon 6,6, nylon 6/6,6 as well as mixtures of the same. Of these, nylon 6 is most preferred. Polyamides used in the practice of this invention may be obtained from commercial sources or prepared in accordance with known preparatory techniques. For example, poly(caprolactam) can be obtained from Honeywell International Inc., Morristown, N.J. under the trademark CAPRON®.
[0021] Exemplary of aliphatic/aromatic polyamides include poly(tetramethylenediamine-co-isophthalic acid) (nylon 4,I), polyhexamethylene isophthalamide (nylon 6,I), hexamethylene adipamide/hexamethylene-isophthalamide (nylon 6,6/6I), hexamethylene adipamide/hexamethyleneterephthalamide (nylon 6,6/6T), poly (2,2,2-trimethyl hexamethylene terephthalamide), poly(m-xylylene adipamide) (MXD6), poly(p-xylylene adipamide), poly(hexamethylene terephthalamide), poly(dodecamethylene terephthalamide), polyamide 6I/6T, polyamide 6T/6I, polyamide 6/MXDT/I, polyamide MXDI, and the like. Blends of two or more aliphatic/aromatic polyamides can also be used. Aliphatic/aromatic polyamides can be prepared by known preparative techniques or can be obtained from commercial sources. Other suitable polyamides are described in U.S. Pat. Nos. 4,826,955 and 5,541,267, which are incorporated herein by reference.
[0022] In the preferred embodiments of the invention, the first polyamide preferably comprises polyamides a nylon 6, nylon 66, nylon 6/66, nylon 66/6, nylon MXD6, or nylon 6I,6T or a nanocomposite of nylon 6, nylon 66, nylon 6/66, nylon 66/6, nylon MXD6 or nylon 6I,6T. Of these, more preferred are nylon 6, nylon 66, nylon 6/66 or 66/6 and mixtures of the same, as well as nanocomposites of nylon 6, nylon 6,6, nylon 6/66 or 66/6 and mixtures thereof. Of these, nylon 6 or nylon 6 nanocomposite is most preferred for the first polyamide.
[0023] The first polyamide is combined with a second polyamide component which is a polyamide copolymer comprising a m-xylylene diamine moiety, an isophthalic acid moiety, and at least one additional moiety comprising a polyamide monomeric precursor, and an optional clay. More particularly, the second polyamide comprises a semi-crystalline polyamide copolymer having a m-xylylene diamine moiety (mXDA), an isophthalic acid (IPA) moiety and at least one additional moiety comprising a polyamide monomeric precursor. The additional polyamide monomeric precursor moiety of the mXDA-IPA copolymers of the invention may generally comprise a dicarboxylic acid as described above. In the preferred embodiments of the invention, the additional polyamide monomeric precursor moiety comprises an aliphatic dicarboxylic acid such as adipic acid, sebacic acid, octadecanedioic acid, pimelic acid, suberic acid, azelaic acid, dodecanedioic acid and glutaric acid. Most preferably, the additional polyamide monomeric precursor moiety comprises adipic acid.
[0024] In the preferred embodiment of the invention, the second polyamide preferably comprises a copolymer comprising from about 20% to about 70% by weight of said m-xylylene diamine moiety, from about 1% to about 30% by weight of said isophthalic acid moiety, and from about 20% to about 60% by weight of said polyamide monomeric precursor moiety. More preferably, the second polyamide comprises a copolymer comprising from about 40% to about 60% by weight of said m-xylylene diamine moiety, from about 5% to about 15% by weight of said isophthalic acid moiety, and from about 30% to about 50% by weight of said polyamide monomeric precursor moiety. Most preferably, the second polyamide comprises a copolymer comprising from about 45 to about 55% by weight of said m-xylylene diamine moiety, from about 7 to about 10% by weight of said isophthalic acid moiety, and from about 35% to about 45% by weight of said polyamide monomeric precursor moiety. Each of the first and second polyamides may be formed using techniques that are well known in the art.
[0025] In the overall polyamide composition, the first polyamide is preferably present in an amount of from about 5% to about 50% by weight of the overall polyamide composition, and the second polyamide is preferably present in an amount of from about 50% to about 95% by weight of the overall polyamide composition. More preferably, the first polyamide comprises from about 5 to about 45 percent by weight and the second polyamide comprises from about 55 to about 95 percent by weight of the overall polyamide composition. Most preferably, the first polyamide comprises from about 10 to about 30 percent by weight and the second polyamide comprises from about 70 to about 90 percent by weight of the overall polyamide composition.
[0026] In a second embodiment of the invention, the above described polyamide compositions further comprise at least one polyamide-compatible oxygen scavenger. The polyamide-compatible, oxygen scavenger preferably comprises a functional, nylon reactive, oxidizable polydiene or oxidizable polyether. Such are low molecular weight, small particles which are compatible and uniformly dispersible in the polyamide. Preferably the nylon reactive, oxidizable polydiene or polyether comprises an epoxy or anhydride functionality such that it reacts with the carboxyl or amino end groups of the polyamide. The functionality in the polydiene or polyether may also react with amide group in the polyamide backbone. The functionality can be pendant to the backbone or at the chain ends of the polydiene or polyether. The preferred functional polydienes are functional polyalkadiene oligomers which can have the following general backbone structure:
where R 1 , R 2 , R 3 and R 4 can be the same or different and can be selected from hydrogen (—H) or any of the lower alkyl groups (methyl, ethyl, propyl, butyl etc.). R 2 and R 3 may also be a chloro (—Cl) group. Illustrative of the backbone structure are polybutadiene (1, 4 or 1,2 or mixtures of both), polyisoprene (1, 4 or 3,4), poly 2,3-dimethyl butadiene, polychloroprene, poly 2,3-dichlorobutadiene, polyallene, poly1,6-hexatriene, etc.
[0027] Specific non-limiting examples of polyamide-compatible, functionalized, oxidizable polydienes as suitable oxygen scavengers include epoxy functionalized polybutadiene (1,4 and/or 1,2), maleic anhydride grafted or copolymerized polybutadiene (1,4 and/or 1,2), epoxy functionalized polyisoprene, and maleic anhydride grafted or copolymerized polyisoprene.
[0028] A preferred oxygen scavenger includes an anhydride functional polybutadiene oligomer. The molecular weight of the functional polydiene oligomer preferably ranges from about 500 about to 8,000, preferably from about 1000 to about 6000 and most preferably from about 1500 to about 5500. When incorporated, it is preferably present in the overall composition in an amount of from about 0.1% to about 10% by weight, more preferably from about 1% to about 10% and most preferably from about 2% to about 6%. The functional, oxidizable polydiene is preferably present as a large number of small particles whose average particle size is in the range of from about 10 nm to about 1000 nm, and wherein the particles are substantially uniformly distributed throughout the polyamide composition. The polyamide composition may comprise either a blend of the polyamide components and the polyamide-compatible oxidizable polydiene or a reaction product of the polyamide components with the polyamide-compatible oxidizable polydiene.
[0029] The polyamide composition of the second embodiment further preferably comprises at least one oxidation promoting metal salt catalyst such as a low molecular weight oxidation promoting metal salt catalyst. Suitable oxidation promoting metal salt catalysts comprise a counterion which is present in acetates, stearates, propionates, hexanoates, octanoates, benzoates, salicylates, and cinnamates and combinations thereof. Preferably the oxidation promoting metal salt catalyst comprises a cobalt, copper or ruthenium, acetate, stearate, propionate, hexanoate, octanoate, benzoate, salicylate or cinnamate, or a combination thereof.
[0030] Preferred metal carboxylates include cobalt, ruthenium and copper carboxylate. Of these, the more preferred are cobalt or copper carboxylate and the most preferred is cobalt carboxylate. When incorporated, the metal salt catalyst is preferably present in the overall composition in an amount of from about 0.001% to about 1% by weight, preferably from about 0.002% to about 0.5% and more preferably from about 0.005% to about 0.1%. The most preferred range is from about 0.01% to about 0.05%.
[0031] Each of the polyamide compositions of the invention preferably further comprise a nanometer scale dispersed clay, known in the art as a nanoclay. A polyamide combined with a nanoclay is also known in the art as a polyamide nanocomposite. Suitable clays are described in U.S. Pat. No. 5,747,560, which is incorporated herein by reference. Preferred clays non-exclusively include a natural or synthetic phyllosilicate such as montmorillonite, hectorite, vermiculite, beidilite, saponite, nontronite or synthetic flouromica, which has been cation exchanged with a suitable organoammonium cation. A preferred clay comprises montmorillonite, hectorite or synthetic flouromica, more preferably montmorillonite or hectorite, and most preferably montmorillonite. A preferred organoammonium cation for treating the clay comprises N,N′,N″,N′″bis(hydroxyethyl), methyl, octadecyl ammonium cation or ω-carboxy alkylammonium cation, i.e., the ammonium cation derived such ω-aminoalkanoic acids as 6-aminocaproic acid, 11-aminoundecanoic acid, 12-aminododecanoic acid. Preferred fine dispersions of nanometer scale silicate platelets may be obtained via an in-situ polymerization of polyamide forming monomer(s) or via melt compounding of polyamide in the presence of the clay. Such methods are described in U.S. Pat. No. 5,747,560. The clay preferably has an average platelet thickness ranging from about 1 nm to about 100 nm, and an average length and average width each ranging from about 50 nm to about 700 nm. It is preferably present in the overall polyamide composition in an amount of from about 0% to about 10% by weight, more preferably from about 0.5% to about 6% and most preferably from about 0.8% to about 4%.
[0032] The polyamide compositions of the invention may optionally also include one or more conventional additives whose uses are well known to those skilled in the art. The use of such additives may be desirable in enhancing the processing of the compositions as well as improving the products or articles formed therefrom. Examples of such include oxidative and thermal stabilizers, lubricants, mold release agents, flame-retarding agents, oxidation inhibitors, dyes, pigments and other coloring agents, ultraviolet light stabilizers, organic or inorganic fillers including particulate and fibrous fillers, reinforcing agents, nucleators, plasticizers, as well as other conventional additives known to the art. Such additives may be used in amounts of up to about 10% by weight of the overall polyamide compositions.
[0033] Representative ultraviolet light stabilizers include various substituted resorcinols, salicylates, benzotriazole, benzophenones, and the like. Suitable lubricants and mold release agents include stearic acid, stearyl alcohol, and stearamides. Exemplary flame-retardants include organic halogenated compounds, including decabromodiphenyl ether and the like as well as inorganic compounds. Suitable coloring agents including dyes and pigments include cadmium sulfide, cadmium selenide, titanium dioxide, phthalocyanines, ultramarine blue, nigrosine, carbon black and the like. Representative oxidative and thermal stabilizers include the Period Table of Element's Group I metal halides, such as sodium halides, potassium halides, lithium halides; as well as cuprous halides; and further, chlorides, bromides, iodides. Also, hindered phenols, hydroquinones, aromatic amines as well as substituted members of those above mentioned groups and combinations thereof. Exemplary plasticizers include lactams such as caprolactam and lauryl lactam, sulfonamides such as o,p-toluenesulfonamide and N-ethyl, N-butyl benzenesulfonamide, and combinations of any of the above, as well as other plasticizers known to the art.
[0034] Suitable fillers include inorganic fillers, including those of fibrous and granular nature, as wells as mixtures thereof. The fibrous fillers include glass, silica glass, ceramic, asbestos, alumina, silicon carbide, gypsum, metal (including stainless steel) as well as other inorganic and carbon fibers. The granular fillers include wollastonite, sericite, asbestos, talc, mica, clay, kaolin, bentonite, and silicates, including alumina silicate. Other granular fillers include metal oxides, such as alumina, silica, magnesium oxide, zirconium oxide, titanium oxide. Further granular fillers include carbonates such as calcium carbonate, magnesium carbonate, and dolomite, sulfates including calcium sulfate and barium sulfate, boron nitride, glass beads, silicon carbide, as well as other materials not specifically denoted here. These fillers may be hollow, for example glass microspheres, silane balloon, carbon balloon, and hollow glass fiber. Preferred inorganic fillers include glass fibers, carbon fibers, metal fibers, potassium titanate whisker, glass beads, glass flakes, wollastonite, mica, talc, clay, titanium oxide, aluminum oxide, calcium carbonate and barium sulfate. Particularly, glass fiber is most preferred. The inorganic fillers should preferably be treated with silane, titanate, or another conventional coupling agent, and glass fibers should preferably be treated with an epoxy resin, vinyl acetate resin or other conventional converging agent.
[0035] Preferably the polyamide compositions of the invention are produced via melt extrusion compounding of the first and second polyamides, as well as any other composition components, including oxygen scavenger compositions and metal salt catalysts. The composition may be formed by dry blending solid particles or pellets of each of the polyamide components and then melt blending the mixture any other components in a suitable mixing means such as an extruder, a roll mixer or the like. Typical melting temperatures range from about 230° C. to about 300° C., more preferably from about 235° C. to about 280° C. and most preferably from about 240° C. to about 260° C. for the polyamide compositions. Blending is preferably conducted for a period of time suitable to attain a substantially uniform blend. Such may easily be determined by those skilled in the art. If desired, the composition may be cooled and cut into pellets for further processing, may be extruded into a fiber, a filament, or a shaped element, or may be formed into films and optionally uniaxially or biaxially stretched or oriented by means well known in the art.
[0036] The polyamide compositions of this invention may be used to produce various single layered or multilayered films, articles, bottles, containers, and the like using conventional processing techniques, including extrusion, lamination, extrusion lamination, coinjection, stretch blow molding, coextrusion blow molding and blown film techniques. The preferred method for making monolayer or multilayer films is by coextrusion. The preferred method for making bottles include extrusion blow molding, coextrusion blow molding, injection blow molding, coinjection blow molding, injection stretch blow molding or coinjection stretch blow molding, and containers are preferably produced via thermoforming techniques. Processing techniques for making blends as well as for making films, sheets, containers and bottles are all well known in the art. For example, the first and second polyamide components (i) and (ii) of the polyamide composition may be pre-blended and then the blend fed into an infeed hopper of an extruder, or each component may be fed into infeed hoppers of an extruder and then blended in the extruder. A melted and plasticated stream from the extruder is fed into a single manifold die and extruded into a layer. It then emerges from the die as a single layer film of material. After exiting the die, the film is cast onto a first controlled temperature casting roll, passes around the first roll, and then onto a second controlled temperature roll, which is normally cooler than the first roll. The controlled temperature rolls largely control the rate of cooling of the film after it exits the die. Once cooled and hardened, the resulting film is preferably substantially transparent.
[0037] When forming a multilayer structure, the material for the individual layers are fed into infeed hoppers of the extruders of like number, each extruder handling the material for one or more of the layers. The melted and plasticated streams from the individual extruders are fed into a single manifold co-extrusion die. While in the die, the layers are juxtaposed and combined, then emerge from the die as a single multiple layer film of polymeric material. After exiting the die, the film is cast onto a first controlled temperature casting roll, passes around the first roll, and then onto a second controlled temperature roll, which is normally cooler than the first roll. The controlled temperature rolls largely control the rate of cooling of the film after it exits the die.
[0038] In another method, a film forming apparatus may be one which is referred to in the art as a blown film apparatus and includes a multi-manifold circular die head for bubble blown film through which the plasticized film composition is forced and formed into a film bubble which may ultimately be collapsed and formed into a film. Processes of coextrusion to form film and sheet laminates are generally known. See for example in “Modern Plastics Encyclopedia”, Vol. 56, No. 10A, pp. 131-132, McGraw Hill, October 1979. Alternatively, individual layers may first be formed into sheets and then laminated together under heat and pressure with or without intermediate adhesive layers.
[0039] As mentioned above, the composition may also be used to form a shaped article through any well known process, including extrusion blow molding and injection stretch-blow molding. An injection molding process softens the thermoplastic blend in a heated cylinder, injecting it while molten under high pressure into a closed mold, cooling the mold to induce solidification, and ejecting the molded pre-form from the mold. Molding compositions are well suited for the production of pre-forms and subsequent reheat stretch-blow molding of these pre-forms into the final bottle shapes having the desired properties. The injection molded pre-form is heated to suitable orientation temperature, often in about the 80° C. to 150° C. range, and then stretch-blow molded. The latter process consists of first stretching the hot pre-form in the axial direction by mechanical means such as by pushing with a core rod insert followed by blowing high pressure air (up to about 500 psi) to stretch it in the hoop direction. In this manner, a biaxially oriented blown bottle is made. Typical blow-up ratios often range from about 5:1 to about 15:1.
[0040] The polyamide compositions of this invention may be formed as an integral layer in a multilayered film, bottle or container which includes one or more layers of another thermoplastic polymer such as polyesters, particularly polyethylene terephthalate (PET) and PET copolymers, polyolefins, ethylene vinyl alcohol copolymers, acrylonitrile copolymers, acrylic polymers, vinyl polymers, polycarbonates, polystyrenes, polyamides, fluoropolymers, and the like. The polyamide compositions of this invention are particularly suitable as barrier layers in the construction and fabrication of multilayer bottles and thermoformed containers in which PET or polyolefin layers function as structural layers. Such PET/polyamide multilayer bottles can be made by coinjection stretch blow molding processes similar to the injection stretch blow molding process as described above. Similarly, such multilayer bottles can be made by coextrusion blow molding. The latter process usually employs suitable optional adhesive tie layers for adhesion.
[0041] Useful polyesters for coinjection stretch blow molding process include polyethylene terephthalate and its copolymers in the intrinsic viscosity (I.V.) range of about 0.5 to about 1.2 dl/g, more preferably in the I.V. range of from about 0.6 to about 1.0 dl/g and most preferably in the I.V. range of from about 0.7 to about 0.9 dl/g. The polyolefins used in coextrusion blow molding preferably comprise polymers of alpha-olefin monomers having from about 2 to about 6 carbon atoms, and includes homopolymers, copolymers (including graft copolymers), and terpolymers of alpha-olefins and the like. Examples of such nonexclusively include ultra low density polyethylene (ULDPE); low density polyethylene (LDPE); linear low density polyethylene (LLDPE); metallocene linear low density polyethylene (m-LLDPE); medium density polyethylene (MDPE); high density polyethylene (HDPE); polypropylene; polybutylene; polybutene-1; poly-3-methylbutene-1; poly-pentene-1; poly-4-methylpentene-1; polyisobutylene; polyhexene and the like. Such polyolefins may have a weight average molecular weight of from about 1,000 to about 1,000,000, and preferably of from about 10,000 to about 500,000. Preferred polyolefins include polyethylene, polypropylene, polybutylene and copolymers and blends thereof. The most preferred polyolefins include polyethylene and polypropylene.
[0042] Preferred fluoropolymers include, but are not limited to, homopolymers and copolymers of chlorotrifluoroethylene, ethylene-chlorotrifluoroethylene copolymer, ethylene-tetrafluoroethylene copolymer, fluorinated ethylene-propylene copolymer, perfluoroalkoxyethylene, polychlorotrifluoroethylene, polytetrafluoroethylene, polyvinyl fluoride, polyvinylidene fluoride, and copolymers and blends thereof. As used herein, copolymers include polymers having two or more monomer components. The most preferred fluoropolymers include homopolymers and copolymers of poly(chlorotrifluoroethylene) (PCTFE). Particularly preferred are PCTFE materials sold under the ACLON™ trademark and which are commercially available from Honeywell International Inc. of Morristown, N.J.
[0043] Suitable copolymers of ethylene and vinyl alcohol suitable for use in the present invention can be prepared by the methods disclosed in U.S. Pat. Nos. 3,510,464; 3,560,461; 3,847,845; and 3,585,177. Suitable acrylonitrile copolymers, acrylic polymers, vinyl polymers, polycarbonates, polystyrenes and fluoropolymers for use in the present invention can be prepared by methods which are well known in the art. Suitable polyamides can be prepared using methods previously described herein. Additional layers may also include adhesive tie layers to tie various layers together. Non-limiting examples of other optional polymeric layers and adhesive tie layers which can be used in films of the present invention are disclosed, for example, in U.S. Pat. Nos. 5,055,355; 3,510,464; 3,560,461; 3,847,845; 5,032,656; 3,585,177; 3,595,740; 4,284,674; 4,058,647; and 4,254,169.
[0044] In a third embodiment of the invention, the polyamide compositions of the invention may comprise direct blends of the first and second polyamides with an additional polymer component. This additional polymer component may comprise any of the aforementioned polymers, particularly including polyethylene terephthalate and PET copolymers, polyolefins, ethylene vinyl alcohol copolymers, acrylonitrile copolymers, acrylic polymers, vinyl polymers, polycarbonate, polystyrene and the like. In this embodiment, the additional polymer component preferably comprises at least about 50% by weight of the overall direct blend composition, more preferably at least about 80% and most preferably at least about 90% by weight of the overall direct blend composition. As with each of the other compositions described herein, these direct blend compositions may be formed into single or multilayer films, as well as other articles such as bottles and containers. However, these direct blends are particularly intended to be formed into single layer structures. The direct blends may also further comprise at least one polyamide-compatible oxygen scavenger and optionally at least one oxidation promoting metal salt catalyst, as described above.
[0045] The single or multilayer films of the invention include at least one polyamide composition layer, which polyamide composition layer has first and second surfaces. In a preferred multilayer film construction, a two layer film is formed which comprises at least one thermoplastic polymer layer attached to at least one of said first and second surfaces of said polyamide composition layer. In another preferred multilayer film construction, a three layer film is formed which comprises at least one thermoplastic polymer layer attached to each of said first and second surfaces of the polyamide composition layer. For example, a three layer film may comprise a PET/polyamide composition layer/PET structure. Other preferred film structures non-exclusively include PE/tie/EVOH/polyamide composition/EVOH/tie/PE; PE/tie/EVOH/polyamide composition/tie/PE; and PE/tie/polyamide composition/tie/PE, where the PE layer may comprise LDPE, HDPE, LLDPE or any other polyethylene layer as described above. Adhesive materials may also be blended into either the PE or EVOH layers, rather than used a discrete layer.
[0046] Optionally, adhesive layers, also known as “tie” layers, may be formed or placed between each film layer. Suitable adhesive layers include adhesive polymers such as modified polyolefin compositions having at least one functional moiety selected from the group consisting of unsaturated polycarboxylic acids and anhydrides thereof. Such unsaturated carboxylic acid and anhydrides include maleic acid and anhydride, fumaric acid and anhydride, crotonic acid and anhydride, citraconic acid and anhydride, itaconic acid and anhydride and the like. Of these, the most preferred is maleic anhydride. The modified polyolefins suitable for use in this invention include compositions described in U.S. Pat. Nos. 3,481,910; 3,480,580; 4,612,155 and 4,751,270 which are incorporated herein by reference. Other adhesive layers non-exclusively include alkyl ester copolymers of olefins and alkyl esters of α,β-ethylenically unsaturated carboxylic acids such as those described in U.S. Pat. No. 5,139,878. The preferred modified polyolefins comprise from about 0.001 and about 10 weight percent of the functional moiety, based on the total weight of the modified polyolefin. More preferably the functional moiety comprises from about 0.005 and about 5 weight percent, and most preferably from about 0.01 and about 2 weight percent. The modified polyolefin composition may also contain up to about 40 weight percent of thermoplastic elastomers and alkyl esters as described in U.S. Pat. No. 5,139,878. Alternatively, one or more adhesive polymers may be directly blended or coextruded into other layers of the film, thus providing adhesion while minimizing the number of layers in the film.
[0047] Films produced according to the present invention may be oriented by stretching or drawing the films at draw ratios of from about 1.1:1 to about 10:1, and preferably at a draw ratio of from about 2:1 to about 5:1. The term “draw ratio” as used herein indicates the increase of dimension in the direction of the draw. Therefore, a film having a draw ratio of 2:1 has its length doubled during the drawing process. Generally, the film is drawn by passing it over a series of preheating and heating rolls. The heated film moves through a set of nip rolls downstream at a faster rate than the film entering the nip rolls at an upstream location. The change of rate is compensated for by stretching in the film.
[0048] The films may be stretched or oriented in any desired direction using methods well known to those skilled in the art. The film may be stretched uniaxially in either the longitudinal direction coincident with the direction of movement of the film being withdrawn from the film forming apparatus, also referred to in the art as the “machine direction”, or in as direction which is perpendicular to the machine direction, and referred to in the art as the “transverse direction”, or biaxially in both the longitudinal direction and the transverse direction. The films may be further annealed or heat treated to further enhance their barrier properties. Heated fluids or IR radiation heaters can be utilized in the annealing or heat treatment processes. Such techniques are well known in the art.
[0049] Films of the invention preferably have a thickness of from about 5 μm to about 400 μm, more preferably from about 10 μm to about 200 μm, and most preferably from about 15 μm to about 100 μm. While such thicknesses are preferred as providing a readily flexible film, it is to be understood that other film thicknesses may be produced to satisfy a particular need and yet fall within the scope of the present invention. Such thicknesses which are contemplated include plates, thick films, and sheets which are not readily flexible at room temperature (approx. 20° C.).
[0050] One noteworthy characteristic of films and articles produced from the composition of this invention is that they exhibit excellent gas barrier properties, particularly oxygen and CO 2 barrier properties. Oxygen permeation resistance or barrier may be measured using the procedures of ASTM D-3985. In general, the films of this invention have an oxygen transmission rate (OTR) of about less than 1 cc.mil/100 in 2 /day at 80% relative humidity (RH) in air at atmospheric pressure. For scavenging compositions, the OTR (in cc.mil/100 in 2/day) preferably ranges from about 0.001 to about 2, more preferably from about 0.001 to about 0.5 and most preferably from about 0.001 to about 0.1 cc.mil/100 in 2 /day at 80% RH in air at atmospheric pressure. The OTR for non-oxygen scavenging compositions measured at 65% RH, 23° C. in pure oxygen is preferably less than about 1.5 cc mil/100 in 2 /day, more preferably more preferably less than about 1.2 cc mil/100 in 2 /day, and most preferably less than about 1.0 cc mil/100 in 2 /day) at atmospheric pressure. In general, the films of this invention preferably have a carbon dioxide transmission rate measured in accordance with ASTM F2476 (conducted at 80% RH, 23° C.) of less than about 2 cc mil/100 in 2 /day, more preferably less than about 1.6 cc mil/100 in 2 /day, less than about 1.0 cc mil/100 in 2 /day at atmospheric pressure.
[0051] The glass transition temperature (Tg) of the polyamide compositions of this invention, as determined by differential scanning calorimetry techniques, are preferably much less than about 120° C., which is generally the upper temperature limit for neat PET's reheat stretch blow moldability into distortion-free bottles. In addition, in coinjection stretch blow molding processes for making mono or multilayer bottles, extensive voiding with potential barrier loss might occur if the Tg of the polyamide composition exceeds about 110° C. The polyamide composition therefore preferably has a Tg of from about 20° C. to about 110° C., more preferably from about 40° C. to about 100° C. and most preferably from about 60° C. to about 90° C.
[0052] The polyamide compositions of this invention preferably exhibit a slow crystallization behavior similar to that of PET, characterized by no or slow onset of crystallization, as determined by the differential scanning calorimetry (DSC) crystallization exotherm (Tcc) peak that occurs upon cooling the melt from 280° C. at a programmed cooling rate of 20° C./min. For PET, Tcc is about 190° C., which is about 70° C. below its crystalline melting point (T m ) of 260° C. Thus, the polyamide composition of this invention preferably exhibits a low Tcc or crystallization temperature of about 160° C. or less, upon cooling from the melt at a cooling rate of 10° C./min in a DSC apparatus. At faster cooling rates (80° C./min) the polyamides of this invention exhibit lower Tcc.
[0053] The following non-limiting examples serve to illustrate the invention. It will be appreciated that variations in proportions and alternatives in elements of the components of the invention will be apparent to those skilled in the art and are within the scope of the present invention.
EXAMPLES
[0054] The following process and characterizations steps were conducted for the following examples and comparative example.
[0000] Process Step 1: Preparation of Catalyst Masterbatch (MB)
[0055] This masterbatch is used as an additive in process step two or three for the preparation of an oxygen scavenging resin. A Leistritz 18 mm co-rotating twin screw extruder equipped with a K-tron volumetric feeder was utilized in preparing the catalyst masterbatch. The screw used in this process was designed with three mixing zones and a venting zone. A blend of nylon 6 (Honeywell B73ZP) pellets and cobalt stearate pastilles (from Shepherd Chemical Co.) was fed into the throat of the extruder at a rate of ten (10) pounds per hour. The blend ratio was 95 weight percent PA-6 (Honeywell B73ZP) and five (5) weight percent cobalt stearate (Shepherd Chemical). After mixing in the extruder, the extrudate passed through a die plate and was quenched in a water bath and finally pelletized.
[0000] Process Step 2: Preparation of Resin Products by Melt Extrusion.
[0056] A Leistritz 18-mm co-rotating twin screw extruder equipped with a K-Tron volumetric feeder was employed. Blends of MXD6/MXDI copolyamide (EMS XS-0501) with either a) nylon 6 polyamide (Honeywell H73ZP), b) nylon 6 nanoclay polymer (Honeywell 4% nanoclay PA6, XA2979) or a nylon 6 15.7% nanoclay masterbatch (Nanocor® nano-polyamide concentrate (NPC)) were fed into the nitrogen-blanketed throat of the extruder at a rate of 10 pounds per hour. The extruder was equipped with two mixing zones consisting primarily of kneading elements. The extruder was equipped with a vacuum zone subsequent to the second mixing zone and prior to the die plate. The extrudate was quenched in a water bath and then pelletized.
[0000] Process Step 3: Preparation of Oxygen Scavenging Composition
[0057] A Leistritz 18-mm co-rotating twin screw extruder equipped with a K-Tron volumetric feeder is employed. A polybutadiene (maleic anhydride functionalized polybutadiene—Ricon 131 MA5) is stored in a sealed drum vessel and metered with a Nichols-Zenith pump directly in the extruder barrel following the feed throat. The polybutadiene is injected directly into the extruder prior to the first (of two) mixing zones via a Leistritz direct liquid injection nozzle. A blend of an MXD6/MXDI copolyamide (EMS XS-0501), at least one of nylon 6, 4% nylon 6 nanocomposite or 15.7% nylon nanocomposite, and the cobalt stearate masterbatch of Process step 1 are fed into the nitrogen-blanketed throat of the extruder at a rate of 10 pounds per hour. The blend consists of approximately 98 weight polyamides and 2 weight percent cobalt masterbatch. The polybutadiene is pumped at a rate such that weight percentages of 1% to 5% polybutadiene are added. The extruder is equipped with two mixing zones consisting primarily of kneading elements. The extruder is equipped with a vacuum zone subsequent to the second mixing zone and prior to the die plate. The extrudate is then quenched in a water bath and pelletized.
[0000] Process Step 4: Preparation of Pellet Blended Products.
[0058] Compositions can be prepared by a pellet blending approach rather than melt compounding. Blending was accomplished by weighing out the required amount of each polyamide material into a large container. The container was tumbled for approximately 5 minutes to ensure thorough mixing of the two components. These blends were used subsequently as feedstock for film or container processing.
[0000] Process Step 5: Monolayer Film Preparation
[0059] A 19 mm Haake single screw extruder equipped with a six-inch (152.4 mm) wide film die was flood fed with pellets, such as those from process 2, 3 or 4. Extruder temperature was set at approximately 260° C. The extrudate passed through the slit die onto a heated Killion cast roll. Film thickness was adjusted via cast roll speed and/or screw RPM to prepare a film with thickness of about 0.001 inch to about 0.004 inch (0.0254 to 0.1016 mm).
[0000] Process 6: Multilayer Film Preparation
[0060] Three Killion single screw extruders equipped with a twelve-inch wide film coextrusion die are utilized to prepare a three, five or seven layer multilayer film. One extruder is flood fed with pellets from process 2, 3 or 4 and made into an inner layer. The second extruder is flood fed with one or more of, for example, polyethylene, polypropylene, polyethylene terephthalate, polycarbonate, ethylene vinyl alcohol or nylon, and extruded into two outer layers. The third extruder is flood fed with an adhesive tie resin which can effectively bind together the incompatible polymers such as a center polyamide layer from the first extruder and skin layers from the second extruder. Extruder temperatures are about 150° C.-300° C. in all three extruders, depending on the polymer film composition. Extrudates are passed through the slit die onto a heated cast roll. Film thickness is adjusted via cast roll speed and/or screw RPM to prepare a film.
[0000] Process 7: Multilayer Bottles (Co-Injection Stretch Blow Molding)
[0061] A three layer co-injection stretch blow molding process was used to prepare multilayer beverage bottles with the following structure: PET/polyamide blend/PET. The total polyamide blend content was 5 weight percent of the total pre-form weight. Pre-forms were prepared with an Arburg coinjection press equipped with a coinjection head/manifold and multilayer perform mold. PET extruder temperature settings were approximately 280° C. Extruder temperature settings for the polyamide blend compositions were approximately 260° C. Finished bottles were prepared on Sidel stretch blow molding equipment, with a pre-form preheat temperature of approximately 90-110° C. In each case, standard processing techniques were utilized.
[0000] Oxygen Transmission Measurements
[0062] Oxygen transmission rate (OTR) measurements were conducted on film samples on a Mocon Oxtran 2/20 apparatus equipped with SL sensors. Tests were conducted at 65% relative humidity (RH) using 100% oxygen and a 23° C. testing temperature. Data was collected and recorded in units of cc mil/100 in 2 /day.
[0000] Carbon Dioxide Transmission Measurements
[0063] Carbon dioxide transmission rate (CO 2 TR) measurements were conducted on film samples on a Mocon Permatran C440 apparatus at 80% RH(CO 2 side set at 80% RH, nitrogen carrier gas side was dry), 23° C. Data was collected and reported in units of cc mil/100 in 2 /day.
[0064] Carbon dioxide transmission measurements were conducted on bottle samples as well. Bottles were carbonated with dry ice to obtain 4.0 volumes of CO 2 gas. The amount of CO 2 gas contained in each bottle was determined by measuring the CO 2 absorption peak using Fourier Transform Infra Red (FTIR) analysis. This information was used to estimate the amount of time required for the bottles to reach 17.5% carbonation loss.
[0065] In addition to the FTIR testing, bottles were carbonated with water and placed onto the Mocon Permatran unit to determine the carbon dioxide permeation rate in cc/pkg/day. The bottles were carbonated to 4.0 volumes CO 2 and held within a chamber on the permeation test device. The chamber was continuously swept with dry purge gas and evaluated for CO 2 content.
Example 1 (Comparative)
[0066] Comparative Example 1 illustrates a polyamide 6 composition that does not include the MXDA-IPA copolymers of the invention. A polyamide composition was formed which formulation comprised 100 weight percent nylon 6. This formulation was prepared via process step five, and later cast into film via conventional techniques. The OTR of this nylon was 3 cc mil/100 in 2 /day. The CO 2 TR of this nylon was measured at 14 cc mil/100 in 2 /day.
Example 2
[0067] A blend of 70 weight % MXD6/MXDI copolyamide (i.e. adipic acid-MXDA-isophthalic acid copolyamides) and 30 weight % nylon 6 was formed and processed via process steps 2, 4, 5 and 7. A 16 oz, 24 gram, 28 mm bottle was formed having a straight wall and petalloid base. The bottle was tested for OTR and CO 2 TR. The OTR was measured at 0.9 cc mil/100 in 2 /day. The CO 2 TR was measured at 1.5 cc mil/100 in 2 /day. The OTR and CO 2 TR were significantly better than the nylon 6 homopolymer of Comparative Example 1. CO 2 permeation testing on a Mocon Permatran unit as described above revealed a CO 2 permeation rate of 0.21 cc/pkg/day. The bottle has a predicted shelf life of 16 weeks.
Example 3
[0068] A blend of 80 weight % MXD6/MXDI copolyamide and 20 weight % nylon 6 was formed and processed via process steps 2 and 5. A film of the composition was tested for OTR and CO 2 TR. The OTR was measured at 0.7 cc mil/100 in 2 /day. The CO 2 TR was measured at 1.1 cc mil/100 in 2 /day. The OTR and CO 2 TR were significantly better than the nylon 6 homopolymer of Comparative Example 1.
Example 4
[0069] A blend of 90 weight % MXD6/MXDI copolyamide and 10 weight % nylon 6 was formed and processed via process steps 2 and 5. A film of the composition was tested for OTR and CO 2 TR. The OTR was measured at 0.4 cc mil/100 in 2 /day. The CO 2 TR was measured at 0.6 cc mil/100 in 2 /day. The OTR and CO 2 TR were significantly better than the nylon 6 homopolymer of Comparative Example 1.
Example 5
[0070] A blend of 70 weight % MXD6/MXDI copolyamide and 30 weight % of a nylon 6 nanocomposite containing 4% nanoclay (Honeywell 4% nanoclay PA6, XA2979) was formed and processed via process steps 2 and 5. A film of the composition was tested for OTR and CO 2 TR. The OTR was measured at 0.6 cc mil/100 in 2 /day. The CO 2 TR was measured at 1.2 cc mil/100 in 2 /day. The OTR and CO 2 TR were significantly better than the nylon 6 homopolymer of Comparative Example 1.
Example 6
[0071] A blend of 70 weight % MXD6/MXDI copolyamide, 15 weight % of a nylon 6 nanocomposite containing 4% nanoclay (Honeywell 4% nanoclay PA6, XA2979) and 15 weight % of a nylon 6 nanocomposite containing 15.7% nanoclay (Nanocor® nano-polyamide concentrate (NPC)) was formed and processed via process steps 2 and 5. A film of the composition was tested for OTR and CO 2 TR. The OTR was measured at 0.5 cc mil/100 in 2 /day. The CO 2 TR was measured at 1.2 cc mil/100 in 2 /day. The OTR and CO 2 TR were significantly better than the nylon 6 homopolymer of Comparative Example 1.
[0072] The above data is summarized in Table 1 below.
TABLE 1 Example Process Wt. % Wt. % PA6 Wt. % PA6 Wt. % MXD6/MXDI Wt. % Wt. % CO 2 Number Steps PA6 4% Nano 15.7% Nano Copolyamide Catalyst MB PBD OTR TR 1 5 100 3 14 2 2, 4, 5, 7 30 0 0 70 0.9 1.5 3 2, 5 20 0 0 80 0.7 1.1 4 2, 5 10 0 0 90 0.4 0.6 5 2, 5 0 30 0 70 0.6 1.2 6 2, 5 15 0 15 70 0.5 1.2
Examples 7-12
[0073] Additional polymer blends are formed via process steps 2, 3, 5 and 7 providing desirable results. Such additional blends are formed as in the following Table 2 below:
TABLE 2 Example Process Wt. % Wt. % PA6 Wt. % PA6 Wt. % MXD6/MXDI Wt. % Wt. % Number Steps PA6 4% Nanoclay 15.7% Nanoclay Copolyamide Catalyst MB PBD 7 2, 3, 5, 7 25 70 2 3 8 2, 3, 5, 7 15 80 2 3 9 2, 3, 5, 7 5 90 2 2 10 2, 3, 5, 7 25 70 2 3 11 2, 3, 5, 7 15 80 2 3 12 2, 3, 5, 7 10 15 70 2 3
Example 13
[0074] A three-layer PET/polyamide blend/PET structure is formed following the techniques of process 6.
Example 14
[0075] A seven-layer PE/tie/EVOH/polyamide composition/EVOH/tie/PE structure is formed following the techniques of process 6.
Example 15
[0076] A seven-layer PE/tie/EVOH/polyamide blend/EVOH/tie/PE structure is formed following the techniques of process 6.
[0077] While the present invention has been particularly shown and described with reference to preferred embodiments, it will be readily appreciated by those of ordinary skill in the art that various changes and modifications may be made without departing from the spirit and scope of the invention. It is intended that the claims be interpreted to cover the disclosed embodiment, those alternatives which have been discussed above and all equivalents thereto. | High gas barrier, delamination-resistant polyamide compositions suitable for extended shelf-life packaging applications are provided. Also provided are polyamide compositions exhibiting high oxygen scavenging capability. The polyamide compositions comprise mXDA-IPA containing copolymers which provide excellent properties to the complete polyamide compositions. Also provided are direct blends of the polyamide compositions with other polymers. The polyamide products are particularly suited for producing barrier packaging articles such as monolayer or multi-layer films, sheets, thermoformed containers and molded bottles. Such articles are useful in a variety of oxygen-sensitive food, beverage, pharmaceutical, and health care product packaging applications. | 2 |
RELATED APPLICATIONS
This patent application is a continuation-in-part of co-pending and commonly assigned patent application U.S. Ser. No. 09/321,964, filed May 28, 1999 entitled “Aldehyde Neutralizer”, now U.S. Pat. No. 6,399,850, the disclosure of which is incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to neutralization of aldehydes for the purpose of complying with waste disposal requirements established by federal and state environmental protection agencies, in particular, with forming non-reversible neutralized aldehydes which do not revert back to toxic aldehydes.
2. Description of Related Art
Waste disposal of aldehydes has become increasingly more difficult over the years. Treatment of wastes containing a certain amount of aldehyde prior to placement of the waste into the environment is required by law. The extent of such treatment may vary depending upon the location of where the waste is generated and the stringency of the environmental standards in that area. For example, waste containing aldehyde may be classified as a hazardous waste in California under 22 C AL . C ODE R EGS., TIT. 22, §66696. Formaldehyde also may be considered a hazardous waste on the federal level under 40 C.F.R. §261.33(e) if it is a commercial chemical product (e.g., pure technical grade formaldehyde or formaldehyde is the sole active ingredient of the product that is to be disposed). Every state has an environmental regulation that is at least as stringent as this formaldehyde standard. State regulations also may be more stringent than this standard.
Additionally, facilities that discharge waste water to Publicly Owned Treatment Works (“POTW”) or directly into navigable waters may be required to meet standards that are established by a government agency. The standard may vary for each facility depending upon the quality of the receiving water and the concentration of aldehyde found in the waste water that is discharged into the environment by industry in that area.
Waste containing aldehyde may be generated by a variety of processes. For example, aldehydes such as glutaraldehyde and ortho-phthalaldehyde (“OPA”) are used in disinfecting medical devices or instruments. Waste containing aldehydes also may be generated by painting operations, stripping operations related to floors, or other manufacturing operations.
Typically, ammonia and sodium bisulfite (“SBS”) are used to treat many aldehydes. These compounds, however, have not proven to be effective at neutralizing OPA in accordance with environmental regulations.
A waste is classified as a hazardous waste in California if the waste being examined “has an acute aquatic 96-hour LC 50 less than 500 milligrams per liter (mg/L) when measured in soft water (total hardness 40 to 48 milligrams per liter of calcium carbonate) with fathead minnows . . . ” 22 C AL . C ODE R EGS., TIT. 22, §66696. LC 50 represents the concentration of a waste that is necessary to kill 50% of a particular animal exposed to a waste.
Note that a nonhazardous waste is generally considered by federal and state environmental agencies as a waste that does not satisfy the criteria set forth in defining a hazardous waste. Therefore, wastes generated in California that have a LC 50 >500 mg/L are nonhazardous wastes and wastes having LC 50 <500 mg/L are classified as hazardous. SBS, for example, in combination with OPA, produces a product that is generally considered hazardous under California environmental law as shown in Table 1 by LC 50 being consistently below 500 mg/L. For this study, CIDEX®OPA (commercially available from Advanced Sterilization Products®, a Johnson & Johnson Company of Irvine, Calif.) was used to supply the OPA.
TABLE 1
Neutralization Of OPA Using SBS
Sample Type
OPA Content (%)
LC 50 (mg/L)
Comments
Fresh CIDEX ® OPA at
0.301%
31.1 mg/L
1
0.3% OPA
Fresh CIDEX ® OPA at
0.158%
50.4 mg/L
2
0.15% OPA
Reuse CIDEX ® OPA at
0.295%
31.1 mg/L
3
0.3% OPA
SBS/OPA = 4:1
N/A
68.3 mg/L
4
SBS/OPA = 2:1
N/A
46.3 mg/L
5
1 Fresh CIDEX ® OPA at 0.3% OPA was prepared by diluting the fresh Cidex OPA solution with deionized water.
2. Fresh CIDEX ® OPA at 0.15% OPA was prepared by diluting the fresh Cidex OPA solution with deionized water to the level of 0.15% of OPA.
3. Reuse of CIDEX ® OPA at 0.3% OPA was prepared by diluting the simulated reuse CIDEX ® OPA (14 days) with deionized water.
4. SBS/OPA = 4:1, 10% SBS (10 ml) was combined with 100 ml of the fresh CIDEX ® OPA solution at 0.3% OPA (sample 1 above) at the SBS/OPA molar ratio of 4 to 1 for 30 minutes, and then the combined solution was used in the 22 CAL. CODE REGS., TIT. 22, § 66696 test for California.
5. SBS/OPA = 2:1, 10% SBS (5 ml) was combined with or 100 ml of the fresh CIDEX ® OPA solution at 0.3% OPA (sample 1 above) at the SBS/OPA molar ratio of 2 to 1 for 30 minutes, and then the combined solution was used for the fish test in the 22 CAL. CODE REGS., TIT. 22, § 66696 test for California
In addition to lacking the ability to effectively neutralize OPA, ammonia and SBS are problematic since they may be harmful to the environment.
FIG. 1 shows that when OPA is combined with SBS at the molar ratio of SBS/OPA=4:0 for 30 minutes, OPA has been neutralized since the OPA concentration is nondetectable in a high performance liquid chromatography (HPLC) analysis method, which has detection limit for OPA at 10 ppm. However, the end product is still classified as a hazardous waste as shown in Table 1. Therefore, even though the aldehyde is neutralized completely by a neutralizer, the end product may still be a hazardous waste.
Although glycine has been shown to neutralize glutaraldehyde (see H. Y. Cheung & M. R. W. Brown, Evaluation of Glycine As An Inactivator of Glutaraldehyde, ASP- 934 J. Pharm. 211 (1982)), the toxicity of reaction products of glycine has not been studied. Therefore, it is not known from this article whether the reaction product is nonhazardous. Accordingly, it is desirable to have a neutralizer that effectively neutralizes aldehydes in compliance with environmental standards and is less toxic to the environment.
Furthermore, it has been observed that neutralization of aldehydes with amino acids under acidic conditions may reversibly form compounds called Schiff's bases. That is, once the Schiff's bases are formed under acidic conditions, the reverse reaction will occur to release back aldehydes. Another problem associated with amino acid neutralized aldehydes is that often the solution formed between the aldehyde and the amino acid has a dark color such as dark green or black. This occurs, for example, during the neutralization reaction between o-phthalaldehyde and the amino acid, glycine. Such color appearance has the perception that the resulting solution is not environmentally friendly even though the solution has been neutralized. Finally, not all methods relating to formation of neutralized aldehydes are as environmentally friendly as others are. This invention is intended to overcome the foregoing shortcomings relating to neutralization of aldehydes as hereinafter described.
SUMMARY OF THE INVENTION
Methods, compositions and devices are disclosed for neutralizing aldehydes to form a nonhazardous product which is non-reversible and environmentally friendly. In one aspect, the invention provides a generally nonhazardous means for neutralizing and reducing aldehydes to form environmentally friendly amino acids.
In one embodiment, the neutralization method comprises combining an amino acid in solution or in solid form with an aldehyde to form a neutralized aldehyde and then reducing the neutralized aldehyde to form an amino acid. Devices for neutralizing and reducing the aldehyde to an amino acid are also disclosed.
Among the advantages of the invention are: a more environmentally friendly end product as the reduced neutralized aldehydes are amino acids and are very similar in backbone structure to natural amino acids, and thus would be expected to be biodegradable and environmentally friendly; the prevention of possible reformation of the aldehydes from the Schiff's bases since the reduction of a Schiff's base is irreversible; the colors of the reduced neutralized aldehydes are pale, not dark or black which would reflect the appearance of a non-toxic material; and once reduced, there would be no further need to treat the waste and the waste could be immediately discharged.
Additional features, embodiments, and benefits will be evident in view of the figures and detailed description presented below.
BRIEF DESCRIPTION OF THE DRAWINGS
The features, aspects, and advantages of the invention will become more thoroughly apparent from the following detailed description, appended claims, and accompanying drawings in which:
FIG. 1 shows the ratio of SBS:OPA and the concentration of OPA remaining in solution after 30 minutes from combining the ingredients.
FIGS. 2 a and 2 b show schematic diagrams for mixing of amino acids and reducing agents with aldehydes.
FIGS. 3 a , 3 b , and 3 c show schematic diagrams of devices embodying the principles of this invention.
FIG. 4 shows a preferred embodiment of a device of this invention.
FIG. 5 depicts the experimental setup for Example 5.
FIG. 6 depicts the experimental setup for Example 6.
DETAILED DESCRIPTION OF THE INVENTION
The invention relates to methods, compositions and devices particularly useful for the environmentally friendly and non-reversible neutralization of aldehydes present in waste generated from sterilizing medical devices (e.g., scalpels, scissors, endoscopes, etc.) or laboratory equipment (e.g., glassware) that have been exposed to microorganisms such as bacteria. As used herein, the term non-reversible is intended to refer to the substantial prevention of the neutralized aldehyde (e.g., amino acid treated aldehyde) from reverting back to the starting or unneutralized aldehyde.
Sterilizing includes disinfecting medical devices. The neutralizer comprises an amino acid selected from amino acids having polar R groups, amino acids having non-polar R groups and amino acids with charged R groups. In one embodiment, the chemical neutralizer is selected from one or more of alanine, proline, amino-caproic acid, phenylalanine, tryptophan, methionine, glycine, serine, cycteine, tyrosine, lysine, arginine, glutamine, aspartic acid, glutamic acid, and histidine.
To neutralize aldehydes, the neutralizer in solution or in solid form may be added to waste water that is in a tank (e.g., a neutralization tank at a waste water treatment plant), or in a small container (e.g., a bucket) where aldehydes must be neutralized before they are placed into a sewer system that may discharge to a POTW or into navigable waters. Solids contaminated with aldehydes (e.g., dirt, rags, or gloves, etc.) may be neutralized by directly adding the neutralizer to the solids or by placing the solids into a container with the neutralizer and, optionally, water.
Amino acids are an improvement over the typical chemicals such as ammonia or sodium bisulfite used to neutralize aldehydes since amino acids quickly and effectively neutralize aldehydes to a level prescribed by federal and state environmental agencies. Amino acids are also less expensive than products such as ammonia and sodium bisulfite.
There are a variety of amino acids that are useful in neutralizing aldehydes. These Amino acids include:
(1) Amino acids with apolar R groups (e.g., alanine, proline, amino-caproic acid, phenylalanine, tryptophan and methionine);
(2) Amino acids with polar R groups (e.g., glycine, serine, cysteine, tyrosine, and glutamine);
(3) Amino acids with charged R groups (e.g., aspartic acid, glutamic acid, lysine, arginine, and histidine); and,
(4) Peptides/polypeptides formed by any number or any type of amino acids and proteins.
A neutralized aldehyde product can be formed by reacting an amino group from an amino acid or proteins with an aldehyde group of aldehydes to produce N-substituted adducts (imines or Schiff's bases) as shown below.
Table 2 shows the ratios of certain amino acids with a CIDEX® OPA solution and the time it takes the selected amino acids to neutralize OPA. CIDEX® OPA is used to disinfect medical devices. OPA is a dialdehyde. It is to be appreciated that the techniques described herein can be applied to most aldehydes present in a waste with the neutralization occurring, for example, according to the adduct formation described above for an aldehyde. Table 2 also shows the LC 50 results when CIDEX® OPA solution has been combined with an amino acid. In most cases, after one hour, the LC 50 of products generated from each of the reactions shown in Table 2 is greater than 500 mg/L which makes these wastes nonhazardous for toxicity as defined under California environmental law 22 C AL . C ODE R EGS., TIT . 22, §66696. The waste comprising aldehyde has been effectively neutralized.
TABLE 2
LC 50 Results Performed IN Accordance With 22 CAL. CODE
REGS., TIT. 22, § 66696 For CIDEX ® OPA Solution Combined
With Amino Acids
LC 50 Neutralization Time
LC 50 results,
LC 50 results,
1 hour after
2 days after
Molar
Weight Ratio
CIDEX ®
CIDEX ®
Ratio
CIDEX ®
OPA solution
OPA solution
OPA/
OPA
is first
is first
Ex-
Amino
Solution/
combined with
combined with
ample
Acids
Amino Acids
Amino Acids
Amino Acids
1
OPA/
200 g/1.2 g
>1000
mg/L
>1000
mg/L-
glycine =
of glycine
(See comment 1)
2000
mg/L
1:2
2
OPA/
200 g/1.4 g
500
mg/L-
>2000
mg/L
arginine =
of arginine
1000
mg/L
1:1
3
OPA/
200 g/1.46 g
100
mg/L-
>2000
mg/L
lysine =
of lysine
500
mg/L
1:1
4
OPA/ε-
200 g/2.1 g
1000
mg/L-
>2000
mg/L
amino-n-
of ε-amino-
2000
mg/L
caproic
n-caproic
acid = 1:2
acid
Comment 1: This data was determined based upon 22 CAL. CODE REGS., TIT. 22, § 66696, 96 hours bioassay. All other data was determined based upon 22 CAL. CODE REGS., TIT. 22, § 66696, 48 hour range bioassay.
In Example 1, CIDEX® OPA solution was neutralized with glycine at the molar ratio of 1:2 of OPA to glycine for one hour. The LC 50 for the neutralization product is >1000 mg/L, making the product nonhazardous under 22 C AL . C ODE R EGS., TIT . 22, §66696.
In Example 2, CIDEX® OPA solution was neutralized with arginine at a molar ratio of 1:1 of OPA to arginine for one hour. The LC 50 for the neutralization product is >500 mg/L, making the product nonhazardous under 22 C AL. C ODE R EGS., TIT . 22, §66696.
In Example 3, CIDEX® OPA solution was neutralized with lysine at the molar ratio of 1:1 of OPA to lysine for two (2) days. The LC 50 for the neutralization product is >2000 mg/L, making the product nonhazardous under 22 C AL. C ODE R EGS., TIT . 22, §66696.
In Example 4, CIDEX® OPA solution was neutralized with ε-amino-n-caproic acid for one hour. The LC 50 for the neutralization product is >1000 mg/L, which is nonhazardous under 22 C AL . C ODE R EGS., TIT . 22, §66696. The molar ratio used is 1:2 of OPA to ε-amino-n-caproic acid. The above examples demonstrate that the amino acids used with the aldehyde (e.g., OPA) effectively neutralize the aldehyde to acceptable levels in accordance with the Califormia hazardous waste rule. As shown above, glycine, lysine, arginine, and ε-amino-n-caproic acid are particularly useful at neutralizing aldehydes, but other amino acids are also effective. Glycine, one example of the neutralizer, is preferred as a ID neutralizer for CIDEX® OPA Solution. A minimum of 25 g of glycine (free base) neutralizer and one hour neutralization time should be used to neutralize one gallon of CIDEX® OPA Solution. It should be noted that the invention described herein is not limited to amino acids in a free base form; rather, the amino acid may be in any physical form.
Table 3 shows the color change and the peak retention time (RT) change observed in a High Performance Liquid Chromatogram (HPLC) analysis after the CIDEX® OPA Solution was combined with amino acids. Colored products from the reaction product may act as an indicator of the effectiveness of the neutralizer. Darker colors such as black, orange, brown, or dark yellow typically indicate that the aldehyde has been neutralized to the levels established as nonhazardous for the current California regulations. But, sometimes such color appearance has the perception that the resulting solution is hazardous even though the solution has been neutralized.
Additionally, as shown in Table 3, the color of the mixture of OPA and the particular amino acid illustrates that neutralization of aldehydes occurs almost immediately when the amino acids are combined with aldehydes. The peak retention time in Table 3 shows the time when the molecule is beginning to change. The peak retention time for OPA is at approximately 1.812 minutes. As shown in Table 3, the OPA peak disappeared while some new peaks appeared after the two components were combined, indicating the OPA was reacting with the amino acids and the reaction products were formed. For example, after OPA is combined with glycine for fifteen minutes, the peak retention times are shown at 0.680 and 0.913 minutes which are different from the peak retention time of OPA that has a peak retention time of 1.812 minutes. These differences of peak retention times in glycine and OPA mixture compared to OPA without an amino acid show that the amino acid is reacting with the OPA. When the peak retention time is no longer significantly changing, the reaction is complete.
TABLE 3
Color Changes and Peak Retention Time (RT) of CIDEX ® OPA
Solution Reaction with Amino Acids
Example 2
Example 1
OPA/
OPA/
arginine =
Example 3
Example 4
OPA
glycine =
1:1
OPA/lysine = 1:1
OPA/g-amino-n-caproic = 1:2
Neutralization
Peak RT
1:2
Peak RT
Peak RT
Peak RT
Peak RT
Time
(min)
Color
(min)
Color
(min)
Color
(min)
Color
(min)
Upon combining
1.812
Red
0 693
Pink to
1 053
Light
0.9611
Light
0.730
components
Yellow
1.010
Orange
1.203
Yellow
1.047
Yellow
1.097
1.677
1.703
Orange
1.797
1.937
15 min
Yellow
0 680
Orange
1.013
Yellow
0.943
Dark
0.727
Black
0.913
1.110
precipitate
0.942
(ppt)
30 min.
Dark
0.685
Orange
1.023
Dark
0.923
Dark ppt
0.725
Brown
0 918
Yellow
0.942
45 min.
Dark
0.608
Orange
1 017
Dark
0.918
Dark ppt
0950
Brown
Yellow
60 min.
Black
0.603
Orange
1.027
Dark
0.913
Dark ppt
0.963
Brown
Yellow
Moreover, agitating or stirring the solution increases the rates of neutralization of the aldehydes.
Table 4 shows various molar ratios of amino acids used to neutralize OPA wherein the OPA solution used contains ˜0.55% OPA. In general, measurable neutralization begins after thirty minutes without physically stirring the solution. After one hour, most of the waste containing OPA has been neutralized in accordance with 22 C AL . C ODE R EGS., TIT . 22, §66696. Neutralization occurs at a faster rate if a higher concentration of amino acids is used and/or the solution is agitated.
TABLE 4
Neutralization Summary of Cidex ® OPA Solution with Amino Acids (LC 50 with Fathead Minnow)
OPA/Amino Acids
Time
Molar Ratio
5 min.
15 min.
30 min.
1 hour
2 days
OPA/L-Arginine,
<100 mg/L
<100 mg/L
<100
mg/L
Not available
Not available
C 6 H 14 N 4 O 2 ) = 4:1
OPA/L-Arginine,
Not available
Not available
Not available
500 mg/L-1000 mg/L
>2000 mg/L
(C 6 H 14 N 4 O 2 ) = 1:1
OPA/ε-Amino-n-
<100 mg/L
<100 mg/L
100-500
mg/L
Not available
Not available
Caprioc Acid,
(C 6 H 13 NO 2 ) = 1:1
OPA/ε-Amino-n-
Not available
Not available
Not available
1000 mg/L-2000 mg/L
>2000 mg/L
Caprioc Acid,
(C 6 H 13 NO 2 ) = 1:2
OPA/Glycine
Not available
Not available
Not available
>1000 mg/L
1000 mg/L-2000 mg/L
(C 2 H 5 NO 2 ) = 1.2
OPA/Glycine
<100 mg/L
<100 mg/L
100-500
mg/L
Not available
Not available
(C 2 H 5 NO 2 ) = 1:4
OPA/L-Lysine
Not available
Not available
Not available
100 mg/L-5000 mg/L
>2000 mg/L
(Acetic Acid)
(C 6 H 14 N 2 O 2 .
C 2 H 4 O 2 ) = 1:1
OPA/L-Lysine
<100 mg/L
˜100 mg/L
100-500
mg/L
Not available
Not available
(Acetic Acid)
(C 6 H 14 N 2 O 2 .
C 2 H 4 O 2 ) = 1:2
As shown in Table 5, glycine is an effective neutralizer for glutaraldehyde solution. Combining 0.4 mole of glycine with 1 mole of glutaraldehyde for 30 minutes can provide a nonhazardous product as shown by an LC 50 result that is greater than the regulatory level of 500 mg/L. In this study, approximately 2.4% by weight of glutaraldehyde in buffered water solution was used.
TABLE 5
Fathead Minnow Test Results For Glutaraldehyde Solutions
Neutralized With Glycine
%
Gly-
cine
Glutaraldehyde/
2.4%
Gly-
in
Glycine Molar
Glutaraldehyde
cine
solu-
LC 50
Ratio
Solution (g)
(g)
tion
Time
(mg/L)
Glutaraldehyde/
200
1.4
0.7
30
minute
>2000
Glycine = 1:0.4
Glutaraldehyde/
200
1.4
0.7
1
hour
>2000
Glycine = 1:0.4
Glutaraldehyde/
200
2.8
1.4
30
minutes
>2000
Glycine = 1:0.77
Glutaraldehyde/
200
2.8
1.4
1
hour
>2000
Glycine = 1:0.77
Glutaraldehyde/
200
5.6
2.7
30
minutes
>2000
Glycine = 1:1.5
Glutaraldehyde/
200
5.6
2.7
1
hour
>2000
Glycine = 1:15
Table 6 shows that glycine may neutralize formaldehyde in accordance with environmental regulations such as 22 C AL . C ODE R EGS., TIT . 22, §66696. In this study, approximately 2.5% by weight of formaldehyde in water was used.
TABLE 6
LC 50 Results Performed In Accordance With 22 CAL. CODE REGS.,
TIT. 22, § 66696 For Formaldehyde With Glycine
Formal-
Formaldehyde/
dehyde
Gly-
% Glycine
Glycine Molar
solution
cine
in mixed
LC 50
Ratio
(g)
(g)
solution
Mixing Time
(mg/L)
Formaldehyde
180
11.25
5.9
30
minutes
>500-1000
Glycine Molar
Ratio = 1:1
Formaldehyde/
180
11.25
5.9
1
hour
>500-1000
Glycine Molar
Ratio = 1:1
Formaldehyde/
180
45
24
30
minutes
>500-1000
Glycine Molar
Ratio = 1:4
Formaldehyde/
180
45
24
1
hour
>500-1000
Glycine Molar
Ratio = 1:4
Based upon the results shown in Table 6, glycine is capable of neutralizing formaldehyde to a level in which the waste product is considered nonhazardous.
While the discovery of forming neutralized aldehydes for lessening the toxic effects of disposing of aldehyde treated wastes was a major advance, the possibility of the neutralized aldehydes in reforming aldehydes under acidic conditions posed a problem in effectively maintaining nonhazardous waste because of the toxic effects of unneutralized aldehyde. The reversible reaction is depicted below for treatment of glutaraldehyde (1) and o-phthaladehyde (4) with the amino acid, glycine (2) to the neutralized products, (3) and (5), respectfully:
It has now been discovered that the treatment of the neutralized products with a reducing agent to form amino acids do not revert back to unneutralized aldehyde. This reaction is depicted below for saturated moieties (6) and (7) as for the reduction of Schiff's bases (3) and (5) treated with the reducing agent NaBH 4 :
Being simple amino acids compounds (6) and (7) would be expected to be biodegradable and thus have significant benefit for the environment. This appears apparent by examination of the resemblance of the structures (6) and (7) with the natural essential amino acid proline, (8). The corresponding resemblance is depicted with bold-faced highlighting of compounds (6) and (7) shown below:
In contrast, Schiff's base (3) and (5) do not have the above characteristics and are likely very different compounds. One skilled in the art would suspect Schiff's bases to be harder to degrade in nature than the corresponding amino acids.
For example, a piece of animal skin could decay in a few days in the wild while men's belts, made from animal skin too, could take many years. This is because the belt (leather) has undergone a tanning process. Tanning processes often employ the glutaraldehyde derivatives, such as depicted as structures (9) and (10) below to cross-link proteins (Ref. a. Fein, M. L. and Filachione, E. M., “Tanning studies with aldehydes”, J. Am. Leather Chem. Assoc., 52, 17, 1957; b. Weligsberger, L. and Sadlier, C., “New developments in tanning with aldehydes”, J. Am. Leather Chem. Assoc., 52, 2, 1957; c. Hopwood, D., “Comparison of crosslinking abilities of glutaraldehyde, formaldehyde, and α-hydroxyadipaldehyde with bovine serum albumin and casein”, Histochemie, 17, 151, 1969). It is well known that OPA has very similar protein cross-liking properties.
The conditions for Schiff's base reduction is easy and convenient. Normally, it involves the mixing of the reducing agent, such as NaBH4, and the imine, such as neutralized aldehyde, in a protonic solvent, such as water, ethanol, or methanol at room temperature.
Formation of the reduced neutralized aldehyde may be accomplished in any manner that results in a reduced neutralized aldehyde. Neutralization and reduction of aldehyde with amino acid and reducing agent can be conducted by mixing all three in a container, or reacting aldehyde with amino acid first, and then reacting the neutralized product with the reducing agent to reduce the neutralized product.
FIGS. 2 a and 2 b depict schematic mixing tanks containing aldehyde showing that amino acid and reducing agent (whether pre-mixed or separately) are added to the aldehyde (FIG. 2 a ) or the amino acid is added before the reducing agent (FIG. 2 b ).
In other embodiments, the reactions can be conducted by passing the aldehyde solution through a filter or cartridge containing amino acid and reducing agent with or without a solid support. The amino acid and the reducing agent can be coated onto a solid material. They can also be mixed or impregnated in the solid support. The amino acid and the reducing agent can be sandwiched between layers of glass wool with or without the solid support.
FIGS. 3 a , 3 b , and 3 c depict schematics of filter or cartridge embodiments of the invention. FIG. 3 a depicts treatment of an aldehyde waste. As shown, the aldehyde waste is discarded into a funnel, which directs the waste down a pipe or tube leading to a filter or cartridge. The filter or cartridge is detachable from the funnel. The filter/cartridge contains the neutralizing amino acid and the reducing agent. After contacting the amino acid and the reducing agent, the neutralized and reduced aldehyde is discharged.
The filter/cartridge may contain the amino acid and reducing agent in one or two zones. FIG. 3 b depicts the one zone embodiment wherein the amino acid and the reducing agents are intimately mixed. FIG. 3 c depicts a two-zone filter/cartridge wherein the first zone contains the neutralizing amino acid and the second zone contains the reducing agent.
A preferred method is first to contact the aldehyde with the neutralizer and then the reducing agent as shown below:
R—CHO (aldehyde)+H 2 N—CH(COOH)R′ (amino acid)→RHC═N—CH(COOH)R′ (imine) RHC═N—CH(COOH)R′ (imine)+Reducer→RH 2 CHN—CH(COOH)R′ (amino acid)
The imine can be reduced by many reducing agents, such as LiAlH 4 (Lithium aluminum hydride), NaBH 4 (Sodium borohydride), NaCNBH 3 (Sodium cyanoborohydride), Na—EtOH (Metal sodium in ethyl alcohol), and H 2 /catalyst (Hydrogen with a catalyst). A preferred reducing agent is NaBH 4 .
One preferred way to accomplish the reduced neutralization of aldehyde is to use a device as shown in FIG. 4 . Referring to FIG. 4, the waste stream containing aldehyde, in this case OPA, in introduced into the device depicted here as a cylinder. The entering OPA passes into a first zone, which neutralizes the OPA forming an imine. In this embodiment, the first zone is depicted to comprise the amino acid glycine supported on silica. After passing through the first zone, the neutralized OPA passes through a second zone, which reduces the neutralized OPA. In this case, the second zone comprises the reducing agent, NaBH 4 supported on silica. Upon exiting the device, the aldehyde is non-reversibly neutralized and thus should not revert back to the toxic aldehyde form.
Suitable amino acids and reducing agents include all of the ones previously described above.
Suitable support materials include any solid material capable of mixing with but not reacting with the amino acid or reducing agent. Such materials include salts, polymers and, more specifically silica, celite, sand, alumina, metal powders, carbon black, clay, pulps, zeolite, or starch. Preferred is silica.
The amino acids and reducing agents may be supported on the support materials in many ways. Most simply the amino acids and reducing agents are mixed together or separately with the support material in a wide variety of ratios. The amino acid or reducing agent may be coated or impregnated on the support by conventional means, again providing there is no reaction between the amino acid and reducing agent with the support.
The feasibility of the device depicted in FIG. 4 is demonstrated in the following examples
EXAMPLE 5
In a plastic column (0.3×5 cm), as shown in FIG. 5, a small amount of glass wool is inserted near the bottom of the column to form a support. To the column was then added a 1:1 by weight mixture of some sodium borohydride and Aldrich silica. The sodium borohydride/silica was added in an amount to comprise 1 cm of the column. Then a mixture of 1:1 by weight mixture of some glycine and Aldrich silica was added in an amount to comprise 3 cm of the column. 4 ml of OPA was added from the top of the column and collected at the bottom of the column. The fluid exiting the column was a brown solution which did not turn green or dark green after standing even when more glycine was added. This concludes that Schiff's base was converted to the saturated species and that the neutralized aldehyde was reduced
EXAMPLE 6
In this example, the same procedure was followed as in Example 5 except that no silica was used. Sodium borohydride was placed in the column, as shown in FIG. 6, in an amount to form a height of 1 cm in the column. Glycine was then placed on top of the sodium borohydride in an amount to form a height of 3 cm in the column. When the 4-ml of OPA was added, identical results were obtained as in Example 5.
In the preceding detailed description, the invention is described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention as set forth in the claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. | Methods, compositions, and devices for alleviating the problems of toxic discharge of aldehydes present in waste streams are disclosed. The methods relate to reducing neutralized aldehydes wherein the neutalized aldehydes are formed by treating aldehydes with amino acids and thereinafter are reduced. These reduced, neutralized aldehydes do not revert back to toxic aldehydes, but form amino acids and thus allow waste containing aldehyde to be more environmentally safely disposed. | 8 |
FEDERALLY SPONSORED RESEARCH
[0001] Not Applicable
SEQUENCE LISTING OR PROGRAM
[0002] Not Applicable
BACKGROUND
[0003] 1. Field of Invention
[0004] This invention relates to ventilation adaptation of conventional tank/bowl toilets.
[0005] 2. Description of Prior Art
[0006] Mainstream modem toilets do not have built-in systems for elimination of air-borne odors originating near or in the toilet bowl. In typical, currently available toilets, such odors are commonly entrained within room air and sometimes beyond the room in which the toilet resides into other living spaces before eventually being evacuated by room exhaust fans installed in the ceilings of the room or rooms. Many devices and methods have been patented for adaptation of conventional toilets to provide ventilation through or from the toilet bowl area for elimination. Yet, to date, none of these devices and system methods has made a significant impact upon the prevalence of toilet air-borne odor ventilation toilets in common use.
[0007] The prior art includes various adaptation systems for air venting of conventional toilets. Most adaptations employ means that require a sophisticated device requiring a costly manufacturing process to provide the device into the marketplace for use. Other means and devices are unattractive, unsanitary, or are not capable of overall positive outcomes. For all such devices and methods, none have made it into the marketplace to any extent that would allow the average citizen reasonable access to the toilet ventilation technology. One could conclude that there are objections that have limited the devices and methods from reaching the common marketplace.
[0008] Objections are speculative, but are surmised to include one or more of the following: 1) Cost of manufacture; 2) Complexity that limits the willingness of manufacturing commitment (related to cost); 3) Technology that does not address all of the technical issues encountered; 4) Aesthetics, based upon appearance of the apparatus; 5) Difficulty of maintaining sanitation and cleanliness of the apparatus or adapted toilet in general.
[0009] An example of at least three of these objections is in a most recent patent, 8505123: 1) The device would require very expensive initial tooling of the mold and manufacturing by injection molding; 2) the device is more complex than is necessary for accomplishing the objective; and, 3) The combination of the function of the device and the interruption of the air flow by use of a “motion sensitive switch connected to a movable portion of the refill mechanism” does not address the technical problems of a plugged toilet outlet or a failed flush and/or refill mechanism. In both cases, the apparatus/system would continue to pump even while the “air outlet in the toilet bowl” filled with water or sewage. This would happen because it is only the motion of the user operated flush device that interrupts the fan motor, unless the overall power switch is turned off by the operator.
[0010] Yet, this is the only such device found that does interrupt the flow of air under any interfering conditions, a necessary but inadequately functioning operation of the prior art.
OBJECTS AND ADVANTAGES
[0011] Accordingly, several objects and advantages of this invention are itemized. The primary object is to safely and affordably provide for the removal of gaseous material from in and around the bowl of a conventional, separable tank/bowl toilet. In this object both the device and the method are unique and novel for providing an advantage over the prior art through: 1) Ease of manufacture of the essential and simple device of the invention without need of expensive processes and/or equipment; 2) Affecting minimal impact to the appearance of the conventional toilet; 3) Flexibility for many options to aesthetically accommodate the minimal change to the appearance of the modified toilet; 4) Ease of cleaning of regions where alterations are made; 5) Sanitary and fail-safe operation in all anticipated and realistic situations encountered by conventional toilets; 6) Marketplace availability of all parts necessary for constructing the device and implementing the method, including all combinations described herein; and, 7) Ability to apply a greater volume per unit time (e.g., cubic feet per minute) of airflow due to protective systems of the methods.
SUMMARY
[0012] The invention is a device and a method combination that uniquely adds a venting capability to a conventional two piece, tank and bowl assembly toilet. The toilet to which the device and method are applied is originally capable of effectively removing waste solids and liquids from the toilet to the sewer system. The added capability of the invention is the efficient and safe removal of gaseous matter introduced to the toilet bowl by extraction through elements of the original toilet and the elements of the invention with the advantage of avoiding toilet airborne odors entering the room air. The advantage is accomplished without interfering with the original purpose of liquid/solid removal processes of the toilet.
DRAWINGS
[0013] There are two drawings, one for the device of the patent, the other for the combination of devices used for the multiple methods described.
[0014] FIG. 1 shows the elements of the ventilation adapter—the device of the patent.
[0015] FIG. 2 shows the device of the patent installed within a conventional toilet and including other elements of the methods. The method elements are appended, in the drawings, with M1 thru M4, depending on the methods of which they are a necessary part. The solid single lines between devices are the necessary electrical connections for particular methods. The double lines with hatching are the ventilation tubing of the indicated methods and the double line without hatching are the electrode lines utilized for the indicated methods.
LIST OF REFERENCE NUMERALS IN DRAWINGS
[0016] Device of the Invention
[0017] 5 —Ventilation Adapter
[0018] 10 —Inner Conduit
[0019] 15 —Outer Conduit
[0020] 20 —Conduit-end Structure
[0021] 25 —Side-arm
[0022] Devices for Methods of the Invention
[0023] 30 —Toilet
[0024] 31 —Toilet Bowl Assembly
[0025] 32 —Toilet Tank Assembly
[0026] 33 a —Flush-water Hole of the Bowl Assembly
[0027] 33 b —Flush-water Hole of the Tank Assembly
[0028] 34 —Ports and Channels of the Bowl Assembly
[0029] 35 —Tank Overflow Tube of the Tank Assembly
[0030] 40 —Ventilation Tube
[0031] 45 —Air-flow Pump
[0032] 46 —Electric Switch
[0033] 50 —Conductance Circuit Interrupter
[0034] 51 —Electrodes of 50
[0035] 55 —Fail-closed Air Valve
DETAILED DESCRIPTION
[0036] The device and methods described in this section, which are the subjects of this patent, are for the purpose of extracting and eliminating airborne odors within and around the bowl and tank of a conventional two piece toilet. The two piece toilet ( 30 ), not a device of the invention, but an essential component of the methods, consists of a tank assembly ( 31 ) and a bowl assembly ( 32 ) joined together to allow passage of flush water from the tank ( 32 ) to the bowl ( 31 ) through the conjoined flush-holes ( 33 a and 33 b ) of the tank and bowl assemblies. Such toilet ( 30 ) is hereinafter referred to as a “conventional toilet” or simply, “toilet”.
[0037] Device of the Invention—Ventilation Adapter
[0038] The device of the invention, the ventilation adapter ( 5 ), is inserted between the tank ( 32 ) and bowl ( 31 ) of the toilet ( 30 ). The ventilation adapter ( 5 ), is a simple double conduit, or tube within a tube, with a side-arm ( 25 ) tube as an extension of the outer conduit ( 15 ). The double conduit has closure and rigidity provided by the conduit-end structure ( 20 ) between walls of the two conduits ( 10 and 15 ) at the tank ( 31 ), or upper, end of the adapter ( 5 ). (Alternatively, the conduit-end structure ( 20 ) can be eliminated if the inner conduit and outer conduit are installed independently such that the inner conduit ( 10 ) and outer conduit ( 15 ) are independently sealed to the bottom of the toilet tank assembly ( 32 ).) The bowl end of the double conduit ventilation adapter ( 5 ) is open to both conduits. The space between conduit walls is not of a critical dimension but is approximately 0.25″ in the preferred embodiment of the invention as represented in the figures.
[0039] The inside diameter of the inner conduit ( 10 ) is approximately the diameter of the toilet flush-water holes ( 33 a and 33 b ) of the tank ( 32 ) and bowl ( 31 ) where joined, which can vary depending on toilet design. Therefore, the inside diameter of the outer conduit ( 15 ) is large enough to provide the necessary space between walls, or approximately 0.25″ of space around the entire circumference.
[0040] The inner conduit ( 10 ) is approximately the same length than the larger diameter outer conduit ( 15 ) at the bowl end but can be somewhat shorter or longer provided it does not restrict the flow of air into the outer conduit ( 15 ). The conduits ( 10 and 15 ) are approximately in the range of 1-3 inches in length but could be longer or shorter depending on needs for the size of the side arm ( 25 ) and other toilet ( 30 ) and vacuum considerations. The side-arm tube ( 25 ) is conjoined to the outer conduit ( 15 ) such that it is an extension of the outer conduit ( 15 ) providing a change in direction and decrease of diameter of the outer conduit ( 15 ). Generally, the side-arm ( 25 ) would be approximately 1-2 inches in inside diameter but could conceivably be larger or smaller in diameter.
[0041] The inner and outer conduits ( 10 and 15 ) are positioned in a vertical orientation when emplaced between the toilet tank/bowl assemblies ( 31 and 32 ). The side-arm ( 25 ) is conjoined to the outer conduit ( 15 ) in a slightly upward (from horizontal) orientation going away from the outer conduit ( 15 ) and extending from the back of the toilet ( 30 ) as shown in FIG. 2 . The bottom rim of the outer conduit ( 15 ) wall is sealed to the base of the bowl assembly by conventional means such that the outer conduit ( 15 ) wall surrounds the toilet bowl flush-water hole ( 33 a ). The inner conduit ( 10 ) wall is positioned such that the toilet bowl flush-water hole has direct passageway for gaseous material to enter the space between the inner conduit ( 10 ) and outer conduit ( 15 ). The conduit-end structure ( 20 ) is sealed to the bottom of the tank assembly with the inner conduit ( 10 ) surrounding the flush-water hole of the tank assembly ( 33 b ). The preferred embodiment of the ventilation adapter is with the conduit-end structure ( 20 ) forming the sealing surface with the bottom of the tank assembly ( 32 ), normally with a gasket or other sealant between the parts. Alternatively, the inner conduit ( 10 ) and outer conduit ( 15 ) could be sealed to the bottom of the tank assembly ( 32 ) independently and the conduit-end structure ( 20 ) eliminated.
[0042] Essential Devices (not of the Invention) for Methods of the Invention
[0043] The methods of the invention include the device of the invention, the ventilation adapter ( 5 ), as emplaced between the tank ( 32 ) and bowl ( 31 ) of the conventional toilet ( 30 ). The methods also include the various ports and channels of the bowl assembly ( 34 ) that are primarily used for the means of flushing the toilet ( 30 ). The methods of the invention employ the ports and channels ( 34 ) to move the gaseous material in the opposite direction of the flush water by means of an air-flow pump ( 45 ).
[0044] In addition to the toilet ( 30 ) and the ventilation adapter ( 5 ) of the invention, other devices are necessary for the methods of the invention. All methods require additional lengths of ventilation tube ( 40 ) leading from the side-arm ( 25 ) of the adapter ( 5 ) to the required air-flow pump ( 45 ) and from the air-flow pump ( 45 ) to the exterior where the gaseous material is expelled. The combination of the outer conduit ( 15 ) of the ventilation adapter ( 5 ), the ventilation tube ( 40 ), and the air-flow pump ( 45 ) are collectively referred to as the gaseous ventilation pathway.
[0045] Optional Devices (not of the Invention) for Methods of the Invention
[0046] Optional devices are employed for additional methods. One optional device is a conductance circuit interrupter ( 50 ). This device employs the means of sensing the presence of water by way of a low voltage current conductance between electrodes ( 51 ). The electrodes ( 51 ) are positioned within the inner conduit ( 10 ) of the adapter ( 5 ) between the toilet tank ( 31 ) and the toilet bowl ( 32 ) and/or in the side-arm ( 25 ) of the adapter ( 5 ). When conductance is established between any set of electrodes ( 51 ), the circuit to the other devices is interrupted and is timed-off for a pre-set number of seconds before the circuit is allowed to resume, presuming there is no longer conductance between the electrodes ( 51 ).
[0047] Another optional device used for an alternative method is a fail-closed air valve ( 55 ). This low-voltage, conductance-actuated, fail-closed air valve ( 55 ) is placed in the ventilation tube ( 40 ) prior to the air-flow pump ( 45 ). The valve is tuned to the open position when there is normal pressure differential required for unobstructed air flow through the system. The tuning is such that if water or any other dense material should enter the air pathway, the increase in pressure differential at the valve ( 55 ) activates the valve ( 55 ) to the closed position relative to the air-flow pathway. It will remain in the closed position until the valve is powered off and then activates when turned on again. The fail-closed air valve ( 55 ) is also closed when there is no electrical power to the valve ( 55 ).
[0048] Method Designations and Operations
[0049] Method 1 (M1)—This basic method employs the flush-water ports and channels ( 34 ) of the toilet ( 30 ), the emplaced ventilation adapter ( 5 ), the ventilation tube ( 40 ) and the air-flow pump ( 45 ). The air-flow pump ( 45 ) is powered on by a normal household electrical circuit through an electric switch ( 46 ) in the room of the toilet. The electric switch ( 46 ) could be a switch manually operated, with a timer or other type of switching signal not associated with the toilet mechanisms. Gaseous material is drawn from the toilet bowl through the ports and channels ( 34 ). In addition, gaseous material is drawn from the toilet tank by way of the tank overflow tube ( 35 ). Gaseous material from both sources is then drawn into the outer conduit ( 15 ), and is, therefore, separated from the flush-water pathway upon entering the outer conduit ( 15 ) of the adapter ( 5 ). The gaseous material is then drawn through the ventilation tube ( 40 ) by the air-flow pump ( 45 ) and finally expelled from the ventilation tube ( 40 ) at the exhaust end. The air-flow pump ( 45 ) is then turned off, by the electric switch ( 46 ) in the room, prior to flushing the toilet ( 30 ).
[0050] Method 2 (M2)—This method is the same as M1 except that the device referred to as the conductance circuit interrupter ( 50 ) is utilized so that the electric switch ( 46 ) of the system does not have to be turned off prior to the toilet ( 30 ) being flushed. The function of the conductance circuit interrupter ( 50 ) is to stop the air-flow pump ( 45 ) when the flush-water is sensed in the inner conduit ( 10 ) of the ventilation adapter ( 5 ) by the electrodes of the conductance circuit interrupter ( 51 ).
[0051] Method 3 (M3)—This method is the same as M1 except that the device referred to as the fail-closed air valve ( 55 ) is utilized so that the electric switch ( 46 ) of the system does not have to be turned off prior to the toilet being flushed. The function of the fail-closed air valve ( 55 ) is to close the gaseous ventilation pathway from the toilet ( 30 ) to the air-flow pump ( 45 ) when there is an increase in pressure differential on the inlet side relative to the outlet side of the fail-closed air valve ( 55 ). This occurs when there is obstruction such as water entering the gaseous ventilation pathway. The fail-closed air valve ( 55 ) will remain closed until the power has been turned off, the gaseous ventilation pathway has been freed for unobstructed gaseous flow and the power has been turned on again.
[0052] Method 4 (M4)—This method is the same as M1 except that it utilizes both the conductance circuit interrupter ( 50 ) and the fail-closed air valve ( 55 ) in combination. In this method, the conductance circuit interrupter ( 50 ) is coupled with the air-flow pump and with the fail-closed air valve ( 55 ) so that the electrical current to the fail-closed air valve ( 55 ) and the air-flow pump ( 45 ) is interrupted when water is present in sensitive areas, as described above, where the electrodes ( 51 ) reside. Without electrical current, the valve ( 55 ) is closed to air flow through the ventilation tube ( 40 ) and the air-flow pump ( 45 ) is powered off, therefore adding additional protection to the gaseous ventilation pathway from entrainment of aqueous or solid material, particularly when relatively higher air flow volume rates are utilized. It is repeated here that the fail-closed air valve ( 55 ) will close when the toilet becomes overfull at the bowl and the ports and channels of the bowl assembly ( 34 ) are obstructed by liquid or solid materials even if the conductance circuit interrupter ( 50 ) has not deactivated the power to the devices ( 45 and 55 ).
[0053] The preferred methods are dependent on the conditions of the application. If the ventilation of the toilet is to be combined with a room ventilation fan, by sharing of an exhaust conduit from the building, or if the ventilation tube ( 40 ) is smaller than optimal (<3-4 inches in diameter), or if the ventilation tube ( 40 ) or exhaust conduit exiting the building is of substantial length or circuitous route, the preferred method is M4. This method allows for protective features as described above, when utilizing a relatively stronger air-flow pump ( 45 ) that may be required for overcoming back-fed air pressure from the described conditions.
[0054] When there is access of a relatively large (3-4 inch diameter) ventilation conduit all the way from near the side-arm ( 20 ) of the ventilation adapter ( 5 ) to the exterior of the building, dedicated solely to the toilet ventilation system of the invention, the preferred method is M2. This method still provides an interruption of gaseous matter flow during the toilet flushing process (primarily so there is no infringement upon the uniform free-flow of flush-water by gravitational acceleration through the ports and channels of the toilet bowl assembly ( 34 )). Yet, a substantially lower-powered air-flow pump ( 45 ) is utilized that will maintain adequate gaseous flow for accomplishing the objective of the invention. This combination will avoid the unnecessary use of excess electrical power, limit noise from the air-flow pump ( 45 ), and eliminate the cost and complexity of adding the fail-closed air valve ( 55 ). The fail-closed air valve ( 55 ) is not necessary when the air-flow pump is incapable to accelarate liquid or solid materials to any substantial degree into the outer conduit ( 15 ) of the ventilation adapter ( 5 ). | The invention is a simple and economical device and a method combination that adds a venting capability to a conventional tank and bowl toilet. The purpose of the invention is the efficient and safe removal of gaseous matter introduced to the toilet bowl, by extraction of the gas through elements of the original toilet and the elements of the invention, with the advantage of avoiding airborne odors entering the room air from the toilet bowl. Advantages over the prior art are economy of parts and unique safety processes that preclude interference with or creation of unsanitary conditions from the liquid/solid removal processes of the unmodified toilet. | 4 |
FIELD OF THE INVENTION
This invention relates in general to shrouds used in the separation of gas from liquid, and in particular to using a boost pump with a crossover in wells lacking the pressure to move a mixed flow upwards to the top of an inverted shroud.
BACKGROUND OF THE INVENTION
In gas well dewatering applications it is desired to draw the well down to the lowest reservoir pressure as possible in order to maximize gas production. To prevent lift pumps from gas locking, inverted shrouds are used as a way to separate gas from liquid. Inverted shrouds are typically long and in effect, raise the intake of the pump to the top of the shroud. Further pressure increase occurs due to the frictional drag in the annulus between the shroud and the casing.
It is becoming increasingly desirable to dewater a zone by placing the ESP pump in a horizontal well-bore. In horizontal gas wells, however, the gas bubble buoyancy forces are not acting in the optimum direction for moving gas out of the well bore. In these wells much of the gas production goes up the casing/tubing annulus. Because a significant length of well-bore is horizontal, it is very difficult to keep the necessary fluid level over the pump. Thus, static liquid in a horizontal gas well may choke the gas flow.
A technique is thus needed to boost the gas and liquid to the vertical or high angle to allow the buoyancy forces to separate the gas from liquid.
SUMMARY OF THE INVENTION
In an embodiment of the present invention, a dewatering apparatus with enhanced gas separation is illustrated, with a mixed flow booster pump located above a motor and within a shroud located in a cased well. The shroud may be inverted and can be combined with a fluid crossover assembly that may have mixed flow and liquid chambers that are isolated from each other. The crossover assembly may be connected to the discharge of the booster pump at an upstream end and at a downstream end to an intake of a lift pump. The crossover assembly can receive mixed flow from the well and has an outlet that directs the mixed flow up into the inside of the inverted shroud into an inner annulus formed by the outer diameter of the lift pump and inner diameter of the shroud where separated gas can escape through an open end on the downstream side of the shroud. The booster pump can be used in wells lacking the required pressure to move the mixed flow upwards through the shroud. Thus, the booster pump only needs to provide enough head to move the mixed flow up to the top of the inverted shroud. To further enhance gas separation, the shroud may be perforated near the downstream end and have a vortex inducer near the perforated section that induces fluid rotation such that the high percentage liquid, such as water, is flung outward, through the perforations and into an outer annulus defined by the shroud's outer diameter and casing inner diameter. High percentage refers to the high percentage of liquid versus gas in the liquid flow.
Once the high percentage liquid is in the outer annulus, gravity causes the liquid to fall downwards and enters a port in the fluid crossover. The port is in communication with the intake of the lift pump, allowing the lift pump to pump the liquid up through a production tubing string extending through the shroud and leading to a wellhead. A seal or packer may be located in the inner annulus above and below the fluid crossover and another seal could be located in the outer annulus between the upstream end of the shroud and the casing.
The invention is simple and provides enhanced gas separation and increased gas handling capability for high flow or low flow gas well dewatering applications, including vertical wells, horizontal wells, slant wells. This invention further advantageously allows for pumping mixed flow gas wells such as those that require dewatering. This invention could help gas dewatering operators have much greater production and in effect lower the overall cost of production.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a well installation in accordance with the invention.
FIG. 2 is an enlarged sectional view of the well installation of FIG. 1 showing the details of a crossover assembly in accordance with the invention.
FIG. 3 is cross sectional view of the crossover assembly of FIG. 1 , taken along the line 3 - 3 of FIG. 2 , in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , an embodiment of a dewatering apparatus 10 is shown located within the casing 12 of a well having perforations 14 to allow fluid flow from the formation. The dewatering, apparatus 10 includes an inverted shroud 16 that may have a separating device or perforated section 18 approximately located at an open top end 20 . A lift pump 22 for pumping fluid to the surface via a production tubing string 24 has an intake 26 that may be connected to a downstream end of a crossover assembly 28 . The lift pump 22 could comprise multiple stages. Intake 26 of lift pump 22 is located downstream from perforated section 18 , meaning that liquid from the well first passes through perforated section 18 before reaching pump intake 26 . A discharge end 30 of a booster pump 32 connects to an upstream end of the crossover assembly 28 to pump a mixed fluid flow of liquid and gas up an inner annulus 34 that is defined by the outer diameter of the lift pump 22 and the inner diameter of the shroud 16 . The upstream, end of crossover assembly 28 means that fluid flowing in inner annulus 34 flows through booster pump 32 before reaching crossover assembly 28 . Fluid flowing into lift pump intake 26 first flows through booster pump 32 and crossover assembly 28 . An outer annulus 36 is defined by outer diameter of the shroud 16 and the inner diameter of the casing 12 . The booster pump 32 may have stages for gas handling and impellers suitable for gas handling.
Both the lift pump 22 and the booster pump 32 are located above a motor 38 in this example, with the motor 38 having a power cable 60 ( FIG. 2 ) that extends to the surface. A shaft 40 is connected to the motor 38 and extends through a seal section 42 , through the booster pump 32 , through the crossover assembly 28 and into the lift pump 22 . This configuration of the shaft 40 allows the motor 40 to drive both the lift pump 22 and the booster pump 32 . Additionally, a sensor 44 may be located on the upstream side of the motor.
Inner annulus seals 46 may be located upstream and downstream of the crossover assembly 28 to prevent recirculation of fluid. Further, an outer annulus seal 48 can be located at the upstream end of the shroud 16 between the shroud 16 and the casing 12 to create a seal between the mixed flow entering from the formation and the separated liquid in the outer annulus 36 .
Further, a vortex inducer 50 may be attached to the production tubing 24 at a point below the perforated section 18 of the shroud 16 to further enhance gas separation. Vortex inducer 50 is located near the downstream end of shroud 16 . which is the end where fluid flowing in annulus 34 is discharged. The apertures in perforated screen 18 are downstream from vortex inducer 50 , thus the fluid first flows through vortex inducer 50 before reaching perforated screen 18 . The vortex inducer 50 induces the mixed flow in the inner annulus 34 to rotate, thereby causing the heavier liquid to move outward towards the perforations in the perforated section 18 and allowing the lighter gas to flow upwards through the open top end 20 of the shroud 16 . The vortex inducer 50 may comprise helical blades attached to a body that may be clamped onto the production tubing.
Referring to FIG. 2 , an enlarged and more detailed view of the crossover assembly 28 and of the booster pump 32 is shown. The booster pump 32 has an intake 62 for receiving the mixed flow from the well. The discharge end 30 of the booster pump 32 is in communication with a mixed flow inlet 64 that opens up into a mixed flow chamber 66 within the crossover assembly 28 . The mixed flow chamber 66 has an outlet 68 in communication with the inner annulus 34 . The crossover assembly 28 further comprises a liquid chamber 70 that may be isolated from the mixed flow chamber 66 .
An opening 72 in the inverted shroud 16 communicates the outer annulus 36 with the liquid chamber 70 to allow high percentage liquid to flow into the liquid chamber 70 of the crossover assembly 28 . As mentioned above, high percentage liquid refers to the high percentage of liquid versus gas in the liquid flow in the outer annulus 36 . The liquid flow chamber 70 has an outlet 74 in communication with the intake 26 of the lift pump 22 . As illustrated in the cross-sectional view of FIG. 3 , a central shaft passage 76 is formed in the crossover assembly 28 to allow the shaft 40 to pass through the crossover assembly to drive the lift pump 22 . The passage 76 is isolated from both the mixed flow chamber 66 and the liquid flow chamber 70 . Radial support bearings 78 may be used within the passage 76 to support the shaft 40 and seals 80 between the shaft 40 and the passage 76 prevent recirculation through the shaft passage 40 .
In operation, referring to FIGS. 1 and 2 , the mixed flow, identified by arrows and an “M,” containing liquid and gas enters the well casing 12 via the perforations 14 below the dewatering apparatus 10 in this example. The mixed flow circulates upward within the shroud 16 past the motor 38 and seal section 42 and into the booster pump intake 62 . The discharge end 30 of the booster pump 32 discharges into the mixed flow chamber 66 of the crossover assembly 28 via mixed flow inlet 64 . The mixed flow then exits the crossover assembly 28 via mixed flow outlet 68 and into the inner annulus 34 .
Once in the inner annulus 34 , the head generated by the booster pump 32 is sufficient to lift the mixed flow downstream past the exterior of the lift pump 22 , production tubing 26 , and to the top of the shroud 16 . If the vortex inducer 50 is located within the shroud 16 at approximately the top end of the shroud 16 , the mixed flow will be induced into rotational motion, causing the heavier liquid in the mixed flow to be slung outwards against the inside of the shroud 16 and concentrating the lighter gas towards the center of the shroud 16 where the gas can continue downstream to the surface via the top open end 20 . If the perforated section 18 is included at the top end of the shroud 16 , the heavier liquid slung outwards will move through the perforations in the perforated section 18 and into the outer annulus 36 . The liquid flow in the outer annulus is a high percentage liquid having a high percentage of liquid versus gas. The liquid flow is identified with arrows and an “L” and moves upstream or downward within the outer annulus 36 under gravitational force. In this embodiment, the liquid flow then enters the liquid flow chamber 70 of the crossover assembly 28 via the passage 72 in the shroud 16 . Once in the liquid flow chamber 70 , the liquid flow flows into the lift pump intake 26 via an outlet 74 in communication with the intake 26 of the lift pump 22 . The lift pump 22 then discharges the liquid into the production tubing string 24 where it is pumped up to the surface.
Although shown as a separate component in the embodiment described above, the crossover assembly 28 may be integral to the shroud 16 , with the chambers 66 , 70 formed into the shroud 16 .
While the invention has been shown in only a few of its forms, it should be apparent to those skilled in the art that it is not so limited and is susceptible to various changes and modifications without departing from the scope of the invention. | An above-motor mixed flow booster pump combined with a fluid crossover that directs up into the inside of an inverted shroud to allow enhanced gas separation. A gas and liquid separator is used to enhance separation. The system provides gas handling capability for high flow or low flow gas well dewatering applications, including vertical wells, horizontal wells, slant wells. The boost pump allows the moving of a mixed flow upwards to the top of an inverted shroud in wells lacking the required pressure. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to transmission and reception of signals. More particularly, this invention relates to the encoding and modulation of transmission signals with digital data and the demodulation and decoding of received signals corrupted by channel induced intersymbol interference.
[0003] 2. Description of Related Art
[0004] In the transmission and reception of digital data, channel induced intersymbol interference is the arrival of multiple copies of a transmitted signal that causes the information from one segment of information to corrupt a subsequent segment of information. The multiple copies of the transmitted signals occur generally because of reflections of the transmitted signals within the environment.
[0005] The level of the reflection determines the level of degradation of the signal received and the probability of the intersymbol interference causing errors in the reception of the signals. Also, the amount of time required for the reflections to transit from the transmitter to the reflection point and thence to the receiver further determines the quantity of intersymbol interference.
[0006] Refer now to FIG. 1 for a discussion of channel induced intersymbol interference in a wireless radio frequency (RF) transmission. In this instance the transmitter 5 is connected to the antenna 10 , which radiates an RF signal. Even though the RF signal emanates from the antenna 10 as a contiguous wavefront, it is shown as three separate wavefronts 35 , 40 , and 50 . The wavefront 35 is travels through the atmosphere in a direct path. The wavefront 40 travels through the atmosphere and is reflected from a landmass 30 such as mountains and hills. The reflected wavefront 45 then arrives at the antenna 15 . The wavefront 50 travels through the atmosphere and is reflected by buildings 25 of a metropolitan area. The reflected wavefront 55 , likewise, then arrives at the antenna 15 .
[0007] The antenna 15 is connected to the receiver 20 . The receiver acquires the transmitted signal and recovers the information modulated within the RF signal. It is apparent that the wavefront 35 travels the most direct route from the transmitting antenna 10 to the receiving antenna 15 . The reflected wavefronts 45 and 55 , on the other hand, arrive at the antenna 15 at some time later than the wavefront 35 . If the amplitude of the reflected wavefronts is larger than the environmental noise, the receiver will acquire the reflected wavefronts 45 and 55 and be indistinguishable from the wavefront 35 , except that they will be delayed in time.
[0008] Refer now to FIG. 2 for a discussion of the channel induced intersymbol interference within a wireless RF data communication system. The digital data 105 and its synchronizing clock 100 is the input signal to the transmitter 5 of FIG. 1. A common method of modulating the RF signal with the digital data 105 is frequency shift keying (FSK) In frequency shift keying, the voltage level of the digital data representing a digit having a binary 0 causes the RF signal to have a first frequency f 0 135 and the digit having a binary 1 causes the RF signal to have a second frequency f 1 140 .
[0009] The transmitter 5 transmits the RF signal 110 from the antenna 10 as described above. The RF signal transits the multiple paths as described with each signal being delayed in time. The direct RF signal λ 1 115 arrives at the antenna after a delay δ 1 145 . The reflected RF signal λ 2 120 arrives at the antenna after a delay δ 2 150 . The reflected RF signal λ 3 125 arrives at the antenna after a delay δ 3 155 .
[0010] The direct RF signal λ 1 115 and the reflected RF signals λ 2 120 and λ 3 125 are superimposed upon each other at the antenna and transferred to the receiver 20 . The receiver 20 employs superheterodyne techniques to extract the digital data from the differences in frequency that defines the digital data. The data message 130 should change from the binary zero to the binary 1 at the time 170 . However, the delayed reflected signals λ 2 120 and λ 3 125 interfere with the direct received signal 115 and cause an uncertainty 160 of the digital data. The digital data may remain at the binary 0 and is not definitely changed until the time 175 . The magnitude of the delayed reflected signals λ 2 120 and λ 3 125 determines the impact of this intersymbol interference. Similarly, the data message 130 should change from the binary 1 to the binary 0 at the time 10 , however, the interference from the delayed reflected signals λ 2 120 and λ 3 125 might cause the data message 130 to remain at the binary 1 until the time 185 . This uncertainty time 165 may cause a misinterpretation of the digital data.
[0011] Similar channel induced intersymbol interference can occur in wireless infrared light transmission as illustrated in FIG. 3. In this case the transmitter 205 and the receiver 220 are generally enclosed within a room 200 . The transmitter 205 excites the light emitting diode (LED) to emit infrared light. A typical type of transmission is on-off-keying (OOK), where the LED is excited for data having a binary one and turned off for data having a binary zero. The light is transmitted to a photodiode 215 . The photodiode 215 is connected to the receiver 220 , which recovers the received light signal and demodulates the received signal to extract the transmitted information.
[0012] The light signal as transmitted from the LED 210 is a contiguous wavefront, but for illustration it is shown as three separate wavefronts 235 , 240 , and 250 . The wavefront 235 represents the portion of the light signal that travels directly to the photodiode 215 . The wavefronts 240 and 250 are transmitted toward the sidewalls of the room 200 and the wavefronts 246 and 255 are reflected to the sidewalls to the photodiode 215 . The reflected wavefronts 246 and 255 travel a longer distance through the room 200 to arrive at the photodiode 215 and thus interfere with the wavefront 235 that arrive earlier.
[0013] Referring to FIG. 4 for a discussion of the modulation of the light signal as transmitted from the transmitter 205 of FIG. 3. The data clock 300 has the frequency rate that the digital data message is gated within the transmitter 210 . The modulation clock (PPM CLK 305 ) that is used to generate the four-pulse position modulated signal of the transmitted signal 310 . Each time slot t1, t2, t3, t4 is divided into four sub-increments s 1 , s 2 , s 3 , s 4 . One sub-increment s 1 , s 2 , s 3 , or s 4 is set to a binary one, in this representation, to represent a two digit binary number. Since only one sub-segment may be occupied for any one time slot t1, t2, t3, t4, the coding can only represent the four possible combinations of the two digit binary numbers. The four-pulse position modulated signal of the data message illustrates the modulation of the four possible binary digit combinations of the dual-bit data and is explained as follows:
Time Slot Dual-Bit Code PPM Encoding t1 00 1000 t2 01 0100 t3 10 0010 t4 11 0001
[0014] The pulse positioned modulated signal 310 is transmitted by activation of the LED 210 . The direct light signal λ 1 320 arrives at the photodiode 215 after a delay δ 1 340 . The reflected light signal λ 2 325 arrives at the photodiode 215 after a delay δ 2 345 . The reflected light signal λ 3 330 arrives at the photodiode 215 after a delay δ 3 350 .
[0015] The direct light signal λ 1 320 and the reflected light signals λ 2 325 and λ 3 330 are superimposed upon each other at the photodiode 215 and transferred to the receiver 220 . The receiver 220 recovers the pulse positioned data message 335 . The pulse positioned data 335 changes from the voltage level of the binary zero to the voltage level of the binary one after the delay δ 1 340 . However, the delay δ 2 345 and δ 3 350 of the reflected signals λ 2 325 and λ 3 330 causes the photodiode to detect the binary one for a time longer than the length of a sub-increment s 1 , s 2 , s 3 , s 4 of a time slot t1, t2, t3, or t4. The magnitude of the reflection maybe insufficient to consistently determine this uncertainty time 355 . Further, if two symbols such as a 11 followed by a 00 are transmitted the detection of the binary one extending beyond the sub-increment s 1 , s 2 , s 3 , s 4 of a time slot t1, t2, t3, or t4 now interferes with a subsequent symbol. The severity of the channel induced intersymbol interference prevents the extension of the bandwidth of communication system beyond the ability of the communication to reliably detect and recover the received data message.
[0016] U.S. Pat. No. 6,169,765 (Holcombe) describes an output signal pulse width error correction circuit and method wherein errors in a data signal conforming to a communications protocol having a prescribed duty cycle are corrected by monitoring a duty cycle of the data signal, comparing the duty cycle to a duty cycle reference voltage corresponding to the prescribed duty cycle, and adjusting a pulse width of the data signal to conform to the prescribed duty cycle of the protocol.
[0017] U.S. Pat. No. 5,394,410 (Chen) explains a technique for encoding data for serial transmission and the correlative technique for decoding the transmitted data.
[0018] U.S. Pat. No. 5,892,796 (Rypinski) illustrates frame format and method for adaptive equalization within an integrated services wireless local area network to prevent fading and intersymbol interference due multiple path radio propagation.
[0019] U.S. Pat. No. 6,118,567 (Alameh, et al.) teaches a waveform encoding method and device provide for generating/receiving a power efficient binary intensity modulated optical data signal from a binary source signal which minimizes a time between adjacent pulse transitions and maximizes a pulse peak amplitude for transmission over a low-power wireless infrared link
[0020] “Efficient Reconstruction of Sequences,” Levenshtein, et al., IEEE Transactions on Information Theory, January 2001, Volume: 47, Issue: 1, pp. 2-22 introduces and provides solutions for problems of efficient reconstruction of an unknown sequence from its versions distorted by errors of a certain type.
[0021] “Spread-Response Precoding for Communication Over Fading Channels,” Wornell, IEEE Transactions on Information Theory, March 1996, Volume: 42, Issue: 2, pp. 488-501 presents “spread-response precoding” to effectively transform an arbitrary Rayleigh fading channel into a nonfading, simple white marginally Gaussian noise channel.
[0022] “Linear Complexity Of A Sequence Obtained From A Periodic Sequence By Either Substituting, Inserting, Or Deleting K Symbols Within One Period,” Jiang et al., IEEE Transactions on Information Theory, May 2000, Volume: 46, Issue: 3, pp. 1174-1177 provides a unified derivation of the bounds of the linear complexity for a sequence obtained from a periodic sequence over GF(q) by either substituting, inserting, or deleting k symbols within one period.
[0023] “On The Synchronizability And Detectability Of Random PPM Sequences,” Georghiades, IEEE Transactions on Information Theory, January 1989, Volume: 35, Issue: 1, pp. 146-156, investigates the problem of synchronization and detection of random pulse-position modulation (PPM) sequences under the assumption of perfect slot synchronization. Bounds on the symbol error probability and the probability of false synchronization that indicate the existence of a severe performance floor are derived. A way to eliminate the performance floor is suggested by inserting ‘special’ PPM symbols in the random data stream.
SUMMARY OF THE INVENTION
[0024] An object of this invention is to provide a communication system where pulse positioned modulated data signals is compensated for channel induced intersymbol interference.
[0025] An object of this invention is to extract pulse positioned encoded data from a received signal corrupted with channel induced intersymbol interference.
[0026] To accomplish at least one of these objects and other objects a communication system has a transmitter and a receiver. The transmitter transmits a signal containing pulse positioned modulated and compensated data symbols The receiver acquires the signal containing the pulse positioned modulated data symbols, recovers the data symbols, and extracts the data.
[0027] The transmitter includes a modulation apparatus connected to receive data and convert the data to pulse positioned modulated data symbols, the pulse positioned modulated data symbols encoded to compensate for the channel induced intersymbol interference The modulation apparatus has a symbol mapping circuit, which receives data symbols to be transmitted and maps the data symbols to a transmission code. The modulation apparatus compares two adjacent data symbol digits, if the two adjacent data symbol digits have a first data level, the data symbol digits are transmitted. If the first digits of the data symbol digits has a first data level and a second digit of the data symbol digits has a second data level, the data symbols are also transmitted. However, if the first and second data symbol digits have a second data level, transmitting a first of the two adjacent data symbol digits is transmitted, a second of the two adjacent data symbol digits is converted to the first data level and the second data symbol digits is then transmitted.
[0028] The receiver has a demodulation apparatus to recover data symbols in the presence of the channel induced intersymbol interference. The demodulation apparatus has a sampling circuit in communication with a signal receiving circuit within the receiver to sample at a regular period received data symbols acquired by the receiving circuit. The samples of the data samples are retained by a sample retaining circuit in communication with the sampling circuit. The sample retaining circuit transfers the retained samples to a symbol mapping circuit. The symbol mapping circuit then recovers the data symbols.
[0029] The symbol mapping circuit executes a method for recovering the data symbols by first determining from two adjacent data symbol digits if a first state transition is present in the data symbol digits. The first state transition indicates that a first of the two adjacent data symbol digits is at the first data level and a second of the two adjacent data symbol digits is the second data level. If the first state transition is present, a first state transition time is recorded. If the first state transition is not present the search to determine the first state transition continues until it is present.
[0030] When the first state transition is determined, a second state transition is determined to be present in the data symbol digits The second state transition indicates that a first of the two adjacent data symbol digits is at the second data level and the first of the two adjacent data symbol digits is the second data level. When the second state transition is present, a second state transition time is recorded. The time difference between the first state transition time and the second state transition time is then calculated. If the time difference is less than a boundary time, at least one of any data symbol digits received subsequently to the second data symbol digit of the two adjacent symbol digits having the first state transitions is set to the first data level. If the time difference is greater than the boundary time, a first data symbol digit received subsequently to the second data symbol digit of the two adjacent symbol digits having the first state transition is set to the first data level and a second data symbol digit to the second data level.
[0031] All data symbol digits received subsequent to the second data symbol digit of the two adjacent symbol digits having the first state transition and prior to a data symbol boundary are set to the first data level. The data symbol digit arriving subsequent to the data symbol boundary to a second data level and all remaining symbol digits of one data symbol subsequent to the data symbol boundary are set to the first data level.
[0032] The method for recovering the data symbols continues by determining if a last data symbol digit of a symbol is at the second data level. If the last data symbol digit is at the second data level, all symbol digits of a following data symbol are determined if they are at the first data level. If all the data symbol digits of the following data symbol are at the first data level, the first symbol digit of the following data symbol is set to the second data level.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] [0033]FIG. 1 is a diagram of the operation of a wireless radio transmitter and receiver illustrating channel induced interference of the prior art.
[0034] [0034]FIG. 2 is a timing diagram illustrating the effects of channel induced intersymbol interference on received digital data in wireless radio frequency channel of the prior art.
[0035] [0035]FIG. 3 is a diagram of the operation of a wireless infrared transmitter and receiver illustrating channel induced interference of the prior art.
[0036] [0036]FIG. 4 is a timing diagram illustrating the effects of channel induced intersymbol interference on received digital data in wireless infrared channel of the prior art.
[0037] [0037]FIG. 5 is a plot of a stream of pulse positioned modulated symbols being mapped to compensate for intersymbol interference of this invention.
[0038] [0038]FIG. 6 is a plot of a stream of pulse positioned modulated symbols transmitted and received demonstrating intersymbol interference of this invention.
[0039] [0039]FIG. 7 is a plot illustrating the detection of state transitions of a received stream of pulse positioned modulated symbols and from the state transitions of the received pulse positioned modulated symbols recovering the transmitted pulse positioned modulated symbols in the presence of intersymbol interference of this invention.
[0040] [0040]FIG. 8 is a plot illustrating the reconstruction of the pulse positioned modulated symbols from the received compensated symbol stream of this invention.
[0041] [0041]FIG. 9 is a block diagram of a transmitter of the communication system of this invention.
[0042] [0042]FIG. 10 is process flow diagram of the method for compensation of pulse positioned modulated signals of the transmitter of FIG. 9.
[0043] [0043]FIG. 11 is a block diagram of a receiver of the communication system of this invention.
[0044] [0044]FIGS. 12 a - 12 c is process flow diagram of the method of for recovery of pulse positioned modulated signals of the receiver of FIG. 11.
DETAILED DESCRIPTION OF THE INVENTION
[0045] The intersymbol interference as described above limits the frequency spectrum usable for the transfer of digital data. The transfer of long strings of zeros and ones or heavy toggling between zeros and ones causes corruption of the digital data due to the multipath effects that induce the intersymbol interference described. The use of pulse positioned modulation provides a relatively low switching rate. Once the receiving system is synchronized to the received signal, the recovery of the data is more reliable since the errors that occur are not position dependent and do not propagate. Certain symbol arrangements however, do cause limitation of the frequency due to the multipath effects that can create intersymbol interference. In symbol combinations (11) followed by (00), and (10) followed by a (00) of a four pulse position modulated encoded data, the intersymbol interference is sufficient to potentially corrupt the received data and make the transmitted data not recoverable. The method and system of this invention employs a recoding of the pulse positioned modulation to compensate for the symbol combinations (11) followed by a (00). The symbols combinations (10) followed by a (00) are determined as a result of the patterns detected.
[0046] Refer now to FIG. 5 for a more detailed discussion of the recoding of the pulse positioned modulation to create a signal which then modulates the transmitted signal (either radio frequency or light signals). The PPM signal shows the digital data (0110001100010011) and formed partitioned to form the symbols SYM 1 , . . . , SYM 8 . The symbols SYM 2 and SYM 3 contain the symbols 10 and 00 that are the first of the potential intersymbol interference candidates. The symbols SYM 4 and SYM 5 contain the symbols 11 and 00 that are the second of the potential intersymbol interference candidates.
[0047] In the case of the four pulse position modulation, as .described in FIG. 4, each symbol is divided into four different times slots s 1 , s 2 , s 3 , and s 4 . Each time slot represents a digit of the symbol and only one of the four different times slots s 1 , s 2 , s 3 , and s 4 may contain the voltage level representative of the binary one. The intersymbol interference for the symbols SYM 4 and SYM 5 is compensated by placing the symbol digit s 1 from a binary one for SYM 5 to a binary zero for the transmission signal. This is an illegal character for the digital data and can be corrected at the receiver as describe hereinafter. Thus all symbols having a data pattern as shown for symbols SYM 4 and SYM 5 are recoded or mapped to the format of the transmit signal (XMIT SIGNAL), where the symbols SYM 4 and SYM 5 are now coded as (0001), (0000).
[0048] Referring to FIG. 6, the transmit signal (XMIT SIGNAL) modulates a wireless RF signal as described in FIG. 2 or a light signal as described in FIG. 4 for broadcast. The wireless RF or light signal is acquired at the receiver. The receiver amplifies wireless RF or light signal and recovers the received signal. The received signal is delayed as described in FIGS. 1 and 3 from the transmitted signal by a delay δ. However, the reflected signals λ 2 and λ 3 of FIGS. 1 and 3 delayed and are superpositioned on the direct signal λ 1 .
[0049] The pulse width of each symbol digit of the pulse positioned modulated data is extended for at least a second symbol digit time slot s 1 , s 2 , s 3 , or s 4 . Thus the symbols SYM 2 and SYM 3 containing the symbols 10 and 00 are now merged to contain the symbol data (0011) (1100). If the reflected signals λ 1 and λ 3 of FIGS. 1 and 3 are delayed even longer, the symbol data could actually be (0011) (1110). The symbols SYM 4 and SYM 5 are similarly corrupted to become (0001) (1000). Thus the recoded data of SYM 5 is now interfered with from the previous symbol SYM 4 .
[0050] The recovery of the received pulse positioned modulated signal is shown in FIG. 7. The rising transitions and the falling transitions of the received signal are recorded and the time difference τ from the rising transition and the falling transition is determined. If the time difference τ is less than a preset parameter, for instance the time of three symbol digits, the first symbol digit of the sequence of binary 1's is retained as the voltage level of the binary one and the remaining symbol digits are set to the voltage level of the binary zero. The symbols SYM 4 and SYM 5 illustrate this. The last symbol digit of symbol SYM 4 and the first symbol digit of the symbol SYM 5 have a voltage level of a binary one. The last symbol digit of symbol SYM 4 is retained at the voltage level of the binary one and the first symbol digit of the symbol SYM 5 is set to the voltage level of the binary zero. This retains the recoding described above.
[0051] Alternately, if the time difference τ is greater the preset parameter the first three symbol digits are set the voltage levels of the binary one, followed by the binary zero, followed by the binary one (101) and the remaining symbol digits of a symbol are set to the voltage level of the binary zero. The symbols SYM 2 and SYM 3 illustrate this recovery The last two symbol digits s 3 and s 4 of the symbol SYM 2 and the first two symbol digits s 1 and s 2 of the symbol SYM 5 all have the voltage level of the binary one. The time from the rising transition between the second and third symbol digits of the symbol SYM 2 and the falling transition between the third and fourth symbol digits of the symbol SYM 3 is greater than the preset parameter (duration of 3 symbol digits). The third symbol digit s 3 of the symbol SYM 2 and the first symbol digit s 1 of the symbol SYM 3 are retained at the voltage level of the binary one and the last symbol digit s 4 of the symbol SYM 2 is set to the voltage level of the binary zero. The remaining symbol digits (s 3 and s 4 ) of the symbol SYM 3 are set to the voltage level of the binary zero.
[0052] The recovered signal now reflects the transmitted signal of FIGS. 5 and 6. FIG. 8 illustrates the final decoding to recover the received version of the original pulse positioned modulated data. The recovered data is examined for the existence of a symbol code having a voltage level of a binary one at the fourth symbol digit s 4 and all the symbol digits s 1 , s 2 , s 3 , and s 4 of the following symbol digit have a voltage level of a binary zero. The first symbol digit s 1 of the following symbol digit is set to the voltage level of a binary one Examining the symbols SYM 4 and SYM 5 , the last symbol digit s 4 of the symbol SYM 4 is at the voltage level of a binary one and the symbol digits s 1 , s 2 , s 3 , and s 4 of the symbol SYM 5 are at the voltage level of the binary zero. The first symbol digit s 1 of the symbol SYM 5 is set to the voltage level of the binary one and the symbol codes for symbols SYM 4 and SYM 5 are recovered as (11) (00).
[0053] Refer now to FIGS. 9 and 10 for a description of the structure and operation of the transmission subsystem of a communication system of this invention. Digital data D 0 , . . . , Dn 400 is acquired (Box 440 ) by the data input register 405 . In this illustration the digital data is originally parallel data such as would be created, transformed, and stored in a computing system The synchronizing clock circuit 410 provides the data clock 412 to gate the input digital data D 0 , . . . , Dn 400 to the data input register 405 at the data rate shown in FIG. 4. The data 407 retained by the data input register 405 is transferred to the pulse position modulator 415 . The pulse positioned modulator 415 groups the data 407 to form (Box 445 ) multiple bit or binary digit symbols as shown in FIG. 4. For a four pulse positioned modulation, the data 407 is grouped into two bit or binary digital symbols. The synchronizing clock circuit 410 provides a pulse positioned clock 413 to the pulse positioned modulator 415 to determine the pulse positioned modulation encoding (Box 450 ) for each of the formed symbols. The pulse positioned clock 413 is equivalent to the pulse positioned modulation clock 305 of FIG. 4. The pulse positioned modulation encoded symbols are then transmitted serially (Box 455 ) as the pulse positioned modulated data 417 to the pulse positioned modulation mapping circuit 420 . The pulse positioned modulation mapping circuit 420 compares adjacent symbol digits of the pulse positioned modulation data 417 to map (Box 460 ) the pulse positioned modulation data 417 to provide a compensation for the presence of channel induced intersymbol interference. When two adjacent symbol digits are compared (Box 465 ) and are both at a voltage level of the binary one, the pulse positioned modulation mapping circuit sets (Box 470 ) the second symbol digit of the pair or symbol digits to the voltage level of the binary zero. The mapping of the pulse positioned modulated data 417 is equivalent to the method described in FIG. 5 where a data symbol (11) is adjacent to a data symbol (00). The pulse positioned modulation mapping circuit 420 has formed the transmission signal 422 , which is transferred to the transmission signal modulation circuit 425 . The transmission signal modulation circuit 425 modulates (Box 475 ) a signal 427 that is to be transmitted, either Frequency Shift Keying an RF Signal or gating a light signal. The modulated signal 427 is the input signal to the transmission driver that excites a transducer such as the transmission antenna 15 of FIG. 1 or the LED 210 of FIG. 3. The modulated signal 435 is then broadcast (Box 480 ) through the transmission medium.
[0054] An illustration of the structure and operation of the receiving subsystem of the communication system of this invention is shown in FIGS. 11 and 12 a - 12 c . The modulated signal 500 is acquired (Box 555 ) by a receiver 505 either through the antenna 20 of FIG. 1 or the LED 210 of FIG. 2. The amplifier and conditioning circuit 510 amplifies, demodulates, and conditions (Box 560 ) the received signal 500 to create the received pulse positioned modulated data 512 . Generally, the transmitter of FIG. 9 will have embedded a synchronization signal and a start and/or stop signal within the transmitted signal. The synchronization signal is detected by the clock synchronization circuit 515 and the clock synchronization circuit 515 generates (Box 565 ) a receiver system clock that is aligned to the embedded synchronization signal. The start signal indicates the beginning of the transmitted data follows immediately upon completion of the start signal. The stop signal indicates the completion of the data message and any following detected data signal is not part of the transmitted message. The start/stop recovery circuit detects the presence of the start and/or stop signals within the received pulse positioned modulated signal.
[0055] Upon detection (Box 570 ) of the start signal, the received pulse positioned modulated data is sampled (Box 575 ) by the data sampling circuit 525 . The clock synchronizing circuit 515 provides a sampling dock to provide at least one sample during a symbol digit s 1 , s 2 , s 3 , and s 4 time to determine the voltage level of the binary digit being sampled. The sampled pulse positioned modulated data 527 is transferred to the sample register 530 where is it retained (Box 580 ) for extraction of the transmitted pulse position modulated data that is corrupted by intersymbol interference. The retained samples are transferred to the sample mapping circuit 540 , which performs the extraction of the transmitted pulse positioned modulated data.
[0056] The current sample for a symbol digit is compared (Box 585 ) to a previous sample of a symbol digit. If the previous symbol digit is at the first voltage level indicating a binary zero and the current symbol digit is a the second voltage level indicating a binary one, a rising edge has occurred (Box 590 ). If the rising edge has not occurred, but the comparison indicates that the previous symbol digit has the second voltage level indicating a binary one and the current symbol digit has the first voltage level indicating a binary zero, then a falling edge has occurred (Box 620 ). However, if the previous and the current symbol digits are equal (either the first level indicating a binary zero or the second level indicating a binary one), then no transition has occurred and the next sample is taken (Box 575 ) and retained (Box 580 ) for comparison (Box 585 ) with the now previous sample.
[0057] When a rising edge occurs (Box 590 ), the sample time at which the rising edge occurs is recorded (Box 595 ). The difference time Δ 1 between the recorded time for the rising edge and a previous falling edge is determined (Box 600 ). Upon comparison (Box 605 ) with a preset time P0 for instance 3×τs (τs being the time duration of a symbol digit) if the difference time Δ 1 is not greater than the preset time P0, the next sample is taken (Box 575 ) and retained (Box 580 ) for comparison (Box 585 ) with the now previous sample.
[0058] When a falling edge occurs (Box 620 ), The sample time at which the falling edge occurs is recorded (Box 625 ). The difference time Δ 2 between the logged time of the rising edge and the logged time of the falling edge is calculated (Box 630 ). The difference time Δ 2 is compared (Box 635 ) to a preset time P1 (for instance 3×τs). If the difference time Δ 2 is less than the preset time P1, the symbol digit at the rising edge having the voltage level of the binary one is retained (Box 640 ) at the binary one and all symbol digits remaining in the symbol up to the falling edge are set (Box 645 ) to the voltage level of the binary zero. This provides the recovery of the symbol digits as discussed above for SYM 4 and SYM 5 of FIG. 7.
[0059] If the difference time Δ 2 is greater than the preset time P1, the symbol digit (Slot 1 ) at the rising edge having the voltage level of the binary one is retained (Box 655 ) at the binary one. The adjacent symbol digit (Slot 2 ) is set (Box 660 ) to the voltage level of the binary zero and the next adjacent symbol digit (Slot 3 ) is retained (Box 665 ) at the voltage level of the binary one. This provides the recovery of the symbol digits as discussed above for SYM 2 and SYM 3 as discussed in FIG. 7.
[0060] The difference time Δ 2 is then compared (Box 670 ) to an even longer preset time P2 (for instance 5×τs). If the difference time Δ 2 is greater the longer preset time P2, the final slot next to a symbol boundary is set (Box 675 ) to the voltage level of the binary zero. The first symbol digit (Slot 1 ) of the following symbol is retained (Box 680 ) at the voltage level of the binary one and all remaining slots of the symbol should be set (Box 685 ) to a binary zero. The sampling is skipped to the next symbol boundary (Box 690 ). The longer preset time P2 allows for the recovery of a set of symbol digits having a coding of (101001) from a received corrupted pulse position modulated data of (11111111). The worst incidence of this occurring would permit the reception of the received pulse position modulated data (0001) (1111) (1110) and then recovery of the transmitted (0001) (0100) (1000).
[0061] Upon completion of the recovery of the transmitted pulse positioned modulated data, the next sample is taken (Box 575 ) and retained (Box 580 ) for comparison (Box 585 ) with the now previous sample. If a rising edge is determined (Box 590 ), the time of the rising edge is recorded (Box 595 ). The difference time Δ 1 between the previous falling edge and the present rising edge is determined (Box 600 ). The difference time Δ 1 is compared (Box 605 ) to the preset time 3×τs and if the difference time Δ 1 is greater than the preset time 3×τs, the first symbol digit (Slot 1 ) of the symbol subsequent to the falling edge is set (Box 610 ) to the voltage level of the binary one. The remaining symbol digits are retained at the voltage level of the binary zero and the sampling skips (Box 615 ) to the next symbol boundary. The sampling and recovery process then continues until the message is complete with the reception of a stop signal or synchronization signal.
[0062] Returning to FIG. 11, the pulse position modulated data 540 recovered by the symbol mapping circuit 535 is transferred to the data extraction circuit 545 . The data extraction circuit 545 decodes the pulse position modulated data to extract the data symbols and assemble the data symbols to the originally encoded data.
[0063] The symbol mapping circuit 535 and the data extraction circuit 545 are in the preferred embodiment logical state machines capable of extremely high speed recovery of the data symbols and extraction of the data. However, it is known in the art that the structure and method described above may be accomplished within a digital signal processor or similar computing system with the functions and processes being programs stored on data storage medium for execution by the processes.
[0064] Further, the preferred embodiment illustrates a four pulse positioned modulated data signal. It is in keeping with the intent of this invention that any number of pulse position modulated symbol digits may be employed to encode the digital data. The structure and method of the communications system of this invention functions with a higher order pulse position modulated encoding.
[0065] The communications systems as shown in FIGS. 1 and 3 illustrate wireless transmission of the broadcast modulated signal. It is keeping with the intention of this invention that the modulated signal be transmitted within a cable, either an electrical signal in a copper cabling or a light signal within a fiber optic cable.
[0066] While this 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. | A communication system compensates pulse positioned modulated data signals for channel induced intersymbol interference and extracts pulse positioned encoded data from a received signal corrupted with the channel induced intersymbol interference. The communication system has a transmitter and a receiver. The transmitter includes a modulation apparatus that has a symbol mapping circuit, which receives data symbols to be transmitted and maps the data symbols to a transmission code. The receiver has a demodulation apparatus to recover data symbols in the presence of the channel induced intersymbol interference. The demodulation apparatus has a sampling circuit in communication with a signal receiving circuit within the receiver to sample at a regular period received data symbols acquired by the receiving circuit. The samples of the data samples are retained by a sample retaining circuit in communication with the sampling circuit. The sample retaining circuit transfers the retained samples to a symbol mapping circuit. The symbol mapping circuit then recovers the data symbols. | 7 |
TECHNICAL FIELD
[0001] The present invention relates to an information display apparatus that displays a screen display content of a mobile terminal on screens of a plurality of in-vehicle terminals.
BACKGROUND ART
[0002] As display apparatuses that provide users with geographical information, music information. Internet information, or the like, in-vehicle or portable car navigation apparatuses, or information terminal apparatuses have been widely spread. In recent years, car navigation apparatuses capable of displaying an image on a plurality of display apparatuses and in-vehicle display control apparatuses that display screen data generated by a mobile terminal apparatus on an in-vehicle display have been know (see, Patent Literatures (hereinafter, abbreviated as PTLs) 1 and 2, for example).
CITATION LIST
Patent Literature
PTL 1
[0003] Japanese Patent Application Laid-Open No, 2005-043695 (Claim 1 and FIG. 1)
PTL 2
[0004] Japanese Patent Application Laid-Open No, 2009-281991 (Claim 1 and FIG. 1)
SUMMARY OF INVENTION
Technical Problem
[0005] However, in the information display apparatus according to the related art, a screen of a mobile terminal is divided into a plurality of still images, and transferred to in-vehicle terminals, respectively, and thus the screen of the mobile terminal can be displayed in a divided manner on screens of two in-vehicle terminals, but when display regions of the two in-vehicle terminals overlap each other, the mobile terminal needs to transmit rectangular screen data including an overlapping portion to both of the in-vehicle terminals. Further, in a case where display-content updating intervals of the two in-vehicle terminals are not in synchronization with each other, even. When the screen content of one of the in-vehicle terminals is to be updated, the screen data needs to be transmitted to both of the in-vehicle terminals, so that there arises a problem in that the transfer amount of image data increases. Further, when it is necessary to perform a vehicle running regulation, the same process is executed in both of the in-vehicle terminals, and thus there arises a problem in that the processing load increases.
[0006] It is an object of the present invention to provide an information display apparatus capable of minimizing the transfer amount of image data and reducing a running regulation processing load when a screen of a mobile terminal is displayed in a divided manner on screens of two in-vehicle terminals.
Solution to Problem
[0007] In order to achieve the object mentioned above, an information display apparatus according to the present invention is configured in the following manner. More specifically, the information display apparatus according to the present invention is an information display apparatus that displays, in a divided manner an image of a mobile screen transmitted from a mobile terminal on a screen of a first in-vehicle terminal and a screen of a second in-vehicle terminal, the apparatus including: an image data acquiring section that collectively acquires screen data transmitted from the mobile terminal in the first in-vehicle terminal; a screen data distributing section that distributes the screen data acquired through the image data acquiring section into screen data necessary for displaying the screen of the first in-vehicle terminal and screen data necessary for displaying the screen of the second in-vehicle terminal; a distributed image storing section that stores the screen data distributed by the screen data distributing section; and an image data transmitting section that transmits, in response to a request from the second in-vehicle terminal, image data corresponding to the request from among the distributed image data stored in the distributed image storing section to the second in-vehicle terminal.
Advantageous Effects of Invention
[0008] According to the present invention, when a screen of a mobile terminal is displayed in a divided manner on screens of two in-vehicle terminals, the transfer amount of image data can be minimized even when display regions of the two in-vehicle terminals overlap each other or even when display-content updating intervals of the two in-vehicle terminals are not in synchronization with each other. Further, it is possible to reduce a running regulation processing load.
BRIEF DESCRIPTION OF DRAWINGS
[0009] FIG. 1 is a block diagram illustrating a configuration of an information display apparatus according to an embodiment of the present invention;
[0010] FIG. 2 is an explanatory diagram illustrating a display screen of a mobile terminal of an information display apparatus according to an embodiment of the present invention;
[0011] FIG. 3 is an explanatory diagram illustrating a display screen of in-vehicle terminal A of an information display apparatus according to an embodiment of the present invention;
[0012] FIG. 4 is an explanatory diagram illustrating a display screen of in-vehicle terminal B of an information display apparatus according to an embodiment of the present invention; and
[0013] FIG. 5 is a flowchart illustrating a processing flow of an information display apparatus according to an embodiment of the present invention.
DESCRIPTION OF EMBODIMENTS
[0014] Hereinafter, an information display apparatus according to an embodiment of the present invention will be described in detail with reference to the appended drawings. In all drawings for describing an embodiment, in principle, the same components are denoted by the same reference numerals, and a description thereof will not be repeated.
[0015] FIG. 1 is a block diagram illustrating a configuration of an information display apparatus according to an embodiment of the present invention. Referring to FIG. 1 , information display apparatus 100 includes single mobile terminal 101 and two in-vehicle terminals, that is, in-vehicle terminal A (first in-vehicle terminal) 102 . and in-vehicle terminal B (second in-vehicle terminal) 103 . image generating section 11 of mobile terminal 101 executes an application program such as a vehicle navigator, a music player, or a browser, and generates image data to be displayed on a mobile screen. Display memory section 12 stores the image data generated by image generating section 11 .
[0016] Image display section 13 causes image data stored in display memory section 12 to be displayed on a mobile screen. Image transmitting section 14 transmits image data of region requested. from in-vehicle terminal A 102 among image data stored in display memory section 12 to in-vehicle terminal A 102 .
[0017] FIG. 2 is an explanatory diagram illustrating a display screen of a mobile terminal of an information display apparatus according to an embodiment of the present invention. Referring to FIG. 2 , display screen 201 of mobile terminal 101 has a rectangular shape including screen data region 202 of in-vehicle terminal A 102 and screen data regions 203 and 204 of in-vehicle terminal B 103 . When point O (0, 0) of FIG. 2 is defined as the origin of a position of display screen 201 of mobile terminal 101 image transmitting section 14 of mobile terminal 101 receives, from in-vehicle terminal A 102 , a request for point C (x 1 , y 1 ) that is a clipping position of screen data region 202 of in-vehicle terminal A 102 and horizontal and vertical lengths (w 1 , h 1 ) of screen data region 202 of in-vehicle terminal A 102 as screen data region 202 of in-vehicle terminal A 102 . Further, image transmitting section 14 of mobile terminal 101 receives, from in-vehicle terminal A 102 , a request for point 1 ) (x 2 , y 2 ) that is a clipping position of screen data region 204 of in-vehicle terminal B 103 and horizontal and vertical lengths (w 2 , h 2 ) of screen data region 204 of in-vehicle terminal B 103 as screen data region 204 of in-vehicle terminal B 103 .
[0018] Referring back to FIG. 1 , image receiving section A (an image data acquiring section and an image data distributing section) 21 of in-vehicle terminal A 102 requests mobile terminal 101 to provide regions necessary for displaying the screen of in-vehicle terminal A 102 and in-vehicle terminal B 103 according to a running state of a vehicle, receives image data transmitted from mobile terminal 101 , and distributes necessary image data to in-vehicle terminal A 102 and in-vehicle terminal B 103 . In other words, image receiving section A 21 distributes image data of screen data region 203 and screen data region 204 of in-vehicle terminal B 103 illustrated in FIG. 2 to in-vehicle terminal A 102 and in-vehicle terminal B 103 , respectively.
[0019] Display memory section A (distributed image storing section) 22 stores image data necessary for displaying the screen of in-vehicle terminal A 102 distributed by image receiving section A 21 , and buffer memory section (clipped image storing section) 23 stores image data necessary for display the screen of in-vehicle terminal B 103 distributed by image receiving section A 211 . Image display section A 24 causes the image data stored in display memory section A 22 to be displayed on the screen of in-vehicle terminal A. Clipping processing section (image data clipping section 25 clips image data of a region necessary for displaying the screen of in-vehicle terminal B 103 requested from image receiving section A 21 from the image data stored in display memory section A 22 , and causes the clipped image data to be stored in buffer memory section 23 .
[0020] FIG. 3 is an explanatory diagram illustrating a display screen of in-vehicle terminal A of an information display apparatus according to an embodiment of the present invention. Referring to FIG. 3 , display screen 301 of in-vehicle terminal A 102 has a rectangular shape including screen data. region 302 of in-vehicle terminal A 102 and screen data region 303 of in-vehicle terminal B 103 . When point O (0, 0) is defined as the origin of a position of the display screen of in-vehicle terminal A 102 , display memory section A 22 stores screen data region 302 of in-vehicle terminal A 102 using an arrangement of point F (x 3 , y 3 ) that is arrangement position of screen data region 302 of in-vehicle terminal A 102 and horizontal and vertical lengths (w 3 , h 3 ) of screen data region 303 of in-vehicle terminal B 103 . Further, clipping processing section 25 clips screen data region 303 of in-vehicle terminal B 103 at a position of point F (x 4 , y 4 ) that is a clipping position of screen data region 303 of in-vehicle terminal B 103 and horizontal and vertical lengths (w 3 , h 3 ) of screen data region 303 of in-vehicle terminal B 103 , and causes the clipped region to be stored in buffer memory section 23 .
[0021] Referring back to FIG. 1 , image transmitting section A (image data transmitting section) 26 requests image receiving section A 21 to provide a region necessary for displaying the screen requested from in-vehicle terminal B 103 , and transmits image data stored in buffer memory section 23 to in-vehicle terminal B 103 according to the running state of a vehicle. Running regulation control section (distribution method changing section, and screen information changing section) 27 determines the running state of a vehicle based on in-vehicle sensor information such as a speed or an ON/OFF state of an emergency brake, and transfers the running state to image receiving section A 21 and image transmitting section A 26 .
[0022] Image receiving section B 31 of in-vehicle terminal B 103 requests in-vehicle terminal A 102 to provide a region necessary for displaying the screen of in-vehicle terminal B 103 , and receives image data transmitted from in-vehicle terminal A 102 . Display memory section B 32 stores the image data received by image receiving section B 31 , and image display section B 33 causes the image data stored in display memory section B 32 to be displayed on the screen of in-vehicle terminal B 103 .
[0023] FIG. 4 is an explanatory diagram illustrating a display screen of in-vehicle terminal B 103 of an information display apparatus according to an embodiment of the present invention. Referring to FIG. 4 , display screen 401 of in-vehicle terminal B 103 has a rectangular shape including screen data region 402 and screen data region 403 of in-vehicle terminal B 103 . When point O (0,0) is defined as the origin of a position of the display screen of in-vehicle terminal B 103 , image receiving section B 31 causes screen data region 402 of in-vehicle, terminal B 103 and screen data region 403 of in-vehicle terminal B 103 to he stored in display memory section B 32 using an arrangement of point G (x 5 , y 5 ) that is an arrangement position of screen data region 402 of in-vehicle terminal B 103 and horizontal and vertical lengths (w 2 , h 2 ) of screen data region 402 of in-vehicle terminal B 103 and an arrangement of point H (x 6 , y 6 ) that is an arrangement position of screen data region 403 of in-vehicle terminal B 103 and horizontal and vertical lengths (w 3 , h 3 ) of screen data region 403 of in-vehicle terminal B 103 .
[0024] A processing operation of the information display apparatus having the above configuration will be described with reference to a processing flow of a flowchart. FIG. 5 is a flowchart illustrating the processing flow of information display apparatus 100 according to an embodiment of the present invention. In FIG. 5 , steps S 101 to S 105 represent a process of mobile terminal 101 , steps S 201 to S 211 represent a process of in-vehicle terminal A 102 , and a process of steps S 301 to S 305 represent a process of in-vehicle terminal B 103 .
[0025] First, the process of mobile terminal 101 will he described with reference to steps S 101 to S 105 . First, mobile terminal 101 performs an arrangement attribute information transmission process in step S 101 . Here, when an application program of mobile terminal 101 is activated, first, arrangement information, and attribute information of a predetermined mobile screen are transmitted from mobile terminal 101 to in-vehicle terminal A 102 . The arrangement information is defined as image information including horizontal and vertical sizes (the number of pixels) and upper left coordinate values of a plurality of rectangular images configuring a mobile screen. The attribute information is defined as a type (a map, a moving image, an operation button, a menu, or the like) of a rectangular image configuring a mobile screen.
[0026] Then, in step S 102 , image generating section 11 of mobile terminal 101 executes an application program such as a car navigation, a music player, or a browser, generates image data to be displayed on a mobile screen, and writes the image data in display memory section 12 .
[0027] Then, in step S 103 , image display section 13 reads application-rendering image data generated in step S 102 from display memory section 12 , and causes the image data to be displayed on the mobile screen. Then, in step S 104 , image transmitting section 14 checks whether there is a request for image data from in-vehicle terminal A 102 , and the process returns to step S 102 when it is determined that there is no request.
[0028] Meanwhile, when it is determined in step S 104 that there is a request for image data from in-vehicle terminal A 102 , in step S 105 , image transmitting section 14 transmits a requested region of the image data generated in step S 102 from display memory section 12 to in-vehicle terminal A 102 , and the process returns to step S 102 .
[0029] Then, the process of in-vehicle terminal A 102 will be described with reference to steps S 201 to S 211 . First, in-vehicle terminal A 102 performs an arrangement attribute information reception process in step S 201 , and performs a rectangular image selection arrangement process in step S 202 . In the process of step S 201 and step S 202 , in-vehicle terminal A 102 receives the arrangement information and the attribute information of the mobile screen from mobile terminal 101 . The user selects a rectangular image that is desired to be displayed on in-vehicle terminal A 102 , and defines the arrangement information as a “region necessary for displaying the screen” of in-vehicle terminal A 102 . Further, the user designates an arrangement position (AX, AY) on the screen of in-vehicle terminal A 102 for the selected rectangular image.
[0030] Here, when the rectangular image data clipped from the mobile screen is displayed on the screen of in-vehicle terminal A 102 according to the “region necessary for displaying the screen,” the rectangular image data is defined as “necessary image data” in in-vehicle terminal A 102 . Further, when the “necessary image data” of in-vehicle terminal A is arranged at coordinate values (AX, AY) used as the origin at the upper left of the screen of in-vehicle terminal A, the “necessary image data” and the coordinate values (AX, AY) are defined as “necessary screen data” of in-vehicle terminal A. Then, the arrangement information and the attribute information of the mobile screen are transmitted. to in-vehicle terminal B 103 .
[0031] Then, in step S 203 , in-vehicle terminal A 102 performs a running state/attribute information check A process. Here, whether or not the screen of in-vehicle terminal A 102 includes attribute information (for example, a moving image) that is prohibited from being displayed during running of the vehicle is checked. When the screen of in-vehicle terminal A 102 includes the attribute information that is prohibited from being displayed during running of the vehicle, a determination is made “according to the running state.” In other words, when the running state received from the riming regulation control section indicates “during stop of the vehicle,” it is determined to be a “region necessary for displaying the screen” of in-vehicle terminal A 102 , and when the running state indicates “during running of the vehicle,” it is determined to be a “region unnecessary for displaying the screen” of in-vehicle terminal A 102 .
[0032] Then, in step S 204 , image receiving section A 21 requests mobile terminal 101 to provide regions necessary for displaying the screen of in-vehicle terminal A 102 and in-vehicle terminal B 103 according to the running state of a vehicle determined by running regulation control section 27 .
[0033] Then, in step S 205 , image receiving section A 21 receives the image data transmitted from mobile terminal 101 in step S 105 . Then, in step S 206 , image receiving section A 21 distributes the image data received in step S 205 according to the display regions of in-vehicle terminal A 102 and in-vehicle terminal B 103 , and writes the distributed image data in display memory section A 22 and buffer memory section 23 .
[0034] Then, in step S 207 , image display section A 24 causes the image data stored in display memory section A 22 in step S 206 to he displayed on the screen of in-vehicle terminal. A 102 . Then, in step S 208 , clipping processing section 25 clips the image data stored in display memory section A 22 in step S 206 according to a region designated by image receiving section A 21 , and writes the clipped image data in buffer memory section 23 .
[0035] Then, in step S 209 , image transmitting section A 26 checks whether there is a request for image data from in-vehicle terminal B 103 , and the process returns to step S 203 when it is determined that there is no request. Meanwhile, when it is determined in step S 209 that there is a request for image data from in-vehicle terminal B 103 , in-vehicle terminal A 102 performs a running state/attribute information cheek B process in step S 210 . Here, whether or not the screen of in-vehicle terminal B 103 includes attribute information (for example, a moving image) that is prohibited from being displayed during running of the vehicle is determined. When the screen of in-vehicle terminal B 103 includes the attribute information that is prohibited from being displayed during running of the vehicle, a determination is made “according to the running state.” in other words, When the running state received from the running regulation control section indicates “during stop of the vehicle,” it is determined to be a “region necessary for screen display” of in-vehicle terminal B 103 , and when the running state indicates “during running of the vehicle,” it is determined to be a “region unnecessary for screen display” of in-vehicle terminal B 103 .
[0036] Then, in step S 211 , image transmitting section A 26 transmits a region requested from in-vehicle terminal B 103 to image receiving section A 21 . Further, image transmitting section A 26 transmits, to in-vehicle terminal B 103 , image data of the region requested from in-vehicle terminal B 103 according to the running state of a vehicle determined by running regulation control section 27 from the image data stored in buffer memory section 23 written in step S 206 and step S 208 , and then the process proceeds to step S 203 .
[0037] Then, the process of in-vehicle terminal B 103 will be described with reference to steps S 301 to S 305 . First, in step S 301 and step S 302 , in-vehicle terminal B 103 performs the arrangement attribute information reception process and the rectangular image selection arrangement process. Here, the arrangement information and the attribute information of the mobile screen are received from in-vehicle terminal A 102 . The user selects a rectangular image that is desired to be displayed on in-vehicle terminal B 103 , and defines the arrangement information as a “region necessary for screen display” of in-vehicle terminal B 103 .
[0038] Further, the user designates an arrangement position (BX, BY) on the screen of in-vehicle terminal B 103 for the selected rectangular image. Here, when the rectangular image data clipped from the mobile screen is displayed on the screen of in-vehicle terminal B 103 according, to the “region necessary for screen display,” the rectangular image data is defined as “necessary image data” in in-vehicle terminal B 103 . Further, when the “necessary image data” of in-vehicle terminal B 103 is arranged at coordinate values (BX, BY) used as the origin at the upper left of the screen of in-vehicle terminal B 103 , the “necessary image data” and the coordinate values (BX, BY) are defined as “necessary screen data” of in-vehicle terminal B 103 .
[0039] Then, in step S 303 , image receiving section B 31 . requests in-vehicle terminal A 102 to provide a region necessary for displaying the screen of in-vehicle terminal B 103 . Then, in step S 304 , image receiving section B 31 receives the image data transmitted from in-vehicle terminal A 102 in step S 304 , and writes the received image data in display memory section B 32 .
[0040] Then, in step S 305 , image display section B 33 causes the image data stored in display memory section B 32 in step S 304 to he displayed on the screen of in-vehicle terminal B 103 , and then the process returns to step S 303 .
[0041] As described above, according to the information display apparatus of the present embodiment. When a screen of a mobile terminal is displayed in a divided manner on screens of two in-vehicle terminals, one in-vehicle terminal receives screen data necessary in both in-vehicle terminals from the mobile terminal, stores image data necessary in the other in-vehicle terminal in a buffer memory, and provides the image data when there is a request from the other in-vehicle terminal. Thus, even when display regions of the two in-vehicle terminals overlap or even when display-content updating intervals of the two in-vehicle terminals are not in synchronization with each other, the transfer amount of image data can be minimized. In addition, one in-vehicle terminal collectively performs the running regulation process, so that the running regulation processing load in the other in-vehicle terminal can be reduced.
[0042] It should be noted that, the functional blocks used in the description of the embodiment described above are typically implemented as LSI devices, which are integrated circuits. The functional blocks may he formed as individual chips, or a part or all of the functional blocks may be integrated into a single chip. The term “LSI” is used herein, but the terms “IC,” “system LSI,” “super LSI” or “ultra LSI” may he used as well depending on the level of integration. In addition, the circuit integration is not limited to LSI and may be achieved by dedicated circuitry or a general-purpose processor other than an LSI. After fabrication of LSI, a field programmable gate array (FPGA), which is programmable, or a reconfigurable processor which allows reconfiguration of connections and settings of circuit cells in LSI may be used. Moreover, should a circuit integration technology replacing LSI appear as a result of advancements in semiconductor technology or other technologies derived flout the technology, the functional blocks could be integrated using such a technology. Another possibility is the application of biotechnology, for example.
[0043] The information display apparatus according to the present invention has been specifically described thus far based on the embodiment. The present invention, however, is not limited to the embodiment, and various modifications are possible within a scope not departing from the gist of the present invention.
[0044] The disclosure of the specification, drawings, and abstract included in Japanese Patent Application No. 2012-74532 filed on Mar. 28, 2012 is incorporated herein by reference in its entirety.
INDUSTRIAL APPLICABILITY
[0045] The image display apparatus of the present invention brings about an effect capable of minimizing the transfer amount of image data and reducing a running regulation processing load when a screen of a mobile terminal is displayed in a divided manner on screens of two in-vehicle terminals, so that the image display apparatus of the present invention can be used in the fields of design and manufacturing of in-vehicle vehicle navigation apparatuses, information terminal apparatuses, portable navigation apparatuses, and information terminal apparatuses.
REFERENCE SIGNS LIST
[0046] 11 Image generating section
[0047] 12 Display memory section
[0048] 13 Image display section
[0049] 14 Image transmitting section
[0050] 21 Image receiving section A
[0051] 22 Display memory section A
[0052] 23 Buffer memory section
[0053] 24 Image display section A
[0054] 25 Clipping processing section
[0055] 26 image transmitting section A
[0056] 27 Running regulation control section
[0057] 31 Image receiving section B
[0058] 32 Display memory section B
[0059] 33 Image display section B
[0060] 100 Information display apparatus
[0061] 101 Mobile terminal
[0062] 102 In-vehicle terminal A (first in-vehicle terminal)
[0063] 103 In-vehicle terminal B (second in-vehicle terminal)
[0064] 201 Display screen of mobile terminal
[0065] 202 Screen data region of in-vehicle terminal A
[0066] 203 , 204 Screen data region of in-vehicle terminal B
[0067] 301 Display screen of in-vehicle terminal A
[0068] 302 Screen data region of in-vehicle terminal A
[0069] 303 Screen data region of in-vehicle terminal B
[0070] 401 Display screen of in-vehicle terminal B
[0071] 402 , 403 Image data region of in-vehicle terminal B | When display of an image that is sent from a portable terminal ( 101 ) for a portable screen is divided into screens for two vehicle mounted terminals, an image receiving unit A ( 21 ) of a vehicle mounted terminal A ( 102 ) receives image data necessary for screen display on both the vehicle mounted terminals from the portable terminal ( 101 ) and stores image data necessary for a vehicle mounted terminal B ( 103 ) in a huller memory unit ( 23 ). Thereafter, a cut-out processing unit ( 25 ) cuts out the image data for the display screen of the vehicle mounted terminal A ( 102 ) and stores the same in the buffer memory ( 23 ). Furthermore, an image transmission unit A ( 26 ) provides image data necessary for screen display by the vehicle mounted terminal B ( 103 ) when required by the vehicle mounted terminal B ( 103 ). | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method and means for erecting a tower and more particularly to a method and means for erecting a wind energy tower wherein tower sections are successively placed upon one another.
2. Description of the Related Art
Wind turbines or wind energy devices are becoming more popular in the production of electrical energy. The wind turbine or wind energy device normally comprises a rotor-driven generator mounted atop a tower which may reach heights of 70 meters or more. The tower is usually comprised of a plurality of tapered or cylindrical tower sections which are secured together in an end-to-end relationship. The tower is normally erected by the use of a large crane. When the tower has been erected, the large crane lifts the turbine onto the top of the tower. The customary method of erecting the tower is quite expensive due to the requirement that the large crane must be present on the job site. Further, in some windy conditions, the lifting of the tower sections by the large crane is hazardous.
SUMMARY OF THE INVENTION
A wind energy tower erecting device is provided for successively erecting tower sections upon a base tower section which extends upwardly from a foundation and which is secured thereto. Normally, the base tower section will be positioned upon the foundation with a small crane. The tower erecting device comprises a skid or skid module upon which is positioned a power source such as an engine, a main winch having a hoisting cable extending therefrom, and a tower section staging platform upon which individual tower sections are successively positioned for erection on the base tower section. The skid module is positioned adjacent the base tower section and is anchored to the foundation by a plurality of bolts.
A jack stand is placed adjacent the base tower section and extends partially therearound. A lower cage is initially positioned on the upper end of the jack stand and extends at least partially around the base tower section. A lower block is secured to the lower cage. The lower cage includes roll bank assemblies mounted thereon which are adapted to engage rails on opposite sides of the tower sections to enable the lower cage and associated structure to be selectively vertically moved on the tower sections. An upper cage is spaced above the lower cage and is interconnected thereto by a supporting frame structure which is comprised of spaced-apart side panels and spaced-apart side trusses.
An upper block is initially removably attached to the base tower section adjacent the upper end thereof and is adapted to be successively attached to the upper ends of the tower sections as they are placed upon the base tower section. The hoisting cable from the main winch extends around the upper and lower blocks in a multi-parted fashion with the free end thereof being secured to the lower block. A bridge assembly is positioned on the upper end of the upper cage and comprises a bridge, trolley and Z-slide. The bridge is a trapezoidal-shaped beam which straddles or bridges the upper end of the upper cage and moves in the Y direction (front to back). The trolley moves with respect to the bridge in the X direction (side to side). The Z-slide is mounted on the trolley and moves in the Z direction (vertical). A tower section connector or load toggle is connected to the Z-slide at the lower end thereof and is comprised of a double gimble-type joint and a load spider. The load spider includes four rotating load arms which are selectively attached to the flange on the upper end of the tower section being transported. An auxiliary power unit is mounted on the bridge assembly for providing power for the bridge assembly and miscellaneous electrical equipment. An auxiliary winch is also positioned on the Z-slide.
The wind energy tower is erected as follows: (1) a small crane is utilized to place the base tower section on the foundation and is bolted into place; (2) the jack stand is positioned around the base tower section; (3) the skid module is moved into place and bolted to the foundation; (4) the roll bank assemblies on the lower cage are opened; (5) the lower cage is lifted onto the jack stand; (6) the roll bank assemblies are moved into an operative engagement position with respect to the rails on the opposite sides of the base tower section; (7) the side panels and side trusses are assembled; (8) one side panel-side truss is secured to one side of the lower cage so as to extend upwardly therefrom; (9) the other side panel-side truss is secured to the other side of the lower cage so as to extend upwardly therefrom; (10) the upper cage is mounted on the upper ends of the side panels by means of a small crane; (11) the upper block is secured to the side of the base tower section at the upper end thereof; (12) the hoisting cable is extended from the main winch on the skid module and connected to the lower block on the lower cage and upper block on the upper end of the base tower section whereby movement of the hoisting cable by the main winch causes the lower cage and the structure supported thereby to be moved vertically with respect to the base tower section; (13) another tower section is placed or staged on the staging platform provided on the skid module; (14) the bridge assembly is manipulated on the upper cage to position the load toggle on the Z-slide within the upper end of the tower section on the staging platform; (15) the load toggle is secured to the flange on the staged tower section; (16) the main winch is operated to cause the hoisting cable to raise the lower cage, upper cage, interconnecting supporting frame structure, bridge assembly and the staged tower section upwardly with respect to the base tower section; (17) when the staged tower section is raised sufficiently, the lower cage is pinned to the rails on the base tower section; (18) the bridge assembly is manipulated so that the staged tower section is positioned over the base tower section and then lowered onto the base tower section; (19) the flange on the lower end of the staged tower section is bolted to the flange on the upper end of the base tower section; (20) the auxiliary winch on the bridge assembly is operated to raise the upper block from the upper end of the base tower section, after it has been disconnected from the base tower section, to the upper end of the staged tower section mounted thereon; (21) the upper block is secured to the staged tower section mounted on the base tower section; (22) the lower cage is unpinned from the rails and is moved downwardly until the lower cage rests upon the jack stand; (23) the bridge assembly is manipulated to position the load toggle within the upper end of another tower section on the staging platform; (24) repeating the necessary steps described above until the wind energy tower is completely erected; (25) using the auxiliary winch to lower the upper block to the ground after it has been removed from the erected tower; (26) removing the bridge assembly, upper cage, side panels and side trusses, lower cage and jack stand from the erected tower; and (27) removing the skid module from the foundation.
It is therefore a principal object of the invention to provide an improved wind energy tower erection device.
A further object of the invention is to provide an improved wind energy tower erection device which eliminates the need for a large crane such as is customarily required.
Yet another object of the invention is to provide an improved wind energy tower erection device which may be used to erect towers having a height which exceeds the reach of even a very large crane.
Still another object of the invention is to provide an improved wind energy tower erection device which is safe to use in practically all weather conditions.
Still another object of the invention is to provide an improved wind energy tower erection device which is durable and reliable.
These and other objects will be apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the apparatus for erecting a wind energy tower;
FIG. 2 is a perspective view of the skid module portion of the apparatus;
FIG. 3 is a partial perspective view of the lower end of the apparatus;
FIG. 4 is a partial perspective view of the upper end of the apparatus illustrating the upper cage and bridge assembly;
FIG. 5 is a side view of the apparatus illustrating the lower cage, etc., its uppermost position with respect to the tower base section;
FIG. 6 is a side view of the apparatus illustrating the lower cage, etc., in its lowermost position supported upon the jack stand;
FIG. 7 is a side view of the apparatus illustrating the lower cage, etc., in its uppermost position with a tower section having been lifted from the staging platform for positioning on the base tower section;
FIG. 8 is a view similar to FIG. 7 except that the bridge assembly has moved the staged tower section to a position over the base tower section;
FIG. 9 is a side view similar to FIG. 8 which illustrates another tower section having been raised from the staging platform;
FIG. 10 is a top view of the apparatus;
FIG. 11 is a top view illustrating the relationship of the lower cage with respect to the rails of a tower section;
FIG. 12 is a top view of the upper block attachment hanger and upper block;
FIG. 13 is a side view of the upper block attachment hanger and upper block;
FIG. 14 is a front view of the upper block attachment hanger and upper block;
FIG. 15 is a bottom view of the upper block attachment hanger and upper block;
FIG. 16 is a perspective view of the Z-slide and load toggle and their relationship to the top flange on a tower section;
FIG. 17 is a front view of the Z-slide and load toggle and their relationship to the top flange on a tower section;
FIG. 18 is a side view of the Z-slide and load toggle and their relationship to the top flange on a tower section;
FIG. 19 is a perspective view similar to FIG. 16 except that the Z-slide is shown mounted on the trolley;
FIG. 20 is a top view of the Z-slide, trolley and load toggle of FIG. 19 ;
FIG. 21 is a bottom view of the Z-slide, trolley and load toggle of FIG. 19 ;
FIG. 22 is a side view of the Z-slide, trolley and load toggle of FIG. 19 ;
FIG. 23 is a front view of the Z-slide, trolley and load toggle of FIG. 19 ;
FIG. 24 is a top perspective view of the load toggle;
FIG. 25 is a bottom perspective view of the load toggle;
FIG. 26 is a top view of the load toggle;
FIG. 27 is a side view of the load toggle;
FIG. 28 is a side view of the load toggle; and
FIG. 29 is a bottom view of the load toggle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, the numeral 10 refers to a base tower section of the wind energy tower to be erected. The base tower section 10 will normally be positioned on a concrete foundation 12 by a small crane (not shown). The base tower section 10 is bolted to the foundation 12 in a conventional fashion. The base tower section 10 includes a pair of longitudinally extending rails 14 and 16 secured to the opposite sides thereof with each of the rails having vertically spaced-apart openings 18 formed therein, each of which is adapted to receive a pin 20 therein as will be described in more detail hereinafter.
Normally, the small crane will be used to mount a single base tower section on the foundation, but one or more tower sections of the tower could be mounted on the base tower section through the use of the small crane. The invention herein will be described as if a single base tower section is erected through the use of the small crane with the other tower sections of the tower being erected through the use of the apparatus of this invention.
The numeral 22 refers to a skid or skid module which is comprised of a tubular framework which is bolted to the foundation 12 . Skid 22 includes a power unit 24 and a main winch 26 having a hoisting cable 28 extending therefrom. If desired, an auxiliary winch may be mounted on the skid 22 for lowering a top block to the ground at the end of a work day. Preferably, the main winch is hydraulically driven by a suitable hydraulic pump on the skid 22 which is driven by the power unit. However, the main winch 26 could be mechanically driven by the power unit if so desired. Power unit 24 is preferably a diesel engine but could be a gas engine or an electric motor. Preferably, the main winch, and associated equipment, are remotely controllable. A tower staging platform 29 is provided on skid 22 for successively supporting the tower sections thereon.
For ease of description, the numeral 30 will refer to the apparatus which is actually movably mounted on the tower. Apparatus 30 is initially positioned on a jack stand assembly 32 which is comprised of four upstanding jack stands 34 , the lower ends of which are positioned on the foundation. The upper ends of the jack stands 34 are preferably positioned approximately sixty inches above the foundation 12 . It is recommended that the jack stands 34 be chained together to prevent the tipping thereof.
Apparatus 30 includes a lower cage 36 which is three-sided to enable the lower cage 36 to be positioned around the base tower section 30 , and the other tower sections as well. For purposes of description, lower cage 36 will be described as including sides 38 , 40 and 42 , each of which are comprised of a tubular framework welded together. Lower cage 36 includes four hollow, vertically disposed corner posts or legs 44 . The lower end of lower cage 36 is normally supported upon the jack stand assembly 32 . The lower end of lower block 46 is pivotally secured to lower cage 36 by a clevis and pin structure 48 . Lower cage 36 includes a pair of roll bank assemblies 49 mounted thereon on opposite sides thereof for engagement with the rails 14 and 16 on the opposite sides of the tower section.
An interconnecting frame assembly or frame structure 50 is selectively secured to lower cage 36 and extends upwardly therefrom. Frame assembly 50 includes side panel 52 which has the lower ends of posts or legs 54 and 56 received within the upper ends of a pair of corner posts 44 and secured thereto by pins 58 (FIG. 3 ). Frame assembly 50 also includes side panel 52 ′ which is identical to side panel 52 and which extends upwardly from side 42 of lower cage 36 . Interconnecting frame assembly 50 also includes side trusses 60 and 62 which are removably secured to lower cage 36 and side panel 52 to add strength and stability to the assembly 50 . Side trusses 60 ′ and 62 ′, which are identical to side trusses 60 and 62 , are removably secured to lower cage 36 and side panel 52 ′ to add strength and stability to the assembly 50 .
Upper cage 64 is selectively removably mounted on the upper end of side panels 52 and 52 ′ of interconnecting frame assembly 50 . As seen in the drawings, one end of upper cage 64 protrudes laterally of the frame assembly 50 . The laterally protruding portion of upper cage 64 is supported by a pair of support arms 66 and 68 , the lower ends of which are connected to side panels 52 and 52 ′, respectively.
The numeral 70 refers to a bridge assembly mounted on rails 72 and 74 of upper cage 64 . Bridge assembly 70 includes a bridge 76 which comprises a pair of spaced-apart trapezoidal-shaped beams that straddle or bridge and rides atop the rails 72 and 74 of upper cage 64 and moves in the Y direction (front to back). Bridge 76 includes four rollers 78 which roll upon the rails 72 and 74 . A pair of hydraulic cylinders (not shown) are secured to and extend between upper cage 64 and bridge 76 for moving bridge 76 in the Y direction. Upper power unit 80 preferably consists of a 24 kw diesel generator set and a 15 hp electric pressure-compensated hydraulic pump. Unit 80 provides power for the bridge assembly 70 and can power miscellaneous electrical equipment. An auxiliary winch 82 is mounted on bridge 76 and has a cable 83 extending therefrom.
A trolley 84 is movably mounted upon the upper ends of the beams of bridge 76 by means of four rollers 86 and moves in the X direction (side to side). As seen in FIG. 19 , trolley 84 includes a pair of spaced-apart frame members 88 and 90 having a pair of frame members 92 and 94 secured to the ends thereof which extend therebetween. A pair of spaced-apart yokes 96 and 98 extend downwardly from frame members 88 and 90 at the ends thereof. A hydraulic cylinder (not shown) is secured to and extends between the bridge 76 and trolley 84 for moving trolley 84 with respect to bridge 76 .
A Z-slide assembly 100 is selectively vertically movably mounted on trolley 84 for movement therewith. As seen in FIG. 19 , Z-slide assembly 100 is positioned between frame members 88 - 90 and 92 - 94 for movement in the Z direction (vertical). Slide assembly 100 includes four vertically disposed posts or frame members 102 , 104 , 106 and 108 interconnected by braces 110 . An arcuate brace 112 is secured to the upper ends of posts 102 and 104 and extends therebetween. Similarly, an arcuate brace 114 is secured to the upper ends of posts 106 and 108 and extends therebetween. Roller assemblies 116 , 118 , 120 and 122 are provided on trolley 84 which engage the posts 102 , 104 , 106 and 108 , respectively. Trolley 84 is also provided with roller assemblies 124 , 126 , 128 and 130 which are also in engagement with posts 102 , 104 , 106 and 108 , respectively. A hydraulic cylinder 132 has its base end (upper) connected to plates 134 and 136 at one end thereof by pin 138 . Similarly, hydraulic cylinder 140 has its base end (upper) connected to plates 134 and 136 at the other end thereby by pin 142 . The rod ends of hydraulic cylinders 132 and 140 are connected to yokes 96 and 98 , respectively. Thus, extension of the cylinder rods of the cylinders 132 and 140 causes the Z-slide assembly to be moved upwardly with respect to bridge 76 . Retraction of the cylinder rods within cylinders 132 and 140 causes the Z-slide assembly to move downwardly with respect to bridge 76 . Preferably, the movement of the bridge, trolley and Z-slide assembly are remotely operated and controlled from ground level or from the tower by workers erecting the tower.
A load toggle or tower connection member 144 is secured to the lower end of Z-slide assembly 100 and includes a double gimble-type joint 146 at its upper end and a load spider 148 at its lower end. The joint 146 has four posts 150 , 152 , 154 and 156 extending upwardly therefrom which are received by and secured to the posts 102 , 104 , 106 and 108 , respectively. Joint 146 includes a first gimble joint defined by pivot pins 158 and 160 and a second gimble joint defined by pivot pins 162 and 164 . Load spider 148 includes vertically spaced plates 166 and 168 having four load arms 170 , 172 , 174 and 176 pivotally secured thereto and therebetween. The load arms 170 , 172 , 174 and 176 each have an elongated opening 178 formed therein for connection to the flange 180 which is secured to the upper end of the tower sections. The diameter of the plates 166 and 168 is less than the diameter of the opening 182 in flange 180 so that the load spider may pass through opening 182 when load arms 170 , 172 , 174 and 176 are folded inwardly. When the load spider 148 has been lowered through the opening 182 by the Z-slide assembly 100 , the load arms 170 , 172 , 174 and 176 are pivoted outwardly beneath the lower surface of flange 180 . The load arms are then bolted to the flange 180 to enable the bridge assembly to lift and transport the tower section as will be described hereinafter.
The numeral 184 refers to an attachment hanger which is used to selectively attach the upper block 186 to a tower section adjacent the upper end thereof. Attachment hanger 184 includes an angled support plate 188 which conforms to the exterior surface of the tower sections. Attachment pin 190 extends from the inner surface of plate 188 and is adapted to be received within an opening formed in each of the tower sections adjacent the upper end thereof. Bracket 192 is mounted on the exterior surface of plate 188 and has support arm 194 of block 186 pivotally secured thereto by pivot pin 196 . The hoisting cable 28 of main winch 26 is threaded around upper block 186 and lower block 46 with the free end thereof being tied to the frame of the lower block 46 as previously described.
The method of assembly the tower erection device of this invention and the method of erecting the wind turbine tower or wind energy tower will now be described. A small crane is utilized to place the base tower section 10 on the foundation 12 with the base tower section being bolted to the foundation. The jack stands 34 of the jack stand assembly 32 are placed around the lower end of the base tower section 10 and are preferably chained together to prevent the tipping thereof. The skid or skid module 22 is then moved into place and bolted to the foundation so that the main winch 26 is in close proximity to the base tower section 10 . The roll bank assemblies 49 on the lower cage 36 are opened and the lower cage 36 is lifted onto the jack stand by means of a small crane. The roll bank assemblies 49 on the lower cage 36 are moved into an operative engagement position with respect to the rails 14 and 16 on the opposite sides of the base tower section 10 .
Side trusses 60 and 62 are secured to side panel 52 and side trusses 60 ′ and 62 ′ are secured to side panel 52 ′. One side panel-side truss assembly is secured to one side of the lower cage 36 so as to extend upwardly therefrom. The other side panel-side truss assembly is secured to the other side of the lower cage 36 so as to extend upwardly therefrom. The upper cage 64 is mounted on the upper ends of the side panels by means of a small crane and secured thereto. The attachment hanger 184 having the upper block 186 secured thereto is secured to the side of the base tower section 10 at the upper end thereof by inserting the connector pin 190 into the hole or opening provided in the upper end of the side wall of the base tower section 10 . The hoisting cable 28 from the main winch 26 is threaded around the lower block 46 and the upper block 186 with the free end of the hoisting cable 28 attached to the frame of the lower block 46 so that movement of the hoisting cable 28 by the main winch 26 causes the lower cage 36 and the structure supported thereby to be moved vertically with respect to the base tower section 10 .
Another tower section 10 a is placed or staged on the staging platform 29 provided on the skid 22 . The bridge assembly 70 is manipulated or moved on the upper cage 64 to position the load toggle 144 on the Z-slide assembly 100 so that the load arms 170 , 172 , 174 and 176 are positioned below the bottom surface of the upper flange 180 on the upper end of the base tower section 10 . The load arms 170 , 172 , 174 and 176 are then pivotally moved outwardly and are connected to the flange 180 by bolts or the like. The main winch 26 is then operated to cause the hoisting cable 28 to raise the lower cage 36 , upper cage 64 , interconnecting frame assembly or structure 50 and bridge assembly 70 and the staged tower section 10 a upwardly with respect to the base tower section 10 . When the staged tower section 10 a is raised sufficiently, the lower cage is pinned to the rails 14 and 16 . The bridge assembly 70 is manipulated so that the staged tower section 10 a is positioned over the base tower section 10 and is then lowered onto the base tower section 10 . The lower end of the staged tower section 10 a is bolted to the upper end of the base tower section 10 . The auxiliary winch 82 on the bridge assembly 70 is operated to raise the attachment hanger 184 and upper block 186 from the upper end of the base tower section 10 , after it has been disconnected from the base tower section 10 , to the upper end of the staged tower section 10 a mounted thereon. The attachment hanger 184 is then secured to the staged tower section 10 a mounted on the base tower section 10 . The lower cage 36 is unpinned from the rails 14 and 16 and is moved downwardly by the hoisting cable 28 of the main winch 26 until the lower cage 36 rests upon the jack stand assembly 32 .
The bridge assembly is then again manipulated to position the load spider 148 of load toggle 144 within the open upper end of another tower section 10 b on the staging platform. The necessary steps described above are repeated until the wind energy tower is completely erected. The auxiliary winch is then used to lower the upper block 186 to the ground after it has been removed from the erected tower. The bridge assembly, upper cage, side panels and side trusses, lower cage and jack stand are then removed from the erected tower. The skid module is then removed from the foundation 12 .
The tower erection device may then be moved to another location for use in erecting another tower. It can be seen that the tower erection device of this invention is convenient and safe to use and permits the erection of a wind energy tower without the use of a large crane which is expensive and which is hazardous in certain weather conditions.
Thus it can be seen that the invention accomplishes at least all of its stated objectives. | A wind energy tower erection device is disclosed together with the method of assembling the same and the method of utilizing the device to erect a wind energy tower. The tower erection device successively places tower sections one upon the other until the tower is erected. | 8 |
[0001] This application claims priority to European application 09002335.9 filed Feb. 19, 2009 and European application 08019899.7 filed Nov. 14, 2008, and Patent Cooperation Treaty Application No. PCT/US2009/03848, filed Mar. 26, 2009, the entire disclosures of which are incorporated by reference.
[0002] This invention relates to a method for the electrolytic treatment of metal substrates, especially for the post-treatment of metal layers deposited on the surface of a substrate.
[0003] It is well-known in the art of surface technology to post-treat metal layers deposited on a substrate surface, either by galvanic deposition, autocatalytic deposition or other methods like PVD or CVD, to adjust the surface characteristics or features. One of the main features intended to increase is the corrosion resistance of the surface layer.
[0004] For example, European patent application EP 1 712 390 discloses the coating of metal surfaces with corrosion inhibiting polymer layers. Here, the surface is contacted with a solution comprising a polyvinyl phosphonic acid or polyacrylic acid prior to a treatment of the surface with a solution comprising monomeric or polymeric resins or a mixture of monomeric and polymeric resins.
[0005] U.S. Pat. No. 6,030,710 discloses aluminium alloy sheets which are provided with the primer layer comprising a reaction product of aluminium oxide or hydroxide and a polyvinyl phosphonic acid/polyacrylic acid copolymer, which primer layer is coated with the polymer coating composition containing polyvinyl chloride or an epoxy.
[0006] U.S. Pat. No. 6,696,106 B1 discloses a primer for radiation cureable coating compositions. Here, an aluminium-polymer composite is made by coating a surface portion of an aluminium alloy body with the primer composition comprising a polyvinyl phosphonic acid/polyacrylic acid copolymer to form a primer layer, coating the primer layer with the radiation cureable polymer precursor, and irradiating the polymer precursor with ultraviolet or electron dim radiation.
[0007] U.S. Pat. No. 6,020,030 also discloses the pre-treatment of aluminium alloy substrates with an aqueous solution containing an organophosphorous compound, preferably a polyvinyl phosphonic acid/polyacrylic acid copolymer, before coating the substrate with the polymer.
[0008] WO 2004/074372 A1 discloses a composition for treating surfaces, said composition containing copolymer as component A comprising in (meth) acrylic acid or the salts thereof, a monomer containing carboxylate and/or monomers comprising groups containing phosphoric acid and/or phosphonic acid or the salts thereof and optionally additional comonomeres. Furthermore, a passivation layer is disclosed, which contains the component A and is applied to a metallic surface.
[0009] While the methods known from the state of the art to post-treat metal layers are more or less capable to increase the corrosion resistance of the metal layers, some of the environmental or application depending influences are so aggressive that layers, also when treated according to the state of the art, cannot restrain from corrosion.
[0010] Amongst others, the chloride induced corrosion of chromium surfaces caused by deicing salts has been a major topic for several years in the field of automotive. Also, the so called red-rust on chromium surfaces that have been plated with trivalent chromium electrolytes is a problem known from the state of the art.
[0011] In another field of application, the fitting industry, Pb-leaching of brass parts for drinking water pipe applications is known to be a problem. The Pb-leaching should be minimised by passivation of the brass metal.
[0012] In the art of decorative coatings, there are intentions to reduce the sensitivity of the surface against fingerprints. To do so, it is known from the state of the art to incorporate polymeric components into a metal layer deposited on the surface, like for example polytetrafluoroethylene particles.
[0013] A drawback of the methods known from the state of the art is that the surfaces still showing some corrosive reactions or that the post-treatment layers increasing the corrosion resistance are not adhered enough to the surface to enable long term corrosion resistance.
SUMMARY OF THE INVENTION
[0014] It is therefore the object of this invention to provide a method which is capable of enhancing a property of a metal substrate, most particularly the corrosion resistance of metal layers deposited on the surface of substrates.
[0015] To do so, the invention proposes a method for the post-treatment of a metal layer deposited on the surface of a substrate, wherein the metal layer after deposition is brought into contact with a corrosion resistant increasing solution, which method is characterised in that during the contacting of the metal layer with the corrosion resistance increasing solution a current is applied between the surface of the metal layer and a counter electrode, whereby the metal layer is anodic contacted and the counter electrode is cathodic contacted.
[0016] The invention is further directed to a process for treating the surface of a non-ferrous metal substrate comprising a constituent metal selected from the group consisting of Cr, Cu, Mn, Mo, Ag, Au, Pt, Pd, Rh, Pb, Sn, Ni, Zn and alloys thereof. An anodic potential is applied to the metal surface in an electrolytic circuit comprising the metal surface, a cathode, and an aqueous electrolytic solution in contact with the metal surface and in electrically conductive communication with the cathode. The electrolytic solution contains an electrolyte comprising anions selected from the group consisting of phosphate, phosphonate, phosphite, phosphinate, nitrate, borate, silicate, molybdate, tungstate, carboxylate, oxalate and combinations thereof. The potential applied to the circuit is such that a constituent metal of the metal substrate is anodically oxidized and reacts with the anion to form a composition at the surface that imparts an enhanced property to the surface.
[0017] The invention is still further direct to a process for treating the surface of a metal substrate comprising a constituent metal selected from the group consisting of Cr, Cu, Mn, Mo, Ag, Au, Pt, Pd, Rh, Pb, Sn, Ni, Fe, Zn and alloys thereof. An anodic potential is applied to the metal surface in an electrolytic circuit comprising the metal surface, a cathode, and an aqueous electrolytic solution in contact with the metal surface and in electrically conductive communication with said cathode. The electrolytic solution contains an anion comprising a polymer having a pendent moiety selected from the group consisting of phosphate, phosphonate, phosphite, phosphinate, sulfate, sulfonate, carboxylate and combinations thereof. The potential applied to said circuit is controlled at a voltage within the range of 0.5 to 20 volts and a constituent metal of the metal substrate is anodically oxidized and reacts with the anion to form a composition at said surface that imparts an enhanced property to said surface.
[0018] In a further aspect, the invention is directed to a process for treating the surface of a metal substrate comprising a constituent metal selected from the group consisting of Cr, Cu, Mn, Mo, Ag, Au, Pt, Pd, Rh, Pb, Sn, Ni, Fe, Zn and alloys thereof. An anodic potential is applied to the metal surface in an electrolytic circuit comprising the metal surface, a cathode, and an aqueous electrolytic solution in contact with said metal surface and in electrically conductive communication with the cathode. The electrolytic solution has a pH not greater than about 6.0 and contains an electrolyte comprising anions selected from the group consisting of phosphate, phosphonate, phosphite, phosphinate, nitrate, borate, silicate, molybdate, tungstate, carboxylate, oxalate and combinations thereof. The potential applied to circuit is controlled within the range between about 0.5 and about 20 volts such that the current density is between about 0.01 and about 2.0 amps/dm 2 of the geometric area of the metal surface in contact with said electrolytic solution, and a constituent metal of the metal substrate is anodically oxidized and reacts with the anion to form a composition at said surface that imparts an enhanced property to said surface.
[0019] The invention is still further directed to a process for treating the surface of a metal substrate comprising a constituent metal selected from the group consisting of Cr, Cu, Mn, Mo, Ag, Au, Pt, Pd, Rh, Pb, Sn, Ni, Zn and alloys thereof. An anodic potential is applied to the metal surface in an electrolytic circuit comprising the metal surface, a cathode, and an aqueous electrolytic solution in contact with the metal surface and in electrically conductive communication with the cathode. The electrolytic solution contains an electrolyte comprising anions selected from the group consisting of phosphate, phosphonate, phosphite, phosphinate, nitrate, borate, silicate, molybdate, tungstate, carboxylate, oxalate and combinations thereof. The potential applied to said circuit is controlled to cause anodic oxidation at the said metal surface, and the current density at the metal surface is controlled such that nascent cations of the constituent metal produced by anodic oxidation of the constituent metal react with said anions at the metal surface without significant formation of any oxide or hydroxide of the constituent metal.
BRIEF DESCRIPTION OF THE DRAWING
[0020] The single FIGURE of the drawing depicts a depth profile analysis as provided by glow discharge optical emission spectroscopy, showing the relative concentrations of elements contained in the nanolayer composition formed at the surface of a chromium substrate according to the process of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The electrolytic treatment process of the invention is capable of increasing the corrosion resistance of metal substrates like, for example nickel layers, copper layers, chrome layers, zinc layers, tin layers, silver layers, iron layers, manganese layers, molybdenum layers, gold layers, platinum layers, ruthenium layers, palladium layers, rhodium layers and lead layers or layers of alloys comprising at least one of the before mentioned metals, like for example Ni—P-alloy layers, brass layers, bronze layers, nickel-silver layers, coin-metal layers, or type-metal layers. Generally, the metal substrate may comprise a metal layer on another object, such as, e.g., a chromium coating on a steel object, or the outer stratum of a metal object itself.
[0022] While being mainly directed to metal layers deposited on an substrate surface, the inventive method is also capable to increase the corrosion resistance of metal surfaces in general, like for example the surfaces of substrates made of steel or stainless steel, brass, or bronze.
[0023] The solution to be used within the inventive method can be an aqueous corrosion resistance increasing solution, which means an aqueous solution comprising a compound which is capable to increase the corrosion resistance of the metal layer deposited.
[0024] Examples for such compounds increasing the corrosion resistance of layers are, for example compounds having moieties like anions of the group consisting of phosphates, phosphonates, phosphinates, nitrates, borates, silicates, molybdates, tungstates, carboxylates and oxalates.
[0025] In certain embodiments of the inventive method, the corrosion resistance increasing solution comprises a compound having hydrophobic carbon-chains with hydrophilic anionic functional groups. Such functional groups are preferably phosphate-groups, phosphonate-groups, sulphate-groups, sulphonate-groups, or carboxyl-groups. Such compounds having hydrophobic carbon-chains with a hydrophilic anionic functional group are, for example polyvinyl phosphonic acid and/or polyacrylic acid, and/or copolymers of such acids. A particularly preferred electrolyte comprises an anion that comprises repeating units derived from vinyl phosphonic acid or vinyl phosphinic acid, for example, a copolymer of vinyl phosphonic acid and (meth)acrylic acid.
[0026] Other examples for a compound having hydrophobic carbon-chains with a hydrophilic anionic functional group are alkylphosphonic acids or alkylsulfonic acids having 10 to 26 carbon atoms.
[0027] According to the inventive method, the potential applied to the circuit is such that the voltage between the cathode and the metal substrate functioning as the anode is between about 0.5 and about 20 v, preferably between about 0.5 and about 3.0 v, and the current density of the applied current can be in a range between 0.001 A/dm 2 and 100 A/dm 2 of the geometric area of the substrate that is in contact with the electrolytic solution, with a preferred range between 0.02 A/dm 2 and 10 A/dm 2 . To minimize formation of a layer comprising an oxide or hydroxide of a constituent metal at the surface of the metal substrate, the current density is most preferably controlled in the lower end of these ranges. Under such conditions, if there is a natural oxide layer at the surface, its thickness is not detectably increased by the electrolytic treatment. Most preferably, the voltage and current density are controlled at levels such that nascent cations produced by anodic oxidation of a constituent metal of the substrate are reacted with the anion of the electrolytic solution at the metal surface without formation of an oxide or hydroxide. Generally, it has been found that formation of oxide or hydroxide is minimized or eliminated if the current density is controlled in the range between about 0.01 and about 2 A per dm 2 of the geometric area. At a current density within this range, it is in some instances possible to remove an existing natural oxide layer by oxidation and incipient dissolution of the constituent metal below the natural oxide layer, causing the oxide layer to slough off the surface of the metal.
[0028] Current can be applied for a time between 0.001 seconds and 10 minutes, preferably between 30 seconds and 3 minutes. When using a low current density within the inventive method, the time the current is applied has to be higher, for example within the range of minutes, while high current densities will needed to be applied only for short times, like for example within the range of milliseconds or seconds. It is generally preferred that the application of current be terminated after the total charge transfer is between about 0.01 and about 100 mAhr per dm 2 of the geometric area of the metal surface that is in contact with the electrolytic solution. More preferably, the total electric charge transfer is in the range between about 0.1 and about 10 mAhr/dm 2 .
[0029] To facilitate control of the current density and minimize formation of anodic oxide on the substrate, it is preferred that the concentration of the anion in the solution be between about 1 and about 50 g/L, more preferably between about 1 and about 25 g/L. Conductivity of the electrolytic solution is preferably between about 1 and about 500 millisiemens. Typically, the conductivity is between about 50 and about 350 millisiemens. In some embodiments, for example, where the anion comprises a hydrophobic carbon chain, such as an anion derived from a polyelectrolyte or ionomer, or another anion having a high molecular weight hydrocarbon moiety, the conductivity is typically in the lower portion of this range, e.g., 50 to 200 millisiemens. The conductivity may be especially low where the anion is not fully dissolved in the electrolytic solution but is instead dispersed or emulsified therein. In other instances, e.g., where the anion comprises a relatively low molecular weight phosphonate or phosphinate, a relatively high conductivity is acceptable or preferable, e.g., 200 to 400 millisiemens or higher. It is also preferred that the applied potential be at the low end of the 0.5 to 20 volt range, e.g., in the 0.5 to 3.0 v range described above. Where a low molecular weight inorganic anion is used, a potential in the range of 0.5 to 2.0 volts is particularly preferred. Somewhat higher voltages have been found necessary where the anion is polymeric, and especially so where the anion is comprised by a solid particulate ionomer or polyelectrolyte dispersed in the aqueous electrolytic solution, or by a liquid ionomer or polyelectrolyte that is emulsified with the aqueous medium. In such instances, the voltage may more typically be in the range between about 2 and about 20 v, such as in the range between about 5 and about 15 v.
[0030] It is further preferred that the pH of the solution be not greater than about 9.0. In most applications, the pH is preferably not greater than about 6.0, more preferably not greater than about 5.0, most preferably between about 2.0 and about 5.0. An acid pH is particularly preferred where the electrolyte comprises a polymeric anion or the substrate is ferrous.
[0031] As noted, it is believed that by the appliance of the anodic current, the oxide layer on the metal or metal layer surface is removed, thereby enabling the corrosion resistance increasing compounds to react with the metal. In this the inventive method differs from the anodic treatment known for aluminium surfaces, where by an anodic current an oxide layer on the metal surface is formed. Application of current under the preferable controlled conditions results in the formation on the metal surface of a nanolayer comprising a composition that comprises a salt or complex of a constituent metal of the metal substrate and an anion contained in the electrolytic solution. Under proper control of voltage and current density within the ranges described above, detectable growth or formation of an oxide layer on the metal surface is avoided, and anodic oxidation causes loss of metal in a marginal substratum of the substrate at the metal surface. In a particularly preferred embodiment, no detectable oxide or hydroxide remains at the metal surface at the time passage of current in the electrolytic circuit is terminated. If the current density and voltage are balanced within the aforesaid ranges, anodic oxidation can cause a loss from the metal surface of a marginal substratum of metal having a thickness in the range of between about 0.0005 and about 0.5 μm, preferably a thickness at least equal to or exceeding the thickness of the nanolayer comprising the salt or complex of the constituent metal and an anion of the electrolytic solution.
[0032] A particular advantage of the process of the invention is the provision on the metal surface of a corrosion-resistant nanolayer having a thickness less than about 100 nm. Known corrosion-resistant coatings are often thick. If the coating is too thick or of the wrong composition, there can be problems of adherence of, e.g., a paint or varnish over the coating. Also, if the coating is too thick, the metal substrate cannot be welded properly. A major advantage of the present invention is that the process yields a passivation layer on a substrate which protects the surface against corrosion, yet is thin enough that it preserves the capability of welding the underlying metal substrate to another metal object.
[0033] According to the method of the invention, it is possible to provide a passivation layer having a thickness significantly less than 100 nm. In certain preferred embodiments of the invention, it is especially preferred that the thickness of the nanolayer be in the range between about 10 and about 50 nm, more preferably between about 10 and about 30 nm, most preferably between about 10 and about 20 nm. A particularly preferred passivation layer comprises a composition that comprises a salt or complex of tin and an anion of the electrolytic solution, most preferably, a polymer comprising a pendent moiety such as phosphate, phosphonate, phosphite, phosphinate, sulfate, sulfonate, or carboxylate.
[0034] Anodic current in the meaning of the invention is as any kind of current having an anodic portion. Therefore, not only pure anodic direct current can be applied, but also alternating current. Also, it is possible to apply the current as a pulse, like it is known from pulse or pulse-revers plating operations. Where alternating current is employed, the cathodic cycle at the surface of the metal substrate can serve a useful purpose in reducing natural oxides and/or hydroxides at the surface, thus presenting a clean metal surface for anodic reaction with the anions in the solution during the anodic phase, thereby forming on the surface the desired nanolayer composition comprising a salt or complex of a constituent metal of the substrate and an anion of the electrolytic solution.
[0035] Surprisingly, a further improvement of the above described method is found by the addition of an aromatic compound having at least one hydroxy group, like phenol or its derivates. Especially capable is the addition of an aromatic compound having at least one hydroxy group which comprises a further functional group having a positive inductive effect on the hydroxyl group.
[0036] Aromatic compounds capable to further improve the inventive methods are compounds of the general structure
[0000]
[0000] wherein R1 is H or OH; R2 is H, OH, F, Cl, Br, —O—R, R—OH, R—COOH, R—CHO, R—O—R, R—CO—R, —SH, —NO 2 , —CN, —COO—R; and R3 to R5 are independently from each other H, C n H 2n+1 , OH, F, Cl, Br, —O—R, R—OH, R—COOH, R—CHO, R—O—R, R—CO—R, —SH, —NO 2 , —CN, —COO—R, wherein R is an unsubstituted or substituted alkyl-group having 1 to 10 carbon.
[0037] Compounds according to the above mentioned general structure are, for example phenol, 3-ethoxyphenol, 3,5-dimethoxyphenol, 3-nitrophenol, resorcinol, 4-ethylresorcinol, 4-chlorresorcinol, phloroglucine, pyrogallol, gallic acid, catechol, dihydroxybenzaldehyde, dihydroxytoluene, 3-hydroxyphenylacetic acid, 3-hydroxybezoic acid, n-octyl gallat, guajacol and 3,5,7-trihydroxyflavone.
[0038] It was found that at least one further functional group in meta-position to the hydroxy group renders a compound according to the above mentioned general structure to be especially useful within the inventive method.
[0039] The addition of the mentioned aromatic compounds to the inventive corrosion resistance increasing solution in the inventive method surprisingly enables to reduce the concentration of the compound having hydrophobic carbon-chains with hydrophilic anionic functional groups, like polyvinyl phosphonic acid and/or polyacrylic acid, even if the aromatic compound is added only in very small amounts.
[0040] The aromatic compound can be added to the inventive corrosion resistance increasing solution in the inventive method at a concentration between 0.45 mmol and 45 mmol, with a preferred range of 2 mmol to 9 mmol.
[0041] Also when added in such a low concentration, the amount of the compound having hydrophobic carbon-chains with hydrophilic anionic functional groups can be reduced by a coefficient of at least 4 to 5. For example, instead of using 4 g/l of a polyvinyl phosphonic acid/polyacrylic acid copolymer (30/70) in absence of an aromatic compound having a hydroxy group, by addition of such an aromatic compound the concentration of the copolymer can be reduced to 1 g/l only. That gains into a reduction of the costs for the commodities used per square meter by at least four times.
[0042] While not being bound to the theory, the applicant believes that due to the anodic contacting of the metal layer, the metal layer is partly dissolved, thereby forming areas of the metal layer surface which are capable to form covalent bondings between the metal surface and the compounds used for the increase of the corrosion resistance. These effects in a very strong bonding of the compounds and/or anions on the metal surface which gains into a corrosion resistance increasing coating strongly adhered to the metal layer surface. Furthermore, due to the current applied the anions and compounds are forced to react or at least interact with the metal layer surface.
[0043] While not being bound to this theory with respect to the additionally used aromatic compounds having at least one hydroxy group, the applicant believes that the aromatic compound is bound to the metal surface by the hydroxy group in a covalent manner. One attempt to explain the reaction is that the hydroxy group, during the anodic treatment, is deprotonated offering a free valence at the oxygen of the hydroxy group. This theory can also explain the improvements gained by the use of an aromatic compound comprising in meta-position to the hydroxy group a group having a positive inductive effect. The positive inductive effect supports the deprotonation of the hydroxy group, thereby enabling the reaction pass to form a covalent binding to the metal surface.
[0044] Concerning the use of the inventive method to increase the corrosion resistance of a precious-metal layer, it is known in the art that corrosion of a composite comprising a substrate and a precious meal layer over the substrate does not necessarily involve corrosive attack on the precious-metal, but may instead involve only attack on the metal forming the layer underneath the precious-metal layer. In other instances, both substrate and precious metal layer are subject to corrosion. In general, such precious-metal layers show pores and cracks leaving open areas of the metal the precious-metal layer is deposited on, like for example nickel or copper. Attempts of the state of the art to increase the corrosion resistance of such layers in general are accompanied with an increase of the thickness of the precious-metal layer to reduce the number of pores and cracks. This boosts the amount of precious metal needed per area, thereby directly increasing the cost significantly. It is believed that when performing the inventive method to a precious-metal layer the corrosion resistance increasing compound does not bind only to the precious-metal, but as well to the metal forming the layer underneath the precious-metal layer. Accordingly, there is no need in the inventive method to increase the thickness of the precious-metal layer to achieve a surface having excellent corrosion resistance. This allows to use very thin precious-metal platings only and to reduce the costs per area in a significant manner.
[0045] A further field of application for the inventive method as well as the inventive corrosion resistance increasing solution is to prepare a metal layer for varnishing it. To varnish a metal layer by lacquer or varnish becomes more and more important in the art of surface finishing. One problem occurring when varnishing metal surfaces is the weak adhesion of the varnish or lacquer to the metal surface. Here, the inventive method and the inventive solution can be used to form a primer on the metal surface. The primer increases the adhesion of the varnish to the metal surface.
[0046] Advantageously, in the inventive method the primer can be adapted to the varnish or lacquer used. Such an adaption can be especially performed by variation of the aromatic compound having a hydroxy group comprised in the inventive post-treatment solution.
[0047] An example for such a use of the inventive method in the art of vanishing is to varnish chrome-wheels in the automotive industry. Here, for example after deposition of a chromium layer on the wheel a mask is put on the chromium surface to transfer a specific pattern to the surface by a lacquer. By appliance of the inventive method to the wheel prior to the varnishing the adhesion of the lacquer to the chromium surface is improved in a significant manner, and at the same time the corrosion resistance of the chromium layer is increased.
[0048] The invention is explained in terms of examples in the following, while not being limited to these examples only.
Example 1
[0049] FIG. 1 shows a depth analysis obtained by glow discharge optical emission spectroscopy profile on a corrosion resistant nanolayer obtained by electrolytic treatment of a chromium substrate in an electrolytic circuit comprising the chromium substrate as the anode, a cathode, and an electrolytic solution containing vinyl phosphonic acid in contact with the substrate. Glow discharge optical emission spectroscopy (GDOES) is a quantitative depth profiling technique that is suited to the chemical analysis of surface coatings. The FIGURE demonstrates the depth profile analysis a coating produced by the electrolytic treatment of this example.
[0050] The results, as illustrated in the GDOES graph demonstrate the depth analysis of the treatment process of this example. The weight percentages of carbon and phosphorus are indicated along the left ordinate and the weight percentages of chromium and oxygen are indicated along the right ordinate. These are plotted against the depth from the surface as expressed in nm along the abscissa.
[0051] From the profiles for carbon, phosphorus, oxygen and chromium shown in FIG. 1 , it may be seen that the salt or complex of chromium produced by anodic oxidation of the chromium and reaction with the anion at the substrate surface is limited to a nanolayer that extends only about 10-20 nm above a level beyond which the composition of the substrate entirely prevails.
[0052] While the GDOES graph of the drawing. illustrates the passivation of a chromium (Cr) substrate, numerous other metal substrates may be protected against corrosion according to the method of the invention. These include, e.g., nickel, copper, zinc, tin, silver, iron, manganese, molybdenum, gold, platinum, ruthenium, palladium, rhodium, and lead, or an alloy comprising at least one of these metals. The process is particularly suited for providing a protective anodic layer over a non-ferrous metal such as nickel, copper, chromium, tin, silver, etc. However, it also provides an advantageous method for protecting ferrous metals without any substantial formation of an oxide layer. It is especially suitable for protection of either ferrous or non-ferrous metals at a pH <6.0, preferably less than about 5.0, more preferably in the range of between about 2.0 and about 5.0.
[0053] The process is particularly suitable for enhancing a surface property of a metal selected from among Cr, Cu, Ag, Au, Ni, P, Sn, and Zn, and alloys thereof, for example, Cr, Ag, Au, Ni and alloys thereof. It is particularly preferred that the metal substrate be substantially free of Al.
Example 1
[0054] A microporous chromium plated grill is brought into contact in a post-treatment procedure with an aqueous solution comprising 30 g/l of a polyvinyl phosphonic acid/polyacrylic acid copolymer at a temperature of 60° C. An anodic current of 0.05 A/dm 2 is applied between the microporous chromium plated grill and a stainless steel counter electrode for 2 minutes. The resulting layer shows a strong improvement of the corrosion resistance against CaCl 2 containing corrosion media in the so called “Russian Mud Test”. The grill was covered with a mixture containing 10 ml water, 2 g CaCl 2 , and 10 g Kaolin. After 168 h testing at 50° C. the surface of the chromium plated grill showed no visible corrosion attack.
Example 2
[0055] A microcracked chromium plated grill is brought into contact in a post-treatment procedure with an aqueous solution comprising 5 g/l of a polyvinyl phosphonic acid/polyacrylic acid copolymer and 5 g/l sodiumphosphate at a temperature of 60° C. An anodic current of 0.15 A/dm 2 is applied between the microcracked chromium plated grill and a stainless steel counter electrode for 1 minute. The resulting layer shows a strong improvement of the corrosion resistance against CaCl 2 containing corrosion media in the so called “Russian Mud Test”. The resulting layer shows also after a treatment with solvents like acetone the same resistance against such CaCl 2 containing corrosion media as before.
Example 3
[0056] A hard chromium plated valve is brought into contact in a post-treatment procedure with an aqueous solution comprising 5 g/l of a polyvinyl phosphonic acid/polyacrylic acid copolymer and 5 g/l sodium metasilicate at a temperature of 80° C. An anodic current of 0.25 A/dm 2 is applied between the hard chromium plated valve and a stainless steel counter electrode for 1 minute. The resulting layer shows a strong improvement of the corrosion resistance in the copper accelerated salt spray test (CASS).
Example 4
[0057] A hard chromium plated valve is brought into contact in a post-treatment procedure with an aqueous solution comprising 6 g/l of a polyvinyl phosphonic acid and 5 g/l sodium metasilicate at a temperature of 80° C. An anodic current of 0.25 A/dm 2 is applied between the hard chromium plated valve and a stainless steel counter electrode for 1 minute. The resulting layer shows a strong improvement of the corrosion resistance in the copper accelerated salt spray test (CASS).
Example 5
[0058] A hard chromium plated valve is brought into contact in a post-treatment procedure with an aqueous solution comprising 7 g/l of a polyacrylic acid copolymer and 5 g/l sodium metasilicate at a temperature of 80° C. An anodic current of 0.25 A/dm 2 is applied between the hard chromium plated valve and a stainless steel counter electrode for 1 minute. The resulting layer shows a strong improvement of the corrosion resistance in the copper accelerated salt spray test (CASS).
Example 6
[0059] A steel panel first was plated with a bright nickel layer. On the nickel layer a chromium layer was deposited from a trivalent chromium electrolyte. The so plated steel panel was brought partly into contact in a post-treatment procedure with an aqueous solution comprising 2.5 g/l of an alkylphosphonic acid (C 18 ), 25 g/l butylglycole, 10 g/l phosphonic acid, and 0.2 g/l ethylhexylsulphate at a temperature of 60° C. An anodic current of 0.05 A/dm 2 is applied between the panel and a stainless steel counter electrode for 30 seconds. The resulting layer shows a strong improvement of the corrosion resistance in neutral salt spray test (NSS). The untreated area of the partly post-treated panel shows after 24 h red rust (pin hole corrosion). The post-treated area shows first red rust after 72 h NSS.
Example 7
[0060] A chromium plated bath room fitting with a dull pearlbright finish is brought into contact in a post-treatment procedure with an aqueous solution comprising 10 g/l of a polyvinyl phosphonic acid/polyacrylic acid copolymer at a temperature of 60° C. An anodic current of 0.05 A/dm 2 is applied between the chromium plated bathroom fitting and a stainless steel counter electrode for 2 minutes. The resulting layer shows a surface, which is less sensitive against fingerprints in comparison to non-post-treated pearlbrite surfaces.
Example 8
[0061] A nickel and chromium plated bathroom fitting with brass as substrate was brought partly into contact in a post-treatment procedure with an aqueous solution comprising 0.5 g/l of an alkylphosphonic acid (C 14 ), 20 g/l butylglycole, 5 g/l benzotriazole, and 0.2 g/l ethylhexylsulphate at a temperature of 50° C. An anodic current of 0.05 A/dm 2 is applied between the bathroom fitting and a stainless steel counter electrode for 4 minutes. The post-treated bathroom fitting was brought into contact with artificial sweat and stored in this for 168 h. After this the Ni, Cu and Pb concentration in the artificial sweat solution, that was leached out from the bathroom fitting was 90% less than for an untreated bathroom fitting under same test conditions.
Example 9
[0062] A microporous chromium plated grill is brought into contact in a post-treatment procedure with an aqueous solution comprising 4 g/l of a polyvinyl phosphonic acid/polyacrylic acid copolymer (30/70) and 5 g/l sodium orthophosphite at a temperature of 60° C. and a pH of 3.5. An anodic current of 0.2 A/dm 2 is applied between the microporous chromium plated grill and a stainless steel counter electrode for 2 minutes. The resulting layer shows a strong improvement of the corrosion resistance against CaCl 2 containing corrosive media in the so called “Nissan-Test. For the Nissan test a mixture of kaolin, CaCl 2 , and water is applied to the metal surface of the chromium plated grill which is stored at a temperature of 60° C. for 48 h to 168 h. After storage the visible corrosion attack caused by the applied CaCl 2 -containing media is used to classify the corrosion resistance of the tested metal surface.
Example 10
[0063] A microporous chromium plated grill was post-treated like explained in example 7, with the difference that the aqueous solution comprises 1 g/l of a polyvinyl phosphonic acid/polyacrylic acid copolymer (30/70) only, 0.5 g/l resorcinol, and 5 g/l sodium-orthophosphite. The resulting layer had the same corrosion resistance like the layer in example 7.
Example 11
[0064] A nickel plated article for jewelry application is plated last with a bright silver layer. The so plated article is brought partly into contact in a post-treatment procedure with an aqueous solution comprising 5 g/l of polyacrylic acid, 10 g/l sodiumphosphonate, 6 g/l phosphoric acid and 1 g/l guajacol at a temperature of 60° C. An anodic current of 0.01 A/dm 2 is applied between the article and a stainless steel counter electrode for 5 minutes. The resulting layer shows a strong decrease of discolouration after storing it for 3 minutes in an aqueous solution comprising 3% of ammoniumsulfide.
Example 12
[0065] A chromium plated plated wheel rim is brought into contact in a post-treatment procedure with an aqueous solution comprising 2 g/l sodiumphosphite and 15 g/l of a polyvinyl phosphonic acid at 50° C. An anodic current of 1 A/dm 2 is applied between the chromium plated wheel rim and a stainless steel counter electrode for 15 seconds. After this time the resulting layer shows strong hydrophilic properties. Therefore a water-based lacquer or even a two-component-acrylic lacquer is easy to apply on the post-treated chromium surface and the final varnishing system shows a strong improvement of adhesion to the chromium surface.
[0066] When introducing elements of the present invention or the preferred embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
[0067] As various changes could be made in the above without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | A process for treating the surface of a metal substrate comprising a constituent metal selected from the group consisting of Cr, Cu, Mn, Mo, Ag, Au, Pt, Pd, Rh, Pb, Sn, Ni, Zn, in some cases Fe, and alloys of these metals. An anodic potential is applied to the metal surface in an electrolytic circuit comprising the metal surface, a cathode, and an electrolytic solution that is in contact with the metal surface and in electrically conductive communication with the cathode. The electrolytic solution may contain an electrolyte comprising anions of phosphate, phosphonate, phosphite, phosphinate, nitrate, borate, silicate, molybdate, tungstate, carboxylate, oxalate and combinations thereof. The anion may comprise a polymer having a pendent moiety selected from the group consisting of phosphate, phosphonate, phosphite, phosphinate, sulfate, sulfonate, carboxylate and combinations thereof. The potential applied to the circuit is such that the substrate is anodically oxidized and reacts with the anion to form a composition that imparts an enhanced property to the metal surface. Preferably, the pH of the electrolytic solution is less than about 6.0, the potential applied is between about 0.5 and about 20 volts, and the current density is between about 0.01 and 2 amps/dm 2 of the geometric surface area of metal in contact with the electrolytic solution and is controlled such that nascent cations of said constituent metal produced by anodic oxidation of said constituent metal react with said anions at the metal surface without significant formation of any oxide or hydroxide of said constituent metal. | 2 |
FIELD OF THE INVENTION
The present invention relates to a drinking straw and more particularly to a therapeutic drinking straw for delivering liquids at an adjustable controlled rate to individuals who have the tendency to drink too fast or too much, for example so as to experience aspiration of liquid, or to individuals who may have swallowing difficulties.
BACKGROUND OF THE INVENTION
Children are known to play with their foods and drinks. While drinking beverages, children often, for various reasons, drink rapidly so as to cause aspiration of liquid, choking, gagging, or “brain freeze”. In particular, children diagnosed with Attention Deficit/Hyperactivity Disorder (AD/HD) are likely to consume their drinks too quickly. AD/HD children are known to fidget with their hands or feet, to engage in physically dangerous activities without considering the possible consequences, to have difficulty playing quietly, and to have difficulty awaiting turns in games, conversations, and other activities. Other children may drink too fast because they are racing with other children or they are too impatient or they are trying to attract attention from peers or adults.
Difficulty in swallowing, leading to a decreased ability to move food and liquid from the mouth to the stomach, is referred to as dysphagia. A patient suffering from dysphagia may encounter medical complications, such as aspiration. Aspiration, wherein all or part of the bolus penetrates the airway below the level of the vocal folds, is commonly encountered by patients whose dysphagia results from cognitive impairment. Impairments in attention, judgement and memory may preclude such individuals from using safe swallowing techniques. Thus, while the motor skills for swallowing thin liquids may be present, the patient may not remember to take small sips or to appropriately monitor his rate of intake, resulting in aspiration.
Although conventional straws may be used to deliver liquids to children and dysphagic persons, they present problems since the rate or amount of liquid swallowed cannot be monitored or controlled. It has been determined that the risk of choking by dysphagic patients may be reduced by drinking with a chin-down head position. Accordingly, therapeutic drinking cups designed to promote such a chin-down head position have been developed and used. One such cup (a “Nosey Cup”) includes a cut-out for the patient's nose so that the cup can be tipped to a drinking position with the chin down. A so-called “Dysphagia Cup” has also been developed, which is internally and externally contoured to promote drinking with a chin down head position. While these devices may prevent choking in dysphagic patients, they do not in any way control the rate or the amount of intake of the liquid.
One known therapeutic drinking straw machine consists of a straw with a pumping mechanism disposed between the two ends of the straw to convey liquid from the source to the mouth of the user. The pumping mechanism includes a manual actuator and a central reservoir such that the actuation of the actuator empties the reservoir and return of the actuator to a rest position re-fills the reservoir. This device allows a specific amount of liquid to be stored in the reservoir and then delivered to the user in order to assist motorically-impaired and cognitively-impaired individuals with swallowing difficulties.
However, the drinking straw machine is difficult and costly to manufacture since it requires a pump, reservoir, and valves. Furthermore, its bulkiness and overall design make the drinking straw machine unappealing, especially to children.
A novelty drinking straw is also known that has a decorative object positioned in the straw and between a pair of stops, which form a compartment. The object and the stops are dimensioned to prevent the movement of the object past the stops while allowing fluid to pass by. This device is designed only as a novelty to increase the attractiveness of the straw and to potentially use the decorative object for advertisement purposes. The object placed within the compartment is not used to block passage of liquid and may even dissolve or float. Novelty drinking straws are also known that are designed to be visually appealing to promote consumer purchases and child use.
Thus, while various straws have been developed to assist cognitive-impaired dysphagic patients or individuals with the tendency to drink rapidly, they are not entirely satisfactory.
SUMMARY OF THE INVENTION
The present invention relates to a drinking straw for regulating the amount of liquid that a user may drink in one sip. The present inventive straw has an elongated hollow member having at least two open ends, at least one end being a suction end adapted for application of a suction force and at least one end being a liquid end adapted for immersion in a liquid beverage. At least one compartment is associated with each suction end and is located between the associated suction end and the at least one liquid end, and the compartment has openings for communicating the liquid beverage therethrough. At least one insoluble object is disposed within the at least one compartment, the object having an outer diameter and/or circumference smaller than an inner diameter and/or circumference of the at least one compartment. The compartment openings and the object(s) are dimensioned to prevent escape of the object(s) from the compartment, and at least one object seals the compartment opening subsequent to the application of the suction force to prevent the movement of the liquid beverage past the opening.
In a preferred embodiment of the invention, the suction end of the drinking straw is further adapted for receipt in the mouth of a user, and may be even further adapted for receipt in the mouth of a user lacking normal mouth control. In another embodiment, the at least one suction end is further adapted to cooperate with a respirator mask to allow a user to use the straw while wearing the mask. The present invention also includes respirator mask in combination with the drinking straw, and may further include a flip top on the at least one suction end adapted for opening and closing the suction end by use of a user's tongue.
In another preferred embodiment of the invention, the at least one object seals the at least one compartment opening subsequent to the delivery of a specified volume of the liquid beverage through the suction end associated with that compartment. Preferably, the specified volume is between about 0.5 to about 50 ml. However, the specified volume may be about 1 to about 40 ml, about 5 to about 30 ml, about 5 to about 20 ml, or about 5 to about 15 ml. In these or in other embodiments, the specified volume is adjustable. The compartment may further include volume markings.
In a preferred embodiment of the invention, the object is a decorative object. Even more preferably, the at least one object does not float in air. In another preferred embodiment of the invention, the object has a density so as to be capable of traveling at a reasonable speed through air and most liquids and does not float in air. In some embodiments, the object has a density between about 1 and about 2 g/ml, about 1 to about 1.5 g/ml, about 1 to about 1.2 g/ml, or about 1 to about 1.1 g/ml. Generally, a density only slightly greater than that of water, or the liquid being drawn through the straw, is preferred.
In another preferred embodiment of the invention, the straw has two or more suction ends. Even more preferably, the at least one object within each of the at least one compartments associated with each suction end is capable of sealing both the compartment opening nearest the associated suction end and the compartment opening nearest the liquid end, but not both simultaneously. Preferably, a suction force applied to at least one suction end effectively seals the compartments associated with the remaining suction ends. In a different embodiment of the invention, the at least one object seals the at least one compartment opening only subsequent to the application of an excessive suction to the suction end associated with that compartment.
Preferably, the at least one compartment has a cross-sectional area substantially similar to a cross-sectional area of the hollow member. However, in a different embodiment, the at least one compartment has a cross-sectional area larger than a cross-sectional area of the hollow member. In a further embodiment, the at least one compartment has a cross-sectional area smaller than a cross-sectional area of the hollow member.
In a preferred embodiment of the invention, the straw is adapted to allow disassembly for cleaning, storage, and/or travel. Preferably, the straw includes male and female thread components for the disassembly and re-assembly of the straw. Screw threads associated with at least one of the compartments of the present invention allow for adjustment of the compartment volume. Both adjustable and non-adjustable embodiments of the invention may have volume markings on the exterior of the compartment, and adjustable versions may have graded volume markings to allow a user to accurately adjust the compartment to a selected volume.
The present invention also contemplates a method and/or a device for treating inappropriate drinking. The method and/or device employs a drinking straw as described above or below provided to a user in need of treatment that delivers the beverages in small, consistently-controlled quantities, and may include training the user to drink appropriately through repeated drinking of liquid through the straw until the user is trained to drink in small, consistent sips. The inappropriate drinking treatable using the present invention may be caused by AD/HD, dysphagia, intoxication, Alzheimer's disease, dementia, ALS, Parkinson's disease, muscular dystrophy, spinal cord injury, paralysis, multiple sclerosis, spasm, epilepsy, or other disease or condition that causes inappropriate drinking or any combination thereof.
The present invention also includes a method for preventing “brain freeze,” the commonly-presented headache associated with over-consumption of ice-cold foods and beverages. The inventive method provides for drinking cold beverages through the straw as described above or below that delivers the beverages in small, consistently-controlled quantities, these quantities being less than the quantity required to cause a headache.
The present invention even further includes a drinking straw adapter for attachment to the end of a conventional drinking straw or tube. The adapter includes an elongated hollow member having at least two open ends, at least one end being a suction end adapted for application of a suction force, and at least one end being an adapter end adapted for communicative attachment to a drinking straw; at least one compartment associated with each at least one suction end and located between the associated at least one suction end and the at least one adapter end and having openings for communicating the liquid beverage therethrough; and at least one insoluble object within the at least one compartment having an outer diameter and/or circumference smaller than an inner diameter and/or circumference of the at least one compartment; wherein the compartment openings and the object are dimensioned to prevent escape of the object(s) from the compartment; and wherein the at least one object seals at least one compartment opening subsequent to the application of the suction force to prevent the movement of the liquid beverage past the opening.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of one embodiment of the present invention.
FIG. 2 . shows a cross-sectional view of one embodiment of the present invention.
FIG. 3 . shows a perspective partial view of one embodiment of the present invention wherein the specified volume is adjustable.
FIG. 4 shows a perspective partial view of one embodiment of the present invention wherein the specified volume is adjustable.
FIG. 5 shows a perspective view of one embodiment of the present invention.
FIG. 6 shows a perspective view of one embodiment of the present invention.
FIG. 7 shows a perspective view of one embodiment of the present invention in combination with a respirator.
FIG. 8 shows a perspective partial view of one embodiment of the present invention.
FIG. 9 shows a perspective partial view of one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
While the invention will be described with reference to the preferred embodiments, it will be obvious to those of ordinary skill in the art that variations of these preferred embodiments may be used, and it is intended that the invention may be practiced otherwise than as specifically described herein. Accordingly this invention includes all modifications and equivalents encompassed within the spirit and scope of the invention as defined by the written description and appended claims.
The therapeutic drinking straw according to this invention is designed to controllably deliver a repeatable quantity of liquid to dysphagic patients or other users. The patients or users may be dysphagic for any number of reasons; generally the reason is a medical reason. The symptoms of the dysphagia may comprise various abnormal behaviors. Common behaviors include excessive suction force, excessive suction duration, rapidly repeated suction, and impeded ability to swallow.
An excessive suction force is suction force beyond that amount required to draw fluid up through a drinking straw. Drinking with excessive suction force may result in fluid being aspirated into the lungs, gagging and/or choking the user. Excessive suction duration is suction duration beyond that required to draw an appropriate mouthful of liquid through a straw. Excessive suction duration may result in choking due to an inappropriately large volume of fluid being present in the mouth. Rapidly repeated suction occurs when the user sucks a second volume of liquid through the straw and into the mouth prior to swallowing the previous mouthful of liquid; this can result in choking. Any user with an impeded ability to swallow must take smaller than normal mouthfuls so as to be able to swallow without difficulty. A user with impeded ability to swallow has an elevated risk of choking at all times.
As is described more fully below, the present invention overcomes those problems noted above, as well as other problems known in the art, by preventing excessive suction and/or limiting the volume that may be drawn through the straw in a single suction event (i.e., a single breath).
The candidate patients or users will typically lack normal mouth control. Persons lacking normal mouth control generally lack the ability to normally control the tongue, lips, and/or jaw so as to consequently lack the ability to hold a drinking straw in their mouth, maintain or create suction around a drinking straw, and/or to effectively manipulate a drinking straw with their mouth. In such a case, the present invention may be provided with, or manufactured to include, an adapter to aid the user in these actions. Examples of such an adapter include a flexible hook or clip for attaching the straw to the user's mouth, a radial flange or disk around the circumference of the drinking straw to act as a gasket for creating and maintaining suction, a cushioned bulge in the straw that assists a user in holding the straw in his mouth by providing an improved mouth-grasping area, a mask having a hole with the straw inserted therethrough, and others known in the art.
The present invention may be combined with a respirator mask so as to make drinking convenient for patients required to wear a respirator mask, such as that shown by example in FIG. 7 . The straw may be inserted through a hole ( 7 ) in the mask or made integral with and protruding through the mask. While the compartment is generally disposed distal to the patient, the compartment may also be disposed on the proximal side of the mask or across the thickness of the mask. The present invention may also include a flip top covering ( 8 ) that can be opened by a patient with his tongue, as shown in exemplary FIG. 8 .
In one embodiment, an example of which is shown in FIG. 1 and FIG. 2 , the present invention is a drinking straw ( 1 ) that includes a drinking tube ( 2 ) with first and second axially extending end portions( 2 a , 2 b ) with an end used as a mouthpiece and another end used as a liquid pick up region. Preferably, the straw is axially symmetrical so that either end can be used as a mouthpiece or pick up region. In between the end openings, there is a compartment ( 3 ) created by two stop regions ( 4 a , 4 b ) for controlling the amount of fluid desired for administration. An insoluble object ( 5 ) made of material non-toxic to the straw-user is disposed within the compartment and dimensioned to substantially prevent movement of the object past the stop regions. The stop regions are generally referred to as “upper” and “lower” stops based on their orientation relative to the user. The upper stop ( 4 a ) is closer to the end upon which the user applies suction force ( 2 a ); the lower stop ( 4 b ) is further from that end. The stop regions may also be referred to as the proximal and distal stops, respectively.
When the straw is not in use, the object will fall by gravitational force away from the upper stop. The object may or may not fall sufficiently to close the lower stop. When suction force is applied at one end of the drinking straw, such as by sucking on that end, the object will be drawn to the stop proximate to that end. While the object is traveling from the lower stop to the upper stop, the liquid will travel continuously from the distal end of the straw to the user's end. However, as soon as the object travels to the upper stop, it completely blocks the stop so as to prevent any more liquid from being administered to the user. This limits the amount that may be consumed by the user at one time. As the suction force is released, the object drops/falls away from the upper stop toward the lower stop.
In a different embodiment, the straw may have more than one suction end. For example, as shown in exemplary FIG. 6 , it may have two suction ends and be generally Y-shaped. In such an embodiment, each suction end will have at least one compartment associated with it, for example on the two arms of the “Y.” The lower, or liquid, end of each compartment will be adapted, like the suction end, so that the insoluble object(s) in each compartment will be effective to seal the lower end of the compartment when reverse suction force is applied, for example to seal the lower end of the left compartment when a user is sucking on the right suction end of the Y-shape. This will have the effect of preventing the intake of air (i.e., loss of vacuum) through the unused end or ends of the straw so that a single user is able to drink through a multi-headed straw.
Preferably the compartment is size-adjustable. One example of the compartment uses material that is flexible enough to stretch or compress yet rigid enough to retain its stretched or compressed shape. One way this may be accomplished is through the use of an accordion-shaped compartment, such as shown by example in FIG. 3 . Another example is a threaded compartment ( 9 ) that may be adjusted in volume by screwing a portion of the compartment inward or outward in relation to another portion of the compartment ( 10 ), such as shown by example in FIG. 9 . In this embodiment, the straw may be adapted to allow disassembly for cleaning, storage, and/or travel. An even further method employs a plunger-type apparatus, such as shown by example in FIG. 4 . The compartment may further include volume markings ( 6 ), as shown in FIG. 5 .
Preferably the object is of such density as to rise and fall at reasonable speeds through most liquids and the air. This way, the user would only have to wait a reasonable period of time before drinking again. A reasonable time is the amount of time a healthy patient requires to swallow a mouthful of liquid and take a breath. Preferably, the travel speed of the object is at a rate so as to ensure safety of the user, taking into account the maximum size of the adjustable compartment so that an impatient user would not experience aspiration by quick release-suction movements and/or overly-rapid repeated suction.
The above qualifications are preferably achieved by regulating the density of the object. Preferably, the object is denser than water. However, the object should not be so dense as to fall to the bottom of the compartment too rapidly or so as not to be able to be drawn up to the top of the compartment quickly enough during a suction event. Appropriate densities typically are between about 1 and about 2 g/ml, about 1 to about 1.5 g/ml, about 1 to about 1.2 g/ml, or about 1 to about 1.1 g/ml. Generally, a density only slightly greater than that of water, or the liquid being drawn through the straw, is preferable. Generally, it is not desirable for the object to float in the liquid as this may result in the compartment being blocked off prior to a sufficient volume of liquid being drawn through the straw. It may or may not be preferable for the object to sink in the liquid, depending upon whether or not the embodiment contemplates the compartment being sealed at its distal end when no suction force is being applied.
Preferably, the object and the compartment can be decoratively shaped or finished to attract consumers, particularly children. The object may be brightly colored, have flecks or speckles of color or glitter, be translucent, be decoratively shaped, have writing or pictures, and the like as is well known in the art. One preferred decorative shape is the ovoid shape of an American football. One preferred decorative coloring or pattern is the hexagonal block pattern as seen on a soccer ball. Another is a stitched pattern as seen on a baseball.
The drinking straw may be constructed using techniques and materials well known in the art. Preferably, the straw is made from polyurethane. The grade, quality, and thickness of the material will be according to standards well known in the art. The straw may be constructed of a lighter grade or thickness of material for a disposable application, but may also be made of a heavier grade or thickness for a multi-use application. Such a straw would be made of material sufficiently durable to withstand repeated washing in an automated washing machine, or of an even greater durability sufficient to withstand autoclaving.
The straw may also be made from biodegradable materials, such as waxed papers, for disposable one-time use. In such a case, the straw, or the straw's packaging, should be labeled with instructions stating that the straw should be discarded after one use.
The present invention may be combined with existing delivery devices or drink containers to enhance those products. The present invention contemplates an adapter that may be attached to the suction end of a conventional drinking straw, the top of a covered cup, or even the lip of a conventional cup. Such an embodiment will preferably be small in size to allow for convenient transport of the device. It may be packaged for individual, disposable use, and made of light-weight material, or it may be constructed of heavier grade material for re-use. A user may carry such an adapter in his pocket for use as needed without the inconvenience of carrying a full-length straw.
To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the description herein are purely illustrative and are not intended to be in any sense limiting. Likewise, not every embodiment of the invention need achieve every advantage disclosed above for any particular preferred embodiment. | A drinking straw for controlling the intake of beverages, comprising an elongated hollow member having at least two open ends, at least one end being a suction end adapted for application of a suction force, and at least one end being a liquid end adapted for immersion in a liquid beverage; at least one compartment associated with each at least one suction end and located between the associated at least one suction end and the at least one liquid end and having openings for communicating the liquid beverage therethrough; and at least one insoluble object within the at least one compartment having an outer circumference smaller than an inner circumference of the at least one compartment; wherein the compartment openings and the object are dimensioned to prevent escape of the object from the compartment; and wherein the at least one object seals at least one compartment opening subsequent to the application of the suction force to prevent the movement of the liquid beverage past the opening. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a paper feeder for storing recording media and an image forming apparatus having the paper feeder, and particularly relates to a paper feeder capable of locking each paper feed cassette to prevent recording media stored in the paper feed cassette from being taken out freely from the paper feed cassette, and an image forming apparatus having the paper feeder.
[0003] 2. Background Art
[0004] Paper feed cassettes of an image forming apparatus such as a printer are generally filled with sheets of plain paper. Occasionally, however, by use of mica toner containing magnetic powder or the like, numeric characters may be printed on securities such as checks charged into a paper feed cassette. The checks or the like subjected to printing thus can be used immediately for economic transactions. From such convenience, printers have been increasingly used for such applications in recent years.
[0005] When a printer is used for such applications, it is necessary to protect the securities in the paper feed cassette from theft. In order to prevent theft, therefore, in the background art, a locking unit or the like is provided for preventing recording media in a paper feed cassette from being taken out freely when printing is performed on securities (see JP-A-2001-121795, page 3, FIG. 1).
SUMMARY OF THE INVENTION
[0006] In the aforementioned document, the case for only one paper feed cassette is taken into consideration, but the case for a plurality of paper feed cassettes is not taken into consideration. When a plurality of paper feed cassettes are provided in the technique disclosed in the aforementioned document, a plurality of locking units must be provided for the paper feed cassettes respectively, and a user must lock the paper feed cassettes individually. Such an operation is troublesome for the user and also disadvantageous in terms of cost. With the number of paper feed cassettes increasing, the technique is more disadvantageous in terms of workability or cost.
[0007] A paper feeder capable of locking a plurality of paper feed cassettes in an easy operation, and an image forming apparatus having the paper feeder is disclosed herein.
[0008] According to an aspect of the invention, a paper feeder includes: a first paper feed cassette in which to store a recording medium with a lock state that is selected from an unlocked state where the recording medium can be taken out therefrom and a locked state where the recording medium cannot be taken out therefrom; a locking portion that determines whether to bring the lock state of the first paper feed cassette into the unlocked state or the locked state; a second paper feed cassette in which to store a recording medium, capable of selectively entering an unlocked state where the recording medium can be taken out therefrom and a locked state where the recording medium cannot be taken out therefrom; and a lock state transmitting portion that transmits the lock state of the first paper feed cassette to the second paper feed cassette to bring the second paper feed cassette into the unlocked state or the locked state in accordance with the lock state of the first paper feed cassette.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present invention may be more readily described with reference to the accompanying drawings:
[0010] [0010]FIG. 1 is a front perspective view showing a laser printer according to a first embodiment of the invention, with an explanatory side view of a gang lock unit provided in the laser printer.
[0011] [0011]FIG. 2 is a schematic perspective view showing a printer body in the laser printer in FIG. 1.
[0012] [0012]FIG. 3 is a sectional view taken on line III-III in FIG. 2.
[0013] [0013]FIG. 4 is a front perspective view showing a laser printer according to a second embodiment of the invention, with an explanatory side view of a gang lock unit provided in the laser printer.
[0014] [0014]FIG. 5A is a schematic perspective view showing a printer fixing bar provided in a support base for supporting the laser printer according to the first embodiment of the invention.
[0015] [0015]FIG. 5B is a schematic perspective view showing a printer fixing bar provided in a support base for supporting the laser printer according to the second embodiment of the invention.
[0016] [0016]FIG. 6 is a front perspective view showing a laser printer according to another embodiment of the invention, with an explanatory side view of a gang lock unit provided in the laser printer.
[0017] [0017]FIG. 7 is a front perspective view showing a laser printer according to another embodiment of the invention, with an explanatory side view of a gang lock unit provided in the laser printer.
[0018] [0018]FIG. 8 is a front perspective view showing a laser printer according to another embodiment of the invention, with an explanatory side view of a gang lock unit provided in the laser printer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Preferred embodiments of the invention will be described below with reference to the drawings.
[0020] [0020]FIG. 1 is a front perspective view showing a laser printer according to a first embodiment of the invention, with an explanatory side view of a gang lock unit provided in the laser printer. The laser printer 1 is constituted by a printer body 1 a and a stack of three paper feed cassette units 1 b , 1 c and 1 d disposed under the printer body 1 a . The paper feed cassette units 1 b , 1 c and 1 d are separate from the printer body 1 a and have the same configuration as one another. Each paper feed cassette unit 1 b , 1 c , 1 d can be removably attached to the printer body 1 a . A user can remove the paper feed cassette unit desirably or install another paper feed cassette unit having the same configuration additionally. More in particular, the printer body 1 a and the paper feed cassette units have foot portions in their bottom surface respectively (only foot portions 61 of the lowest paper feed cassette unit 1 d are shown in FIG. 1). The printer body 1 a and the paper feed cassette units are disposed in a stack without any misalignment due to the foot portions 61 engaging with lower units respectively.
[0021] Here, each member is denoted by a reference numeral with a suffix “a”, “b”, “c” or “d” showing which one of the printer body 1 a and the paper feed cassette units 1 b , 1 c , 1 d the member belongs to.
[0022] A paper feed cassette 6 a storing securities such as checks as recording media is provided in the printer body 1 a removably in a direction perpendicular to the paper of FIG. 1. Similarly in each paper feed cassette unit 1 b , 1 c , 1 d , a paper feed cassette 6 b , 6 c , 6 d is provided removably in a unit body 60 b , 60 c , 60 d . Incidentally, a recess portion 16 a , 16 b , 16 c , 16 d for making the user easier to put his/her fingers therein when he or she pulls out each paper feed cassette 6 a , 6 b , 6 c , 6 d is formed at the front of the paper feed cassette 6 a , 6 b , 6 c , 6 d.
[0023] A gang lock unit is provided on the front left side of each paper feed cassette 6 a , 6 b , 6 c , 6 d . The gang lock unit performs gang locking as follows. That is, as soon as the paper feed cassette 6 a provided in the printer body 1 a is brought into a locked state, the gang lock unit automatically brings the paper feed cassettes 6 b , 6 c and 6 d of the paper feed cassette units 1 b , 1 c and 1 d stacked under the printer body 1 a , into the locked state.
[0024] Incidentally, the locked state means a state where the paper feed cassette 6 a , 6 b , 6 c , 6 d is prohibited from being pulled out, so that checks 3 in the paper feed cassette 6 a , 6 b , 6 c , 6 d cannot be taken out. An unlocked state means a state where the paper feed cassette 6 a , 6 b , 6 c , 6 d is allowed to be pulled out so that the checks 3 can be taken out.
[0025] A tag 14 is exposed to the apparatus front on the left side of the paper feed cassette 6 a of the printer body 1 a (see FIG. 2), while a lock gear 51 a , a cylinder 54 a fixed to the back side of the lock gear 51 a , and so on, are stored in the apparatus. That is, all the members of the gang lock unit but the tag 14 provided on the left side of the paper feed cassette 6 a of the printer body 1 a are stored in each unit but invisibly from the front surface. However, in order to make the description easier, those members are shown by the solid lines in the front view on the right side of FIG. 1, and shown schematically in the explanatory view on the left side of FIG. 1.
[0026] A key hole 14 a to which a key 90 can be inserted is formed in the tag 14 . The key hole 14 a is formed continuously in the lock gear 51 a and the cylinder 54 a in the printer body 1 a which will be described later. That is, the front end of the key 90 is designed to penetrate the tag 14 and the lock gear 51 a and reach the inside of the cylinder 54 a.
[0027] Lock gears 51 a , 51 b , 51 c and 51 d are provided correspondingly to the paper feed cassette 6 a of the printer body 1 a and the paper feed cassettes 6 b , 6 c and 6 d of the paper feed cassette units 1 b , 1 c and 1 d respectively. Each lock gear 51 a , 51 b , 51 c , 51 d is a circular plate-like member having a gearing groove formed in its circumferential edge. A columnar cylinder 54 a , 54 b , 54 c , 54 d is fixed to the back side of the lock gear 51 a , 51 b , 51 c , 51 d.
[0028] A hook 53 a , 53 b , 53 c , 53 d and a locking bar 52 a , 52 b , 52 c , 52 d are fixed to the circumferential surface of the cylinder 54 a , 54 b , 54 c , 54 d in turn in order of increasing distance from the tag 14 . Accordingly, the cylinder 54 a , 54 b , 54 c , 54 d rotates with the rotation of the lock gear 51 a , 51 b , 51 c , 51 d in the locking operation, so that the hook 53 a , 53 b , 53 c , 53 d and the locking bar 52 a , 52 b , 52 c , 52 d fixed to the cylinder 54 a , 54 b , 54 c , 54 d also rotate together.
[0029] Each locking bar 52 a , 52 b , 52 c , 52 d is a bar-like member which is received in a recess portion 55 a , 55 b , 55 c , 55 d provided in the locking-portion-side side surface of the paper feed cassette 6 a , 6 b , 6 c , 6 d in the locked state. In FIG. 1, the locking bars 52 a , 52 b , 52 c and 52 d in the locked state are shown by the solid lines and in the unlocked state are shown by the broken lines.
[0030] A grappling portion is formed at the tip of each hook 53 a , 53 b , 53 c , 53 d . The hooks 53 a , 53 b and 53 c except for the lowest hook 53 d engage with hook destinations 80 b , 80 c and 80 d provided to project on the top of the unit bodies 60 b , 60 c and 60 d in the paper feed cassette units 1 b , 1 c and 1 d , respectively. Each hook destination 80 b , 80 c , 80 d is a bar extending perpendicularly to the paper of FIG. 1. The hook destination 80 b , 80 c , 80 d is attached to be put between two vertical members (not shown) attached to the top of the paper feed cassette unit 1 b , 1 c , 1 d . Thus, the hook destination 80 b , 80 c , 80 d is disposed to project on the top of the unit body 60 b , 60 c , 60 d.
[0031] On the other hand, the hook 53 d provided for the paper feed cassette 6 d closest to a support base 200 supporting the apparatus engages with a printer fixing bar 201 provided in the support base 200 . The printer fixing bar 201 is a U-shaped member, which is attached to project from the surface of the support table 200 as shown in FIG. 5A. The support base 200 provided with the printer fixing bar 201 thus is sold, particularly as a support of the laser printer 1 according to this embodiment, in set with the laser printer 1 .
[0032] Incidentally, in the same manner as the locking bars 52 a , 52 b , 52 c and 52 d , in FIG. 1, the hooks 53 a , 53 b , 53 c and 53 d in the hooked state are also shown by the solid lines and in the unhooked state are also shown by the broken lines.
[0033] The lock gears 51 a and 51 b are connected to each other through three transmission gears 70 a , 71 b and 72 b disposed between the lock gears 51 a and 51 b . The lock gears 51 b and 51 c are connected to each other through three transmission gears 70 b , 71 c and 72 c disposed between the lock gears 51 b and 51 c . The lock gears 51 c and 51 d are connected to each other through three transmission gears 70 c , 71 d and 72 d disposed between the lock gears 51 c and 51 d.
[0034] Accordingly, when the key 90 is inserted into the key hole 14 a of the tag 14 provided in the printer body 1 a and the key 90 is rotated in the illustrated arrow direction (clockwise), the lock gear 51 a rotate in the arrow direction together with the tag 14 . This rotation is transmitted to the lock gears 51 b , 51 c and 51 d in the lower paper feed cassettes 6 b , 6 c and 6 d through the transmission gears 70 a , 71 b , 72 b , 70 b , 71 c , 72 c , 70 c , 71 d and 72 d . In such a manner, all the gears rotate in the arrow direction in FIG. 1 substantially concurrently.
[0035] Incidentally, in this embodiment, the printer body 1 a has one lock gear and one transmission gear, and each paper feed cassette unit 1 b , 1 c , 1 d has one lock gear and three transmission gears. The lowest transmission gear 70 d provided in the paper feed cassette unit 1 d disposed undermost does not serve to transmit the gear rotation. For example, when another paper feed cassette unit is further stacked under the paper feed cassette unit 1 d , the transmission gear 70 d will serve as a transmission gear.
[0036] With the rotations of the plurality of gears, the locking bars 52 a , 52 b , 52 c and 52 d and the hooks 53 a , 53 b , 53 c and 53 d fixed to the cylinders 54 a , 54 b , 54 c and 54 d respectively also rotate in the arrow direction in FIG. 1, respectively. As soon as the key 90 rotates to reach the position of the locked state, the locking bars 52 a , 52 b , 52 c and 52 d are received in the recess portions 55 a , 55 b , 55 c and 55 d of the paper feed cassettes 6 a , 6 b , 6 c and 6 d , while the hooks 53 a , 53 b , 53 c and 53 d move in the unit stack direction, that is, downward so as to engage with the hook destinations 80 b , 80 c and 80 d and the printer fixing bar 201 fixed onto the support base 200 , respectively.
[0037] Incidentally, the locking bars 52 a , 52 b , 52 c and 52 d are removable. For example, therefore, when only the locking bar 52 b is removed, only the paper feed cassette 6 b in the paper feed cassette unit 1 b will avoid gang locking and keep its unlocked state even if the other three paper feed cassettes 6 a , 6 c and 6 d are brought into the locked state.
[0038] The locking gears 51 a , 51 b , 51 c and 51 d , the locking bars 52 a , 52 b , 52 c and 52 d , the hooks 53 a , 53 b , 53 c and 53 d and the transmission gears 70 a , 71 b , 72 b , 70 b , 71 c , 72 c , 70 c , 71 d , 72 d and 70 d constituting the gang lock units are stored in the printer body 1 a and the paper feed cassette units 1 b , 1 c and 1 d respectively, and prevented from projecting outside the apparatus even when the paper feed cassettes 6 a , 6 b , 6 c and 6 d are in the locked state.
[0039] Next, the printer body 1 a of the laser printer 1 will be described in detail with reference to FIGS. 1 to 3 . FIG. 2 is a schematic perspective view showing the printer body 1 a in the laser printer 1 in FIG. 1. FIG. 3 is a sectional view taken on line III-III in FIG. 2.
[0040] As shown in FIGS. 1 and 2, a manual paper feed tray 13 is installed openably and closably above the paper feed cassette 6 a of the printer body 1 a . An operating portion 15 is provided in a surface formed further above the manual paper feed tray 13 and obliquely from the side surface of the printer to the top thereof as shown in FIG. 2. The operating portion 15 is provided with a liquid crystal display 15 a and a plurality of buttons 15 b . Settings in the laser printer 1 are shown in the liquid crystal display 15 a . When the user pushes the buttons 15 b , the user can do various settings on the laser printers 1 .
[0041] The check 3 fed from the paper feed cassette 6 a or the manual paper feed tray 13 in the printer body 1 a is subjected to print processing through the process in which the check 3 is carried along a feed path inside the printer body 1 a as will be described later. Then, the check 3 is delivered onto a paper outlet tray 36 by the rotations of a paper delivery roller pair 35 shown in FIGS. 2 and 3.
[0042] Here, the internal configuration of the printer body 1 a will be described with reference to FIG. 3. First, a pressure plate 8 , a paper feed roller 9 and a separation pad unit 10 are provided inside the paper feed cassette 6 a mounted in the lower portion of the printer body 1 a . The paper feed roller 9 is provided above a one-end-side end portion of the paper feed cassette 6 a . The paper feed roller 9 rotates intermittently.
[0043] The pressure plate 8 has a top on which the checks 3 can be laid, and a bottom urged upward by a spring 8 a . In addition, the pressure plate 8 is supported swingably at one end more distant from the paper feed roller 9 . Thus, the other end of the pressure plate 8 closer to the paper feed roller 9 is made movable in the up/down direction. The paper feed roller 9 and the separation pad unit 10 are disposed to face each other. A separation pad (not shown) made from a member having a high friction drag is pressed toward the paper feed roller 9 by a spring 10 b disposed on the back side of a pad backing 10 c in the separation pad unit 10 .
[0044] The check 3 fed from the paper feed cassette 6 a is fed to a feed roller pair 11 and a resist roller pair 12 through the paper feed roller 9 and the separation pad unit 10 along a feed path 7 shown by the chain line in FIG. 3. The check 3 is corrected for skewing in the position of the resist roller pair 12 . The check 3 corrected for skewing is then sent to an image forming position P of the process unit 18 (a contact portion between a photoconductor drum 23 and a transfer roller 25 which will be described later, that is, a transfer position where a toner image on the photoconductor drum 23 is transferred to the check 3 ), and subjected to printing therein.
[0045] The process unit 18 is constituted by a drum cartridge, a developing cartridge 24 , and so on. The drum cartridge includes the photoconductor drum 23 , a Scorotron type charger 37 serving as a charging unit, the transfer roller 25 serving as a transfer unit, and so on. The developing cartridge 24 can be removably attached to the drum cartridge. The developing cartridge 24 has a toner storage portion 26 , a developing roller 27 serving as a developing unit, a layer thickness limiting blade (not shown), a toner feed roller 29 , etc. Incidentally, the toner storage portion 26 is filled with mica toner containing magnetic powder and suitable for the check 3 used as a recording medium as in this embodiment. A toner image carried on the surface of the photoconductor drum 23 is transferred to the check 3 when the check 3 passes between the photoconductor drum 23 and the transfer roller 25 .
[0046] In addition, a scanner unit 17 is disposed on the lower surface side of the paper outlet tray 36 . The scanner unit 17 has a laser beam emitting portion (not shown), a polygon mirror 20 to be driven to rotate, lenses 21 a and 21 b , a reflecting mirrors 22 , etc. Then, a laser beam emitted from the laser beam emitting portion in accordance with given image data is passed through or reflected on the polygon mirror 20 , the lens 21 a , the reflecting mirrors 22 and the lens 21 b in that order. Thus, the surface of the photoconductor drum 23 serving as a photoconductor in the process unit 18 is scanned and irradiated with the laser beam at a high speed.
[0047] A fixing unit 19 serving as fixing means to thermally fix the image on the check 3 is disposed on the downstream side of the process unit 18 along the feed path 7 . The fixing unit 19 has a heating roller 30 , a pressure roller 31 disposed to press the heating roller 30 , and a feed roller pair 32 provided on the downstream side of the rollers 30 and 31 . The heating roller 30 is made from metal such as aluminum, and provided with a heater such as a halogen lamp for heating so that the toner transferred onto the check 3 in the process unit 18 is fixed thermally when the check 3 passes between the heating roller 30 and the pressure roller 31 . After that, the check 3 is carried to the position of the paper delivery roller pair 35 by the feed roller pair 32 .
[0048] Incidentally, the laser printer 1 according to this embodiment can perform double-sided printing. However, the laser printer 1 is generally set for single-sided printing when the check 3 is used as a recording medium. In setting of single-sided printing, the check 3 carried to the delivery roller pair 35 after the single-sided printing is delivered onto the paper outlet tray 36 by the rotation of the paper delivery roller pair 35 .
[0049] On the other hand, for example, assume that setting is done for double-sided printing when a sheet of plain paper is used as a recording medium. In such a case, the front and back of the sheet of plain paper fed to the paper delivery roller pair 35 after single-sided printing are reversed due to the reverse rotation of the paper delivery roller pair 35 , and fed toward the resist roller pair 12 again along a reverse path 41 and a refeed path 40 a following the reverse path 41 . In the refeed path 40 a , the sheet of paper is carried while being held between a plurality of pairs of refeed rollers 43 a and 43 b disposed at a distance from one another, and fed to the resist roller pair 12 again through a refeed guide 45 . Then, the sheet of paper is subjected to printing on the other unprinted side thereof by the process unit 18 . The sheet of paper after the double-sided printing is delivered onto the paper outlet tray 36 due to the rotation of the paper delivery roller pair 35 as described above.
[0050] Incidentally, description has been made above on the case where the check 3 is fed from the paper feed cassette 6 a provided in the printer body 1 a . However, the check 3 can be selectively fed also from the paper feed cassette 6 b , 6 c , 6 d in the paper feed cassette unit 1 b , 1 c , 1 d shown in FIG. 1, through a paper feed cassette unit feed path 46 (see FIG. 3). Incidentally, a mechanism or control for feeding recording media selectively from paper feed cassette units disposed in a stack are known well. Therefore, their detailed description will be omitted here.
[0051] As described above, the laser printer 1 according to the first embodiment has the four paper feed cassettes 6 a , 6 b , 6 c and 6 d so that various kinds of prints can be stored in the paper feed cassettes 6 a , 6 b , 6 c and 6 d severally. To bring the paper feed cassettes 6 b , 6 c and 6 d into the locked state, only the paper feed cassette 6 a having a locking portion is operated so that the other paper feed cassettes 6 b , 6 c and 6 d can be also brought into the locked state concurrently by gang locking. Such a configuration can reduce the cost in comparison with the case where a locking portion is provided for each of the four feed cassettes 6 a , 6 b , 6 c and 6 d . In addition, the locking operation becomes easy for the user because it will go well if locking is performed on only the paper feed cassette 6 a having the locking portion without any necessity of performing locking on the paper feed cassettes 6 a , 6 b , 6 c and 6 d individually.
[0052] When all the paper feed cassettes 6 a , 6 b , 6 c and 6 d are brought into the locked state by gang locking, paper feed cassettes used frequently or unnecessary to be protected from theft are also locked. This may be disadvantage for the user. Such disadvantageous can be solved in this embodiment. That is, the locking bars 52 a , 52 b , 52 c and 52 d are made removable. A locking bar corresponding to a paper feed cassette unnecessary to be locked is removed, and recording media unnecessary to be protected from theft are stored in the paper feed cassette.
[0053] In addition, an apparatus which can solve the disadvantage that a paper feed cassette used frequently or unnecessary to be protected from theft is locked can be realized by a comparatively simple configuration in which the locking bars 52 a , 52 b , 52 c and 52 d are made removable thus. In addition, the operation to remove the locking bars 52 a , 52 b , 52 c and 52 d is comparatively easy for the user.
[0054] In addition, in response to locking, the hook 53 d provided in the paper feed cassette 6 d closest to the support base 200 projects toward the support base 200 , and engages with the printer fixing bar 201 provided in the support base 200 . The laser printer 1 can be fixed to the support base 200 in concurrence with locking by such a comparatively simple configuration. The event that securities are carried away and stolen together with the laser printer 1 can be prevented easily and at a low price.
[0055] Although the three paper feed cassette units 1 b , 1 c and 1 d are used in this embodiment, a desired number of paper feed cassette units can be attached to the printer body 1 a . Thus, the options of the user can be broadened and the degree of freedom of the laser printer 1 is improved.
[0056] When gang locking is performed in response to locking, the printer body 1 a and the paper feed cassette units 1 b , 1 c and 1 d removably attached to the printer body 1 a are fixed to one other. It is therefore possible to prevent the event that securities are stolen together with each paper feed cassette unit 1 b , 1 c , 1 d removed from the printer body 1 a.
[0057] More in particular, in response to locking, the lock gears 51 a , 51 b and 51 c rotate so that the hooks 53 a , 53 b and 53 c move toward the paper feed cassette units 1 b , 1 c and 1 d , and engage with the hook destinations 80 b , 80 c and 80 d provided in the paper feed cassette units which are destinations of the hooks 53 a , 53 b and 53 c , respectively. Thus, the printer body 1 a and the paper feed cassette units 1 b , 1 c and 1 d disposed in a stack are fixed to one another. Accordingly, a desired number of paper feed cassette units can be installed so that the degree of freedom of the laser printer 1 is improved. In addition, the event that securities are stolen together with each paper feed cassette unit removed from the printer body 1 a can be prevented easily, at a low price and with a comparatively simple configuration.
[0058] In addition, the gang lock unit is constituted by a plurality of gears such as lock gears and transmission gears. Due to such a comparatively simple configuration, a laser printer which can lock a plurality of paper feed cassettes with an easy operation can be manufactured easily and at a low price.
[0059] Next, a laser printer according to a second embodiment of the invention will be described with reference to FIG. 4. Here, parts similar in structure to those in the laser printer 1 according to the first embodiment are denoted by the same reference numerals correspondingly, and their description will be omitted. FIG. 4 is a front perspective view showing the laser printer according to the second embodiment of the invention, with an explanatory side view of a gang lock unit provided in the laser printer.
[0060] This embodiment is different from the first embodiment in the configuration of the gang lock unit. First, as shown in FIG. 4, each hook 153 a , 153 b , 153 c , 153 d in this embodiment is received in its corresponding unit in the unhooked state as shown by the broken line in FIG. 4, but it projects downward outside the unit in the hooked state as shown by the solid line.
[0061] Hook destinations 180 b , 180 c and 180 d and a printer fixing bar 202 are disposed in positions corresponding to the tips of the hooks in the locked state. In the first embodiment, each hook destination 80 b , 80 c , 80 d is disposed on the top of the unit body 60 b , 60 c , 60 d while the printer fixing bar 201 is attached to project from the surface of the support base 200 . In this embodiment, however, each hook destination 180 b , 180 c , 180 d is disposed inside a unit body 160 b , 160 c , 160 d without projecting from the unit body 160 b , 160 c , 160 d , while the printer fixing bar 202 is disposed inside a hole 200 x formed in the surface of the support base 200 as shown in FIG. 5B.
[0062] Each transmission gear is received in the printer body or each unit in the first embodiment. In this embodiment, however, each transmission gear projects outside the apparatus. That is, a transmission gear 170 a provided in a printer body 101 a projects downward from the bottom of the printer body 101 a , and lowest transmission gears 170 b , 170 c and 170 d provided in paper feed cassette units 101 b , 101 c and 101 d respectively project downward from the bottoms of the paper feed cassette units 101 b , 101 c and 101 d respectively. Incidentally, in spite of such a structure where the transmission gears project outside the apparatus, the lowest transmission gear 170 d is received in a hole 200 x formed in the surface of the exclusive support base 200 as shown in FIG. 4 when the paper feed cassette unit 101 d is mounted on the exclusive support base 200 . Thus, the laser printer 101 can be supported adequately on the support base 200 .
[0063] As described above, in the laser printer 101 according to the second embodiment, differently from the laser printer 1 according to the first embodiment, the printer fixing bar 202 does not project from the support base 200 . Accordingly, it is possible to avoid such a disadvantage that something is caught by the printer fixing bar 202 after the laser printer 101 has been moved.
[0064] However, in this embodiment in which the printer body 101 a and the paper feed cassette units 101 b , 101 c and 101 d are stacked vertically and supported on the support base 200 , they may be put on a support base which is not the exclusive support base 200 having the hole 200 x formed in the surface. In such a case, at the time of locking, there is a fear that the surface of the support base is injured by the tip of the hook 153 d provided in the lowest paper feed cassette unit 101 d , or the hook 153 d is damaged. On the other hand, in the first embodiment, the hook destinations 80 b , 80 c and 80 d are formed on the tops of the unit bodies 60 b , 60 c and 60 d of the paper feed cassette units 1 b , 1 c and 1 d respectively. It is therefore unnecessary to make the tips of the hooks 53 a , 53 b and 53 c project into the unit bodies 60 b , 60 c and 60 d of the adjacent paper feed cassette units 1 b , 1 c and 1 d respectively. Accordingly, even in the locked state, each hook 53 a , 53 b , 53 c is kept in the printer body 1 a or the unit body 60 b , 60 c , 60 d of the paper feed cassette unit 1 b , 1 c , 1 d provided therewith. It is therefore possible to solve the disadvantage that the support base is injured or the hook 153 d is damaged.
[0065] Although the preferred embodiments of the invention have been described above, the invention is not limited to the embodiments. Various changes in design can be made on the invention without departing from the claimed scope thereof.
[0066] For example, although the embodiments have been described on the case where a laser printer is adopted as an example of an image forming apparatus according to the invention, the invention is also applicable to various image forming apparatuses including other printers of an inkjet type and the like, copying machines, facsimile machines, and so on.
[0067] In addition, the toner storage portion 26 in the process unit 18 maybe filled with regular nonmagnetic toner. Although it is suitable to fill the toner storage portion 26 with mica toner containing magnetic powder when securities such as the checks 3 are used as recording media as in the embodiments, it may be filled with nonmagnetic toner when sheets of plain paper are used as recording media.
[0068] Although the unlocked/locked state of each paper feed cassette 6 a , 6 b , 6 c , 6 d is selected by use of a mechanical configuration, that is, a plurality of gears in the embodiments, for example, the unlocked/locked state may be selected by an electronic lock (power lock) or the like.
[0069] For example, FIG. 6 shows a configuration using a power lock. As shown in FIG. 6, the printer body 1 a and the paper feed cassette units 1 b , 1 c and 1 d are provided with power lock portions 1101 a , 1101 b , 1101 c and 1101 d . The power lock portions 1101 a , 1101 b , 1101 c and 1101 d are connected through a bus 1102 to a controller 1103 that is provided in the printer body 1 a . The controller 1103 is configured to control a locked state and an unlocked state of each of the power lock portions 1101 a , 1101 b , 1101 c and 1101 d . When the key 90 is inserted into the power lock portion 1101 a and the key 90 is rotated in the illustrated arrow direction (clockwise), the power lock portion 1101 a brings the paper feed cassette 6 a into a locked state. Concurrently, the controller 1103 detects that the power lock portion 1101 a to be in a locked state, the controller 1103 controls the power lock portions 1101 b , 1101 c and 1101 d to bring into the locked state in accordance with the locked state of the power lock portion 1101 a . In such a manner, the locked state of the power lock portion 1101 a is transmitted to the other power lock portions 1101 b , 1101 c and 1101 d . In addition, the controller 1103 may transmit the unlocked state of the power lock portion 1101 a to the power lock portions 1101 b , 1101 c and 1101 d . The controller may be operated through the operation portion 15 .
[0070] Further, the unlocked/locked state of each paper feed cassette 6 a , 6 b , 6 c , 6 d is selected by use of alternative mechanical configuration, such as a link member, or a belt. FIG. 7 shows a configuration in which the unlocked/locked state of each paper feed cassette 6 a , 6 b , 6 c and 6 d is selected by use of link members 1201 . FIG. 8 shows a configuration in which the unlocked/locked state of each paper feed cassette 6 a , 6 b , 6 c , 6 d is selected by use of belts 1301 . In these configurations, the lock gears 51 a , 51 b , 51 c and 51 d are mechanically connected with each other by the link members 1201 or the belts. Accordingly, rotation of the lock gear 51 a is transmitted to the other lock gears 51 b , 51 c and 51 d and gang lock of the paper feed cassette 6 a , 6 b , 6 c and 6 d are realized.
[0071] The transmission gears may be omitted in the embodiments. In this event, adjacent lock gears are designed to be connected to each other directly. Further, various configurations may be adopted for the gang lock unit if it can perform so-called gang locking in which when at least one of paper feed cassettes with a locking portion is brought into the locked state, the other paper feed cassettes having no locking portion are also brought into the locked state automatically.
[0072] Although the embodiments have been described on the case where the paper feed cassette 6 a which is one of the four paper feed cassettes and which is provided in the printer body 1 a is provided with the key hole 14 a and so on as a locking portion, the invention is not limited to such a configuration. For example, the locking portion may be provided not in the printer body 1 a but in one of the paper feed cassette units. Alternatively, a plurality of locking portions may be provided in the paper feed cassette units respectively. The number or assignment of locking portions can be modified variously. However, when the locking portion is provided in the printer body 1 a while no locking portion is provided in any paper feed cassette unit as in the embodiments, the paper feed cassette units can be made to have the same configuration as one another. It can be therefore noted that the configuration in the embodiments is advantageous in terms of manufacturing or selling of the paper feed cassette units.
[0073] Although the paper feed cassettes are provided in the printer body 1 a and the paper feed cassette units 1 b , 1 c and 1 d separate from one another respectively in the embodiments, two or more paper feed cassettes may be provided in the printer body 1 a while no paper feed cassette unit is provided. In this case, at least one of the paper feed cassettes provided in the printer body 1 a is provided with a locking portion.
[0074] In addition, the arrangement of the plurality of paper feed cassettes is not limited to a vertical line as in the embodiments. Paper feed cassettes may be arranged horizontally. Alternatively, a plurality of paper feed cassettes are disposed both vertically and horizontally. The same thing applies not only to the arrangement of a plurality of paper feed cassettes provided in one unit but also to the arrangement of paper feed cassette units.
[0075] Although the locking bar 52 a , 52 b , 52 c , 52 d is made removable to avoid gang locking in the embodiments, the invention is not limited to such a configuration. Gang locking may be avoided by various other means. Alternatively, such a unit capable of avoiding gang locking may be not provided.
[0076] Although the embodiments have been described on the case where the printer fixing bar 201 , 202 provided in the support base 200 for supporting the printer is engaged with a hook provided in a paper feed cassette unit so that the printer can be fixed to the support base concurrently with gang locking of the printer, the invention is not limited to such a configuration. The printer may be fixed to the support base concurrently with gang locking by various other means. Alternatively, such an apparatus fixing unit maybe not provided.
[0077] When paper feed cassette units separate from the printer body are provided removably, the printer body and the paper feed cassette units are fixed to one another concurrently with gang locking by engagement between hooks and hook destinations in the embodiments. The invention is not limited to such a configuration. The body and the units may be fixed by various other means. Alternatively, such a unit fixing unit may be not provided.
[0078] In the embodiments, the hook provided in a paper feed cassette unit having another paper feed cassette unit disposed thereunder serves to fix the units to each other, while the hook provided in a paper feed cassette having no paper feed cassette unit disposed thereunder and being closest to the support base serves to fix the printer to the support base. That is, each hook has different functions in accordance with its disposition. This is advantageous in terms of reduction in number of parts. However, a unit fixing unit and an apparatus fixing unit may be provided separately. For example, another hook may be provided as an apparatus fixing unit.
[0079] While the invention has been described in conjunction with the specific embodiments described above, many equivalent alternatives, modifications and variations may become apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention as set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention. | A paper feeder includes: a first paper feed cassette in which to store a recording medium with a lock state; a locking portion that determines whether to bring the lock state of the first paper feed cassette into the unlocked state or the locked state; a second paper feed cassette in which to store a recording medium, capable of selectively entering an unlocked state and a locked state; and a lock state transmitting portion that transmits the lock state of the first paper feed cassette to the second paper feed cassette to bring the second paper feed cassette into the unlocked state or the locked state in accordance with the lock state of the first paper feed cassette. | 1 |
[0001] This is a continuation and claims priority of application Ser. No. 12/845,326 filed Jul. 28, 2010, that application incorporated by reference in its entirety in this present application.
FIELD OF THE INVENTION
[0002] This invention relates to robotic lawn mowers, and more specifically to a boundary sensing system for a robotic mower.
BACKGROUND OF THE INVENTION
[0003] Robotic mowers may include boundary sensing systems to detect the boundary wire. Boundary sensing systems may detect if the robotic mower is inside or outside the boundary wire. When the robotic mower reaches the boundary wire, a vehicle control unit may prompt the traction drive to stop and/or turn around. A boundary sensing system is needed that also can accurately and reliably determine the distance of a robotic mower to the boundary wire.
SUMMARY OF THE INVENTION
[0004] The present invention provides a robotic mower boundary sensing system with a boundary driving circuit on a charging station transmitting an encoded signal on a boundary wire, a boundary sensor on a robotic mower and including an inductor receiving the encoded signal, and vehicle control unit on the robotic mower receiving the encoded signal from the boundary sensor and decoding the signal and cross correlating the received signal to determine the distance of the boundary sensor from the boundary wire.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is schematic drawing of a robotic mower within a main boundary wire according to a preferred embodiment of the invention.
[0006] FIG. 2 is a block diagram of a boundary sensing system for a robotic mower according to a preferred embodiment of the invention.
[0007] FIG. 3 is a block diagram of an orientation and heading system for a robotic mower that may be used with the boundary sensing system of FIG. 2 .
[0008] FIG. 4 is a block diagram of an improved area coverage system for a robotic mower according to a first embodiment of the invention.
[0009] FIG. 5 is block diagram of an embodiment of a wide area coverage that may be used with the improved area coverage system of FIG. 4 .
[0010] FIG. 6 is a block diagram of an embodiment of a local area coverage that may be used with the improved area coverage system of FIG. 4 .
[0011] FIG. 7 is a block diagram of an embodiment of a boundary following system that may be used according to one embodiment of the invention.
[0012] FIG. 8 is a block diagram of a boundary following system that may be used according to an alternative embodiment of the invention.
[0013] FIG. 9 is a block diagram of a boundary following system for a robotic mower with a single according to another alternative embodiment of the invention.
[0014] FIG. 10 is a block diagram of a stuck detection system for a robotic mower according to a preferred embodiment of the invention.
[0015] FIG. 11 is a schematic diagram of a boundary sensor according to a preferred embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] In one embodiment shown in FIG. 1 , robotic mower 100 may be powered by battery pack 109 that may be charged periodically at charging station 105 . Vehicle control unit 101 may control all of the electronic functions of the robotic mower. For example, vehicle control unit 101 may command a pair of traction motors 110 , 111 to turn traction drive wheels, blade motor 112 to rotate a cutting blade or blades, battery pack 109 , a user interface and various sensors.
[0017] Vehicle control unit 101 may be a printed circuit board assembly that serves as the main control board for the robotic mower. The vehicle control unit may interpret and process information from various sensors, and use that information to control and operate the pair of traction motors to drive the robotic mower over a yard in order to maintain the lawn, and to drive the blade motor. For example, the vehicle control unit may be connected to a number of sensors including one or more boundary sensors 119 , as well as one or more obstacle sensors or accelerometers. The vehicle control unit also may communicate with the battery pack in order to monitor the status of the battery pack to maintain a charge for one or more lithium ion batteries in the battery pack. The vehicle control unit also may be connected to a user interface module including an LCD display along with several indicator lights and key buttons for operator input.
[0018] In one embodiment, the vehicle control unit may include a microcontroller such as an LQFPSTM32F103ZET6 processor from ST Microelectronics. The microcontroller may have 512 kB of internal flash memory and 64 kbytes of internal RAM. The microcontroller may contain an ARM Cortex M3 core, may run at a maximum core clock frequency, and may use an onboard AtoD converter. The vehicle control unit may contain external static random access memory (SRAM) connected to the microcontroller with a 16 bit FSMC bus and have a minimum capacity of 1 Megabit.
[0019] In one embodiment, the vehicle control unit may include three external EEPROM integrated circuits. For example, the EEPROMs may each be 125 kilobyte ICs for a total capacity of 384 kilobytes. The EEPROMs may use and SPI interface to the microcontroller and may be used to store configuration data. The vehicle control unit may use the microcontroller's internal real time clock module.
[0020] In one embodiment, the vehicle control unit may interface and control a blade motor controller to power and control blade motor 112 that drives the cutting blade on the robotic mower. For example, blade motor 112 may be a permanent magnet brushless DC motor, such as the EBM Papst 63.20 BLDC motor having a typical output shaft speed range of about 4000 rpm. The vehicle control unit may have three inputs which receive signals from hall effect rotor position sensors contained in the blade motor, such as Melexis US 2884 Hall effect sensors. The vehicle control unit may sense the speed of the blade motor using feedback from the Hall effect sensors, and may sense the current through the blade motor phases combined.
[0021] In one embodiment, the vehicle control unit may be connected to traction motor controllers for each of the left and right traction motors 110 , 111 . Each traction motor may be a permanent magnet brushless DC motor, such as a EBM Papst 42.20 BLDC motor having a typical output shaft speed range of about 2080 rpm. The vehicle control unit may have three inputs which receive signals from Hall effect rotor position sensors, such as the Melexis US2884 Hall effect sensor contained in each traction motor. The vehicle control unit may sense the speed of each traction motor using a feedback from a hall sensor, and may sense the current through the traction motor phases combined.
[0022] Still referring to FIG. 1 , in one embodiment, robotic mower 100 may operate in a specified area 102 that is surrounded by main or outer boundary wire 103 which may form a loop positioned at or below the ground or turf surface. Additionally, inner wire 104 may be a shorter loop provided within the area of the main boundary wire where charging station 105 is positioned. The main boundary wire and inner wire may be connected to charging station 105 .
[0023] In one embodiment, boundary drive circuit 106 may be contained in charging station 105 , and may drive signals on the main boundary wire and the inner wire. The fundamental frequency of the waveform on the main boundary wire may be about 2 kHz. The robotic mower may have a boundary wire sensor 119 to detect the waveform and provide a signal to the vehicle control unit to indicate the distance of the sensor to the main boundary wire.
[0024] In one embodiment shown in the block diagram of FIG. 2 , the charging station may drive the main boundary wire and inner wire from a single h-bridge device. The h-bridge may drive both boundary wires, but only one of the boundary wires at a time, to minimize power requirements and component costs.
[0025] In one embodiment, the boundary driving circuit may transmit a unique ID on the main or outer boundary wire loop ten times per second in block 201 . In block 203 , the boundary driving circuit may encode the ID with a 4 bit Barker code to improve the signal to noise ratio and reduce susceptibility to noise interference. The resulting 1's and 0's are called chips. A process gain of 6 dB may be achieved with four chips, where process gain is the ratio of chip rate to data rate. In block 205 , the microprocessor may encode the Barker coded ID using Manchester encoding to ensure there always is a line voltage transition for every bit or chip.
[0026] In one embodiment, in block 207 , one or more boundary sensors on the robotic mower may receive the encoded boundary wire magnetic signal, and send the signal to the vehicle control unit. In block 209 , the vehicle control unit may amplify the received signal. In block 211 , the vehicle control unit's analog to digital converter may sample the amplified signal, preferably at a rate of 200 kHz. In block 213 , the vehicle control unit may buffer the sample data for further processing. The boundary wire magnetic signal may be very small and similar in amplitude to the background noise if the robotic mower is a significant distance from the main boundary wire loop. This limits the amount of amplification that can be applied to the signal, and it may be difficult to detect the signal using traditional hardware/software methods.
[0027] In one embodiment, in block 215 , the vehicle control unit may cross correlate the received signal (at the boundary sensor's present position) with a known waveform (at a known distance to the boundary wire) to identify the start bit in the data buffer and determine if the data is inverted, indicating the sensor is outside the main boundary loop, or normal, indicating the sensor is inside the main boundary loop. The peak to peak amplitude of the known waveform may be the theoretical maximum that the boundary sensor and vehicle control unit can receive without distorting the signal. Cross correlation is done by converting the known waveform data and the sampled waveform data from the time domain into the frequency domain. This may be accomplished by running a FFT on the data, multiplying the FFT results together, and then running an inverse FFT on the result of that product.
[0028] In block 217 , the vehicle control unit may decode the Manchester and Barker coding, and verify the ID against the identification stored in non-volatile memory. In block 219 , the vehicle control unit may determine the relative distance of the sensor from the outer boundary wire. The cross correlation function may provide the time lag difference between the known waveform (at a known distance to the boundary wire) and the unknown received sampled waveform (the boundary sensor's distance to the boundary wire). The location in time of the maximum peak value of the lag provides the starting location in time of the transmitted data packet located in the sampled waveform data. The amplitude of the lag is proportional to the difference between the known waveform's maximum amplitude and the received sample data's maximum amplitude. For example, if the known waveform has a maximum peak value of 1.65 volts or 2048 A/D (0.000805 volts per count) counts, and the resulting cross correlation lag value is 360, the peak amplitude of the sampled data is 360*0.00805=0.2898 volts.
[0029] In one embodiment, the robotic mower may have one boundary sensor to indicate proximity of the sensor to the wire. FIG. 11 is a schematic diagram of an embodiment of the electronic circuit of a boundary sensor on the robotic mower. The boundary sensor may include a sense coil L 1 and a circuit to amplify and filter the signal from the sense coil before it is applied to the A/D input of the vehicle control unit. The battery pack on the robotic mower may have a minimum power input voltage of 20V and a maximum power input voltage of 30 v. The vehicle control unit may have a +5V power supply V5P to the boundary sensors, and the vehicle control unit may provide a 2.5V reference Vref to each boundary sensor. The signal range for each sensor may be 0V to 5.25V.
[0030] In one embodiment, sense coil L 1 may be an inductor that detects the magnetic field generated by the current flowing in the main or outer boundary wire and/or inner boundary wire. For example, sensor coil L 1 may be a 100 mH 10% inductor Bournes RL622-104K-RC. The maximum peak voltage of the sense coil L 1 may be approximately 75 mV when the sensor is located six inches from the boundary wire.
[0031] In one embodiment, the boundary sensor circuit may include a quad op amp with transimpedance amplifier U 1 -A, band pass filter U 1 -B, variable gain amplifier U 1 -C, and comparator U 1 -D. For example, the quad op amp may be a National Semiconductor LMV6484IMX Op Amp (Quad). A valid signal from the final stage output of the quad op amp may be greater than about 100 mV.
[0032] In one embodiment, transimpedance amplifier U 1 -A may convert the current induced in sense coil L 1 into a voltage and amplify that voltage. Resistor R 1 may convert the output current from sense coil L 1 into a voltage. The output voltage of the transimpedance amplifier may be equal to the input current multiplied by the feedback resistor R 1 . For example, resistor R 1 may be 100 kΩ. Capacitor C 1 may provide stability to prevent the transimpedance amplifier from oscillating. Oscillation may be the result of capacitance of the input sensor and the op amp itself. For example, C 1 may be a 47 pF 50V 10% C0G ceramic capacitor.
[0033] In one embodiment, band pass filter U 1 -B may provide a second order Sallen-Key high pass filter to cancel noise such as low frequency noise from the traction wheel motors of the robotic mower. Capacitors C 2 and C 3 and resistors R 2 and R 3 may set the corner or roll off frequency of the filter. For example, R 2 and R 3 may be 1 Meg Ohm 1/16 W 1% resistors, and C 2 and C 3 may be 100 pF 50 V 5% C0G ceramic capacitors. The output of the high pass filter may be followed by resistor R 4 and capacitor C 4 , which may perform low pass filtering. For example, R 4 may be a 10.0 k 1/16 W 1% resistor, and C 4 may be a 47 pF 50V 10% C0G ceramic capacitor. Capacitor C 5 may be a decoupling capacitor with a voltage rating high enough for the maximum voltage on the +5V power supply. For example, C 5 may be a 0.1 pF 16V 10% X7R MLC capacitor.
[0034] In one embodiment, the quad op amp also may include variable gain amplifier U 1 -C. Resistors R 5 and R 6 may set the gain of the variable gain amplifier, and resistor R 6 may provide the negative feedback. For example, R 5 may be a 10.0 k, 1/16 W, 1% resistor, and R 6 may be a 100 kΩ, 1/16 W 1% resistor. Dual diode D 1 may automatically reduce the gain when the received signal strength is higher, such as when the robotic mower is very near the boundary wire. If the output voltage of variable gain amplifier U 1 -C is too high, one of the pair of diodes D 1 may conduct and clamp the voltage across resistor R 6 , reducing the gain. As the input voltage to the amplifier increases, a point will be reached where the diodes conduct. Beyond this point the feedback from the output to the inverting input will be equal to the voltage across the diode. For example, D 1 may be an NXP BAV99LT1G high-speed switching dual diode.
[0035] In one embodiment, the boundary sensor circuit also may include unity gain buffer U 2 -A to buffer the output of variable gain amplifier U 1 -C before connection to the vehicle control unit via a wiring harness. For example, unity gain buffer U 2 -A may be a National Semiconductor LM771 op amp. Capacitor C 7 may be a bypass capacitor for unity gain buffer U 2 -A. For example, capacitor C 7 may be a 0.1 pF 16V 10% X7R MLC capacitor.
[0036] In one embodiment, the boundary sensor circuit may include comparator U 1 -D which may form a Schmitt trigger comparator circuit to provide an output that indicates whether or not the received signal strength is great enough to be considered a valid signal. If the received signal is greater than the threshold, the output of the comparator will be high. Resistors R 7 and R 8 may form a voltage divider used to set the threshold for a valid signal, indicating a valid signal instead of noise. For example, R 8 may be a 5.62k, 1/16 W 1% resistor, and R 7 may be a 200Ω 1/16 W 1% resistor. Resistors R 9 and R 10 may configure the hysteresis of the comparator, with R 10 providing the positive feedback. R 9 and R 10 together set the upper and lower thresholds of the Schmitt trigger comparator. For example, R 9 may be a 5.62 k 1/16 W 1% resistor and R 10 may be a 1 Meg Ohm 1/16 W 1% resistor.
[0037] In an alternative embodiment, the robotic mower may have a plurality of boundary sensors 119 , and most preferably three boundary sensors mounted at or near the front of the robotic mower and a fourth boundary sensor mounted at or near the back of the robotic mower. The vehicle control unit may receive input from each of the boundary sensors regarding strength of the signal from the main boundary wire to indicate proximity of the sensor to the wire.
[0038] In the alternative embodiment described in FIG. 3 , the vehicle control unit may use signals from four boundary sensors to determine orientation and heading of the robotic mower with respect to the boundary wire. In block 302 , the vehicle control unit may sign the boundary distance signal from each boundary sensor to indicate if the sensor is inside or outside the main boundary wire. In block 304 , the vehicle control unit calculates Δ 1 as the difference between the distance from the center front sensor to the main boundary wire, compared to the distance from the back sensor to the main boundary wire. In block 306 , the vehicle control unit calculates Δ 4 as the difference between the left front sensor to the main boundary wire, compared to the distance from the right front sensor to the main boundary wire. In block 308 , the vehicle control unit confirms the dimensions between the sensors on the mower based on fixed values stored in memory. For example, these dimensions may include L 1 between the front center and back sensors, and L 2 between the left and right front sensors. In block 310 , the vehicle control unit confirms that the values calculated for Δ 1 and Δ 4 are within the ranges that are possible given the specified dimensions, L 1 and L 2 . In block 312 , the vehicle control unit calculates a pair of angles using trigonometric equations with Δ 1 , Δ 4 , L 1 and L 2 . The angles may be θ 1 =arcsin(Δ 1 /L 1 ) and θ 2 =arccos(Δ 4 /L 2 ).
[0039] In one embodiment, in block 314 , the vehicle control unit determines which of the four possible heading quadrants the robotic mower is in relative to the main boundary wire. For example, if Δ 1 is greater than or equal to 0 and Δ 4 is less than or equal to zero, the heading is in quadrant 1. In block 316 , the vehicle control unit calculates the heading angle of the robotic mower given the heading quadrant from the preceding step. For example, in quadrant 1, the angle θ=360 degrees−arcsin(Δ 1 /L 1 )×180 degrees/π. The angle θ of the mower will be within the range from 0 degrees to 360 degrees. In block 318 , the vehicle control unit may flip the angle for readings outside the main boundary wire.
[0040] In one embodiment, the vehicle control unit may select the type of area coverage used by the robotic mower for mowing within the main boundary wire. Using the steps described below in the block diagram of FIG. 4 , the vehicle control unit may command the robotic mower to switch from one type of area coverage to another without operator intervention and without discontinuing mowing. The vehicle control unit may select the type of area coverage based on input from one or more boundary sensors 119 regarding distance of the robotic mower to the main boundary wire, current draw of electric blade motor 112 that rotates one or more cutting blades, and the type of area coverage used during a specified preceding time period which may be stored in the vehicle control unit memory.
[0041] In one embodiment shown in the block diagram of FIG. 4 , in block 400 the robotic mower may be activated to start area coverage, such as by an operator or by an internal or external timer. The vehicle control unit then may run the routine described in the block diagram about every 40 milliseconds. In block 401 the vehicle control unit may determine if the robotic mower is in the charging station, preferably by checking if the voltage on the charger contacts is within a specified range. If the robotic mower is in the charging station, in block 402 the vehicle control unit may command the traction wheel motors to leave the charging station by rotating in reverse for a specified distance or duration to back up the robotic mower out and away from the charging station, then turn the robotic mower around. The vehicle control unit may determine how much each wheel motor has rotated based on pulse feedback from the Hall effect sensor in each motor. If the vehicle control unit determines the robotic mower is not in the charging station, in block 403 the vehicle control unit may determine if the leave dock instruction is still active. If the leave dock instruction is still active, in block 404 the vehicle control unit may command the wheel motors of the robotic mower to continue executing the leave dock instruction.
[0042] In one embodiment, in block 405 the vehicle control unit may determine if a bump is detected, indicating the robotic mower has contacted an obstacle. Bump detection may be provided to the vehicle control unit by one or more accelerometers attached to the chassis and/or top cover of the robotic mower. The accelerometer may be a three axis accelerometer such as the ST LIS302DL which also may be used to sense lifting and orientation, and may communicate to the microcontroller with a SPI bus at the voltage logic level of the microcontroller. If the accelerometer indicates an obstacle is bumped, in block 406 the vehicle control unit may command both traction motors to reverse direction for a specified distance or duration and then turn the robotic mower around.
[0043] In one embodiment, if no bump is detected, in block 407 the vehicle control unit may determine if a specified coverage such as boundary coverage was executed within a specified preceding time period such as seven days. The vehicle control unit memory may store data on the type of coverage executed for a specified preceding time period. If boundary coverage was not executed during the specified preceding time period, in block 408 the vehicle control unit may command the traction motors to execute boundary coverage. Preferred boundary coverages are described below.
[0044] In one embodiment, if the specified boundary coverage was executed within the preceding time period specified in block 407 , in block 409 the vehicle control unit may determine if the robotic mower is closer to the boundary or perimeter wire than a specified distance, using input from one or more boundary sensors 119 . If the robotic mower is closer than the specified distance, in block 410 the vehicle control unit may command the traction motors to reverse direction for a specified duration and then turn the robotic mower around.
[0045] In one embodiment, if the robotic mower is not closer than the specified distance to the boundary wire, in block 411 the vehicle control unit may determine if the wheel motors are currently executing the reverse and turn around function. If the motors are still in reverse for the prespecified distance or duration, or have not finished turning the robotic mower around, in block 412 the vehicle control unit may command both traction wheel motors to continue the reverse and turn around functions.
[0046] In one embodiment, if the vehicle control unit determines the reverse and turn around function is currently active, in block 413 the vehicle control unit may determine if the blade load is greater than a first predetermined specified value X which indicates uncut grass. Higher current means higher blade load and torque, indicating longer, uncut grass. Lower current, lower blade load and torque, indicates shorter, cut grass. If the blade load is greater than the first value, in block 414 the vehicle control unit may command the traction wheel motors to execute local area coverage. A preferred local area coverage is described below.
[0047] In one embodiment, if the blade load is not greater than the predetermined specified value X, in block 415 the vehicle control unit commands the traction wheel motors traction motors to execute wide area coverage. A preferred wide area coverage is described below.
[0048] In one embodiment, the vehicle control unit may execute wide area coverage by commanding the left and right wheel motors to drive the robotic mower in a straight line until an obstacle or boundary wire is encountered. When the robotic mower encounters the boundary wire or obstacle, the vehicle control unit may command the wheel motors to reverse and back up the mower for a prespecified distance and then turn the robotic mower around, preferably less than 180 degrees, to follow a path that diverges from the preceding forward path. Alternatively, the vehicle control unit may specify and execute other methods of wide area coverage, including but not limited to traveling in arcs instead of straight lines.
[0049] In a preferred embodiment shown in the block diagram of FIG. 5 , wide area coverage may begin executing in block 500 . In block 502 , the vehicle control unit may set the forward ground speed of the traction wheel motors at a nominal speed, and to maintain the same yaw or steering angle (i.e., 0 degrees for a straight path) so that the robotic mower travels in a straight line.
[0050] In one embodiment, in block 504 the vehicle control unit determines if the robotic mower has bumped an obstacle, as indicated by one or more accelerometers, for example. If the robotic mower has detected an obstacle, in block 508 the vehicle control unit may command both traction wheel motors to rotate in reverse to back up at a reduced ground speed, and to maintain the same yaw angle. If the robotic mower has not bumped an obstacle in block 504 , the vehicle control unit may determine if one or more boundary sensors indicate the mower is closer to the main boundary wire than a prespecified threshold distance in block 506 . If one or more boundary sensors indicate the robotic mower is not close to the main boundary wire, the vehicle control unit commands the left and right wheel motors to continue rotating forward as indicated in block 502 . If the boundary sensor(s) indicate the robotic mower is close to the main boundary wire, in block 508 the vehicle control unit may command the wheel motors to rotate in reverse at a reduced ground speed, and to maintain the same yaw angle. In block 510 , the vehicle control unit may determine if the traction wheel motors have rotated in reverse a prespecified or threshold time or distance. If the traction wheel motors have not rotated the prespecified time or distance in reverse, the vehicle control unit may command the motors to continue in reverse as indicated in block 510 .
[0051] In one embodiment, once the traction wheel motors have rotated for the threshold distance or time in reverse, in block 512 the vehicle control unit may set a target yaw angle at a prespecified angle, preferably less than 180 degrees, and command the left and right wheel motors to turn the robotic mower around at a ground speed of zero. In block 514 , the vehicle control unit determines the turn error from the target yaw angle. In block 516 , once the turn angle reaches the target yaw angle, the vehicle control unit may command the traction wheel motors to rotate in forward again at a nominal speed and maintain the same yaw angle (i.e., 0 degrees), as specified in block 502 . If the turn angle has not reached the target yaw angle yet, the vehicle control unit will command the traction wheel motors to continuer turning the robotic mower around, and then calculate the turn error again in block 514 .
[0052] In one embodiment, local area coverage may be a path that spirals outwardly, either clockwise or counterclockwise, from the robotic mower's initial position. Alternatives for local area coverage may include other patterns starting from an initial position of the robotic mower. As shown in the block diagram of FIG. 6 , in block 600 the vehicle control unit begins executing local area coverage. In block 604 , the vehicle control unit may determine the radius from the spiral center, where local area coverage began, to the current location of the robotic mower. When local area coverage begins the radius value is zero, and may be incremented based on the difference in radius between sequential passes of the robotic mower around the spiral. Thus, the radius value is a function of how many degrees the robotic mower has traveled around the spiral, and the spacing of the spiral based on the robotic mower's effective cutting width. In block 606 , the vehicle control unit may determine if the radius is less than a prespecified minimum value. If it is less than the minimum value, in block 608 the vehicle control unit may command the traction wheel motors to rotate at a minimum forward ground speed. In block 610 , the vehicle control unit may determine if the radius is less than an intermediate value. If the radius is less than the intermediate value, in block 612 the vehicle control unit may command the traction wheel motors to rotate at a reduced forward ground speed, which may be greater than the minimum speed. In block 614 , the vehicle control unit may command the traction wheel motors to rotate at a nominal forward ground speed, which may be higher than the reduced speed, if the radius is at least the intermediate value. In block 616 , the vehicle control unit determines the desired change in yaw angle for the sample, which may be a function of the time period between function calls, the ground speed, and the radius. In block 618 , the vehicle control unit may add the desired change in yaw angle to the spiral total. In block 620 , the vehicle control unit may determine the desired yaw angle for the robotic mower, which may be based on the current yaw angle plus the desired change in yaw angle.
[0053] In one embodiment, the robotic mower may execute boundary coverage, or return to the charging station, on a path along or parallel to the boundary wire using the system described in the block diagram of FIG. 7 . The vehicle control unit may use this system based on input from one boundary sensor on the robotic mower regarding strength of the signal from the main boundary wire to indicate proximity of the sensor to the wire. The vehicle control unit may use input from the boundary sensor to direct the traction wheel motors to follow a path along or at a specified distance parallel to the boundary wire.
[0054] As shown in FIG. 7 , in block 700 , the vehicle control unit may command the left and right traction motors to start rotating in forward on a path at a specified distance parallel to the boundary wire. In block 701 , the vehicle control unit compares the input from the boundary sensor to the specified distance, to decide if the robotic mower is too close or too far from the boundary wire. If the boundary sensor indicates it is within the specified distance to the boundary wire, in block 702 the vehicle control unit commands the left and right wheel traction drive motors to continue rotating straight ahead. If the boundary sensor indicates it is too close or too far from the boundary wire, in block 703 the vehicle control unit determines if the error or deviation from the specified distance has decreased, by comparing the boundary sensor input to one or more previous boundary sensor inputs, preferably spanning a time period of at least about one second. If the error has not decreased, in block 704 the vehicle control unit commands the left and right wheel motors to turn the vehicle at a larger acute angle (such as 30 degrees) away from or back toward the boundary wire, depending on whether the robotic mower is too close or too far from the boundary wire. If the error has decreased, in block 705 , the vehicle control unit commands the left and right wheel motors to turn the vehicle at a reduced acute angle (such as 4 degrees) away from or back toward the boundary wire, depending on whether the boundary sensor is too close or too far from the boundary wire.
[0055] In an alternative embodiment, the vehicle control unit may command the robotic mower to execute boundary coverage using one or more patterns along the boundary or perimeter wire. This boundary coverage may use a pattern that minimizes turf damage or rutting along the boundary due to repetitive wear from the robotic mower's traction drive wheels and caster wheels. For example, boundary coverage may use variable traffic patterns such as a zig-zag pattern to shift the wheel tracks each time the robotic mower executes boundary coverage along the boundary or perimeter wire. Other alternatives also may be specified by the robotic mower controller for boundary coverage, including but not limited to sine or square wave patterns along the boundary or perimeter wire.
[0056] In one embodiment, the vehicle control unit may use information received from one or more boundary sensors regarding the distance of the robotic mower to the boundary wire, to alternate the robotic mower's path between driving toward and away from the boundary wire at a specified angle. For example, as shown in FIG. 8 , the vehicle control unit may execute boundary coverage beginning in block 800 . In block 802 , the vehicle control unit may set a flag as a function of the distance between the boundary sensor and the boundary wire. For example, the flag may be set at 0 if the boundary sensor indicates it is within a threshold distance to the boundary wire, or 1 if it is further than the threshold distance. In block 804 , the vehicle control unit may specify the yaw angle of the robotic mower in relation to the main boundary wire at either plus 45 degrees or minus 45 degrees, depending on the flag setting. In block 806 , the vehicle control unit may command the left and right wheel motors to move the robotic mower forward at a reduced forward ground speed. In block 808 , the vehicle control unit may determine if the robotic mower is within a minimum distance to the boundary wire. If the robotic mower is within the minimum distance, the vehicle control unit may reset the flag in block 802 . If not, the vehicle control unit may determine if the robotic mower is farther than a maximum distance from the boundary wire in block 810 . If the robotic mower is further than the maximum distance, the vehicle control unit may reset the flag in block 802 . Otherwise, the vehicle control unit may command the wheel motors to continue rotating forward at the reduced speed, as shown in block 806 . Thus, the vehicle control unit may command the traction motors to toggle back and forth between plus 45 and minus 45 degrees as a function of the robotic mower's distance to the perimeter wire.
[0057] In one embodiment, the robotic mower's path along the boundary wire may change or shift each time it executes boundary coverage. The shift ensures that the same turf is not repeatedly contacted and compacted by the robotic mower's wheels. The shift may occur because the robotic mower will often have a different starting position each time it starts executing boundary coverage. Additionally, a shift may result from changing the boundary coverage pattern by including variables in the vehicle control unit logic such as the minimum and maximum distances used to toggle the desired orientation, or using a different angle other than 45 degrees.
[0058] In one embodiment, the vehicle control unit may vary the distance of the robotic mower's path when the robotic mower executes home finding to return to the charging station. The vehicle control unit may specify a return path that is offset from the main boundary wire, and varies over a range of available paths between a minimum offset and a maximum offset. By varying the offset from the main boundary wire, the traction drive wheels of the robotic mower will not wear or damage the turf along the wire. The minimum and maximum allowable offset from the main boundary wire may be preselected or constant. Alternatively, the offset may be incremented or reduced each time the robotic mower returns to the charging station.
[0059] In one embodiment, as shown in FIG. 9 , the vehicle control unit may execute home finding in block 900 . In block 902 , the vehicle control unit may find the main boundary wire using one or more boundary sensors. In block 904 , the vehicle control unit may select a random variable. Alternatively, in block 906 the vehicle control unit may increment a variable from the last execution of the home finding task. In block 908 , the vehicle control unit may determine the desired offset from the boundary wire based on the random or incremented variable. In block 910 , the vehicle control unit may command the wheel motors to rotate at the nominal forward speed, and at a yaw angle needed to maintain the desired offset. In block 912 , the vehicle control unit determines if the inner loop wire is detected by the boundary sensors. If the inner loop wire is not detected, the vehicle control unit may continue commanding the wheel motors to rotate forward as shown in block 910 . If the inner loop wire is detected, in block 914 the vehicle control unit commands the wheel motors to reduce speed, and sets the yaw angle to orient the robotic mower to enter the charging station.
[0060] In one embodiment, the vehicle control unit memory may record and store the time when an obstacle or boundary wire has been last detected, and may determine the robotic mower is stuck if a prespecified amount of time elapses before the robotic mower encounters an obstacle or boundary wire again. Preferably, an accelerometer or similar device may be used to detect obstacles, and one or more boundary sensors may be used to detected the boundary wire. The timer duration may be prespecified by the operator or as a function of the size of the area to be mowed, obstacle density, vehicle speed and navigation rules. Additionally, the timer duration may be a function of the type of area coverage being executed by the robotic mower.
[0061] In one embodiment, the timer duration may be the product of the expected maximum distance between obstacles or boundaries, and the robotic mower's expected travel speed. The timer duration may be relatively short during boundary coverage because the vehicle control unit expects to encounter the boundary again after traveling only a short distance. The timer duration for wide area coverage may be determined from the maximum span between opposite boundaries if the robotic mower travels in a straight line.
[0062] In one embodiment, as shown in FIG. 10 , the vehicle control unit may execute stuck detection in block 1000 . In block 1002 , the vehicle control unit may set a timer based on maximum distance and mower speed. In block 1004 , the vehicle control unit may determine if an obstacle or boundary wire is detected by an accelerometer or boundary sensor. If an obstacle or boundary wire is detected, in block 1006 the vehicle control unit may command the robotic mower to reverse and turn around, and then reset the timer again in block 1002 . If an obstacle or boundary wire is not detected, in block 1008 the vehicle control unit may determine if the timer exceeds a specified maximum time. If the timer does not exceed the specified maximum, the vehicle control unit may resume checking if an obstacle or boundary wire is detected in block 1004 . If the specified maximum time is exceeded, in block 1010 the vehicle control unit may execute a stuck vehicle task to safely move or stop the robotic mower.
[0063] Having described the preferred embodiment, it will become apparent that various modifications can be made without departing from the scope of the invention as defined in the accompanying claims. | A robotic mower boundary sensing system includes a boundary driving circuit on a charging station transmitting an encoded signal on a boundary wire, a boundary sensor on a robotic mower and including an inductor receiving the encoded signal, and a vehicle control unit on the robotic mower receiving the encoded signal from the boundary sensor and decoding the signal and cross correlating the received signal to determine the distance of the boundary sensor from the boundary wire. | 8 |
BACKGROUND OF THE DISCLOSURE
[0001] This disclosure relates to saving energy supplied to a clothes dryer, and more particularly relates to methods to improve clothes dryer energy usage while preferably using the same components or hardware found in typical commercially available clothes dryers and also to novel apparatus for enhancing dryer efficiency. It will be appreciated that the disclosure may also find application in a combination washer/dryer apparatus, or by selectively using one or various ones of the different features to be described below.
[0002] Appliances for drying articles such as clothes dryers are generally known in the art. Various ways of using heat energy for drying wet clothes in a clothes dryer are also known. For example, a user or consumer may set a predetermined drying time for drying the clothes. This requires the user to estimate the drying time and generally results in the clothing articles being over-heated or under-heated. Selection of an unnecessarily long drying time results in over-heating the clothing articles, higher energy consumption, and the potential for damaging the clothes. Selection of too short a drying time results in the user needing to select a new drying time and subsequently monitor the dryness of the clothes through one or more additional drying periods.
[0003] Other models of clothes dryers employ sensors and associated controllers that receive sensor signals and predict a moisture content and degree of dryness in the articles. For example, a temperature sensor or humidity sensor provides appropriate signals to the controller and in response to the input data, the controller predicts a percentage of moisture content and a degree of dryness of the clothing articles. Commonly-owned U.S. Pat. No. 5,899,005 is generally representative of such a clothes dryer and associated process.
[0004] Another clothes dryer and associated method stores historical data in a memory. An initial drying time estimate is calculated, and the final time estimate re-calculated based on input time and moisture parameters from one or more sensors, which are then periodically compared to the estimates stored in the memory until such time as the drying cycle is terminated. For example, U.S. Pat. No. 7,478,486 is also commonly-owned by the assignee of the present application and representative of such an arrangement.
[0005] There is an ever-increasing desire to save energy in association with operating appliances and particularly for a clothes dryer. The clothes dryers at present are able to give complete drying performance with the help of various sensors and controls as noted above. However, by design both airflow rate and drum inlet air temperature are maintained constant. As a result, the supply of energy can be either more or less than actually required depending on different stages of the clothes drying process. Energy savings in known units is typically achieved by regulating the supply to the heater or by not allowing the clothes to over-heat with the assistance of controls and sensors. However, the goal of known arrangements is slightly different, i.e., to achieve complete drying without any clothing over-heat. These arrangements, however, are not believed to sufficiently save energy and there is a perceived need for improvement.
[0006] Thus, a need exists for obtaining similar drying performance with less energy consumption, and preferably using many of the same components or hardware to achieve these goals.
SUMMARY OF THE DISCLOSURE
[0007] An exemplary method of drying wet clothes includes dividing a drying cycle into at least three drying periods, including a preheating stage, a latent heat transfer stage, and a sensible heat transfer stage. The method further varies air residence time in at least one of the stages relative to another stage by varying the drying air flow rate and drum inlet air temperatures.
[0008] The varying step includes providing a low or first airflow rate in the preheating stage at an elevated air inlet temperature, providing an increased or second airflow in the latent heat transfer stage that is greater than the first airflow rate, and at a lower air inlet temperature, and increasing the airflow rate to a greatest or third airflow rate, and at a lowest air inlet temperature.
[0009] Alternatively, airflow rate may be higher in the sensible or third heat transfer stage than in the latent heat transfer stage.
[0010] A low airflow may also be provided just prior to termination of the drying cycle.
[0011] In one exemplary embodiment, the air inlet temperature is approximately 290° F. at an airflow rate of approximately 90 CFM (cubic feet per minute) in the preheating stage, the temperature is reduced to approximately 260° F. at an airflow rate of approximately 140 CFM in the latent heat transfer stage, and the air inlet temperature reduced to approximately 220° F. at about 190 CFM in the sensible heat transfer stage.
[0012] The process may include introducing air from an external warm air source, such as an attic or warm outside ambient air.
[0013] An exhaust air recovery assembly includes an exhaust passage that receives air from a drum of the associated dryer and directs the air to an associated outside vent. A recirculation passage receives air from the associated dryer housing, circulates the air about the exhaust passage, and directs the air toward a heater intake of the associated dryer.
[0014] A controller may be further included for varying amounts of the air re-circulated in the associated dryer housing.
[0015] A primary advantage of the present disclosure is reducing energy consumption.
[0016] Another advantage is saving energy supplied to a clothes dryer by changing the air residence time and inlet air temperatures in the dryer drum at different stages of the clothes drying process.
[0017] Still other benefits and advantages may be achieved in accordance with the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of a clothes dryer as used in the present disclosure.
[0019] FIG. 2 is a graph of a typical drying cycle.
[0020] FIG. 3 is a graphical comparison of drum inlet air temperatures for normal and proposed cycles.
[0021] FIG. 4 is a graphical comparison of drum outlet air temperatures for normal and proposed cycles.
[0022] FIG. 5 is a table of various characteristics illustrating an energy savings of approximately 16.61%.
[0023] FIG. 6 is a graphical representation of typical normal operation of a dryer using 5400 watts of heater power.
[0024] FIG. 7 is a graphical representation similar to FIG. 6 using a heater power of only 2700 watts.
[0025] FIG. 8 is a graphical representation of an alternative drying cycle in which the heater power is curtailed from 5400 watts to 2700 watts part way through the cycle.
[0026] FIG. 9 is graphical representation of yet another alternative where heater power is stepped down in increments from 5400 watts to 2700 watts.
[0027] FIG. 10 is a schematic representation of alternative sources of warm air to reduce energy costs.
[0028] FIG. 11 is a perspective view of an exhaust air heat recovery assembly for use with a dryer.
[0029] FIG. 12 is an enlarged cross-sectional view through a heat exchange component used in FIG. 11 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Turning first to FIG. 1 , a clothes dryer 110 includes a cabinet or main housing 112 having a first or front panel 114 , a second or rear panel 116 , and a pair of third and fourth, or side, panels 118 , 120 disposed in spaced relation from each other by the front and rear panels, a fifth or bottom panel 122 , and a sixth or top cover 124 . Within the housing 112 is a drum or container 126 mounted for rotation around an axis, shown here as a substantially horizontal axis HA. Motor 144 rotates the drum about the horizontal axis through a drive means such as pulley 146 and belt 148 . The drum is preferably generally cylindrical in shape, and typically has an imperforate outer cylindrical wall 150 and a front flange or wall 160 that has an opening 162 to the drum. Clothing articles or other fabrics are loaded into the drum 126 through the opening 162 . A plurality of tumbling ribs (not shown) are usually provided within the drum 126 to lift the articles and allow the articles to tumble back toward the bottom of the drum as the drum rotates. The drum includes a rear wall 170 rotatably supported within the main housing 112 by a suitable fixed bearing. The rear wall 170 includes a plurality of openings or holes 172 that receive hot air that has been heated by a heater, such as a combustion chamber 174 and a rear duct 176 . The combustion chamber 174 receives ambient air via an inlet 178 . Although the clothes dryer shown in FIG. 1 is a gas dryer, it could just well be an electric dryer without the combustion chamber 174 and the rear duct 176 . Instead in an electric clothes dryer, the air is heated by an electric heating element or heater. Heated air is drawn from the drum by a blower fan 180 which is also advantageously driven by the motor 144 . The air passes through a screen filter 182 which traps lint particles in a manner known in the art. As the air passes through the screen filter 182 , it enters a trap duct seal 184 and is passed out of the clothes dryer through an exhaust duct 186 . After the clothing articles have been dried, they are removed from the drum via the opening 162 .
[0031] A temperature sensor 190 and a wetness sensor 192 are often used to predict moisture content and degree of dryness of the clothing articles in the container. The temperature sensor 190 senses the temperature of the heated air passing through the screen filter, for example, while the wetness sensor 192 senses the wetness of the clothes in the drum, for example. The temperature sensor may be a commercially available sensor such as an Omega Thermocouple-type K, and the wetness sensor may be a commercial off-the-shelf item such as a Parametrics HT-119, although such commercially available components are representative only and one skilled in the art will appreciate that other components that serve these purposes could be used without departing from the scope and intent of the present disclosure. The temperature and wetness sensors provide signal representations of the temperature of the heated air, and the wetness of the clothes in the drum, respectively, to a controller 194 . The controller 194 is responsive to the temperature sensor and the wetness sensor and, as described below, the controller may then alter operation of the dryer in various ways to save energy over known arrangements (including varying the temperature or flow rate of the air into the drum, varying amounts of re-circulated air, etc.).
[0032] It will also be appreciated that although the following results are taken from an electric dryer, i.e., an electric heating element, the concept would also be equally applicable to a gas dryer, or combination gas/electric dryer without departing from the principles of the present disclosure. The clothes dryers, at present are able to give complete drying performance, with the help of various sensors/controls. However, in the present process, both air flow rate and drum inlet air temperature are maintained constant, by design. Due to this phenomenon, the supply of energy could be either more or less than actually required, depending on different stages of the clothes drying process and hence giving a scope for optimizing energy consumption. This disclosure of varying the air flow rate and drum inlet air temperature, at different stages of the clothes drying process, will give the similar drying performance, with less energy consumption.
[0033] An electric clothes dryer uses hot air, heated by heater and circulated by a blower, for drying clothes. Water in the wet clothes is removed due to a gradient in partial pressures of water vapor between the hot air entering the dryer drum and the air layer adjacent to wet clothes. The higher the wet cloth temperature, the higher the partial pressure gradient and the higher the partial pressure gradient, the more water removal rate from the clothes. Also, there will be two modes of heat transfer between the hot air and the wet clothes; one is the sensible heat transfer from hot air to wet clothes and the other is latent heat of vaporization that is taken from wet clothes. Based on the net effect of these two modes of heat transfer, the clothes temperature will either increase or remain unchanged.
[0034] A typical clothes drying process can be divided into three zones, namely a preheating zone, a latent heat transfer zone and a sensible heat transfer zone (see FIGS. 3 and 4 ). During the preheating zone, wet clothes take the heat from the hot air and the temperature of the clothes increases, as the sensible heat transferred from hot air will be more than the latent heat of vaporization. The temperature of wet clothes will increase to reach a plateau (see FIG. 4 ) and the latent heat transfer zone starts. During this zone, the sensible heat transferred from hot air and the latent heat of vaporization will be very close and hence, the wet clothes temperature will remain more or less constant. Once the water in the wet clothes reduces below certain levels, again the sensible heat transferred from hot air will be more than the latent heat of vaporization and hence the temperature of clothes start increasing, until the hot air supply is stopped.
[0035] This disclosure is about supplying air for different zones (see FIGS. 3 and 4 ), for example:
[0000] 1) Preheating zone: higher inlet air temperature (290° F.) at lower air flow rate (90 CFM), so that the clothes temperature can increase faster;
2) Latent Heat Transfer zone: slightly lower inlet air temperature (260° F.) and higher airflow rates (140 CFM) than the preheating zone, so that more heat can be transferred without any increase in clothes temperature and hence no damage to the clothes; and
3) Sensible heat Zone: the lowest inlet air temperature (220° F.), at the highest air flow rates (190 CFM), to ensure that moisture is driven out and the clothes temperature will not increase unnecessarily.
[0036] For a given drum volume and cloth load, the air residence time is a function of the airflow rate into the drum. Generally speaking, by varying the airflow rate and the inlet air temperature during different stages of the drying cycle, an energy savings of up to sixteen percent (16%) can be achieved for similar drying performance. As shown in FIG. 2 , drum inlet and outlet temperatures (in degrees Fahrenheit) are graphed relative to time (in minutes) where the temperature and relative humidity are monitored in a typical drying cycle. In such a drying cycle, drum inlet air temperature does not change significantly once it reaches a peak of approximately two hundred forty degrees (240°) F. as represented by plot 200 . As will be appreciated, this occurs at approximately fifteen minutes after beginning the drying cycle, and continues through until the heat source is de-energized as shown in FIG. 2 , at approximately forty-five minutes, at which time the inlet temperature drops dramatically between forty-five and fifty minutes. The drum outlet air temperature 202 increases to approximately one hundred degrees (100°) F. and remains unchanged for a significant period of time, e.g., between about five minutes to about twenty-five minutes into the cycle, and then begins to steadily increase to approximately one hundred thirty degrees (130°) F. about forty-five minutes into the cycle. At the end of the dryer cycle, i.e., between approximately forty-five and fifty minutes as shown in the example of FIG. 2 , the drum outlet air temperature then decreases. In FIG. 2 , the dry cycle is a time controlled dry cycle and thereby automatically terminated at the end of the time period, although it will be appreciated that the dry cycle could be based on the sensed outlet temperature increasing to the level of the inlet air temperature and then terminated.
[0037] The rate of heat transfer between hot air and wet clothes can be improved in one of two ways, by increasing the temperature of the entering air, or by increasing the air residence time. Increasing the temperature of entering air has the limitation that clothes are potentially damaged if the temperature reaches an overheat condition. Increasing the air residence time has the potential to improve the rate of heat transfer while avoiding this limitation. For a given drum volume and load of clothes, air residence time can be increased by reducing airflow rate into the drum. Hot air entering the drum of the dryer transfers heat to the wet clothes and carries the water vapor along with it. During an initial part of the drying cycle, water in the wet clothes absorbs more heat from the hot air without much increase in the temperature of the clothes. Increasing the air residence time during this part of the drying cycle results in an increase in the rate of heat transfer between the hot air and the water in the wet clothes. Hence, energy supplied to heat the air is reduced as the airflow rate is reduced.
[0038] Referring now to FIGS. 3 & 4 , a clothes drying cycle can be divided into three relatively distinct divisions or zones, namely a preheating zone 220 , a latent heat zone 222 , and a sensible heat zone 224 . During the preheating zone, initially heat from the heated inlet air is used to heat the damp clothes and the drum that contains them. As the clothes become warmer less heat is absorbed and the sensed temperature of the inlet air increases until the air temperature reaches approximately the temperature of the latent heat of vaporization for the moisture remaining in the clothes, at which level the sensed inlet air temperature reaches a temporary plateau. During this plateau period, referred to as the latent heat zone, moisture continues to be removed from the clothes until a point is reached where the heat available from the inlet air exceeds that absorbed as latent heat of vaporization and the sensed air temperature begins to gradually increase. This occurrence marks the transition from the latent heat zone to the sensible heat zone. In the typical dry cycle illustrated by plot 230 , the preheat zone comprises approximately the first fifteen minutes of the dry cycle, the latent heat zone comprises approximately the next 10 minutes of the dry cycle and the sensible heat zone comprises the balance of the dry cycle. Given this characteristic nature of the dry cycle further modifications relative to the typical dry cycle can be made that reduce the energy consumption. For example, rather than maintaining a constant airflow rate and drum inlet air temperature as employed in a typical drying cycle, to achieve energy savings, varying airflow rates and air entry temperatures over various portions of the entire drying cycle results in energy savings. As shown in the graph of FIG. 4 , plot 230 is representative of a typical or normal drum inlet air temperature that is brought up to approximately two hundred forty degrees (240°) F. in the preheating zone 220 and remains at around two hundred forty degrees (240°) F. through the latent heat zone 222 and sensible heat zone 224 before decreasing at the end of the cycle. Plot 232 represents a drying cycle in which the airflow and drum inlet air temperatures are altered throughout the three distinct zones to result in further energy savings. In this exemplary embodiment the drum inlet air is heated to an elevated temperature of approximately two hundred ninety degrees (290°) F. during a first or preheat portion of the dry cycle (the preheat zone 220 ) and a first airflow rate of approximately ninety (90) CFM is implemented which is less half the typical rate of 190 CFM while in this preheat zone 220 . In this exemplary embodiment, the preheat zone comprises approximately the first fifteen minutes of the drying cycle. Through testing, it was determined that the dryer chassis, drum and other metal components need to be heated before modulating the airflow could be beneficial and this was determined to occur at about fifteen minutes in testing, although it is recognized that under other conditions, a different time period may be used.
[0039] In the latent heat zone 222 , which comprises approximately the next ten minutes of the drying cycle, the drum inlet air temperature is reduced to a second predetermined temperature level of approximately two hundred sixty degrees (260°) F. in this embodiment, while the airflow rate is increased to a second predetermined rate of approximately one hundred forty (140) CFM. The controlled reduction in sensed inlet air temperature is time based for this example but could be incorporated in the dryer control software as a look-up table depending on cycle selection, load size and initial moisture content. The ten minute period is again selected through experimental data for this example (with recognition that this time period may be different under different conditions). The time intervals would be different for different loads and initial moisture contents. Maximizing the humidity in the exit air is the goal. As the temperatures in the clothes load increases, the capacity of carrying moisture also increases. The rationale is that the airflow is reduced hence increasing the temperature and increasing moisture content of the exit air. Removing the air more rapidly at the point of high moisture content helps keep the total dry time down due to not tripping the thermostats too early.
[0040] In the sensible heat zone 224 of FIG. 3 , the drum inlet air temperature is further reduced to a third pre-determined temperature (approximately two hundred twenty five degrees) (225° F. in this embodiment) and the air flow rate is still further increased to a third pre-determined rate (approximately one hundred ninety (190) CFM in the exemplary embodiment). This lower air temperature, at a higher airflow rate, insures that moisture is driven out and that the clothing temperature will not increase unnecessarily.
[0041] The drum outlet air temperature is illustrated in FIG. 4 . In a typical drying process, the drum outlet air temperature begins to increase approximately twenty-five minutes into the cycle. It is determined that this may cause unnecessary wasting of heat energy. This is represented by the plot 240 in FIG. 4 . As a result of the control implemented in the embodiment of FIGS. 3 and 4 , the drum outlet air temperature begins to increase after approximately the thirty-fifth minute. This, of course, evidences a savings of heat energy. The plot illustrated at 242 in FIG. 4 suggests that the air temperature reaches one hundred degrees) (100° F. faster in the preheating zone with less energy supply when compared to the typical operating cycle. The plots 240 and 242 of FIG. 4 represent outlet temperatures that result from operating the dryer in a manner, which produces the inlet temperature plots 230 and 232 of FIG. 3 .
[0042] The tabulated test results are shown in FIG. 5 which compares results 250 of a normal or typical drying cycle, where the airflow rate and power input to heater are constant over the entire cycle, with results 252 of proposed variations of air inlet temperature and airflow rate as described above in connection with FIGS. 3 and 4 . A substantially comparable relative moisture content is achieved at the end of a timed drying cycle (total of fifty minutes in the exemplary tests), with a significant energy reduction measured on an electric heater of approximately 0.5 kilowatt hours or an estimated energy savings of approximately 16.61% by implementing the variations in air inlet temperature and airflow rate. Thus, energy savings by varying both the airflow rate and the drum inlet air temperature as shown in the tabulated results is achieved without any additional hardware required for the clothes dryer and by simply modifying the algorithm used by the microcontroller to control drum inlet air temperature and airflow rate. It will also be appreciated that this energy savings feature can be used in a stand-alone clothes dryer or also implemented in a washer-dryer combination machine. With no real increase in drying time, the consumer can be provided the option of a significant energy savings by implementing these features. Feedback from the sensors as fed to the microcontroller allows for required changes in operation of the blower and heater coil to alter the airflow rate and drum inlet air temperature, respectively.
[0043] FIGS. 6-9 are graphical representations of still other methods to improve the energy usage associated with clothes dryers. As represented in FIG. 6 , a typical drying operation, which serves as a base-line for comparison purposes, may employ an electrical heater that is supplied with a constant heater power of five thousand four hundred (5400) watts (plot 260 ). This correlates to a dryer inlet air temperature of approximately two hundred forty degrees) (240° F. as represented by plot 262 . The drum outlet temperature, represented by plot 264 , is generally constant over much of the dryer operation and then increases from about ninety degrees (90°) F. to approximately one hundred fifty degrees (150°) F. toward the end of the timed cycle. The relative moisture content is shown to decrease over the drying cycle as evidenced by plot 266 .
[0044] In one arrangement, the heater power is cut in half, i.e., to approximately two thousand seven hundred (2700) watts as evidenced by graph 280 in FIG. 7 . The inlet drum air temperature is still maintained at approximately two hundred forty degrees (240°) F. (plot 282 ), the drum outlet air temperature remains substantially the same (plot 284 ), and the relative moisture content varies slightly over the same time period as represented by plot 286 . Thus, although the relative moisture content curve is slightly different in FIG. 7 than in FIG. 6 , it ultimately reaches approximately the same final level over the same time period and yet the dryer only uses half the heater power at two thousand seven hundred (2700) watts.
[0045] A variation on the theme is shown in FIG. 8 , where heater power is supplied at the higher wattage level, five thousand four hundred (5400) watts for a predetermined period of the time (about one-half the time period) and then changed to the reduced heater power level of two thousand seven hundred (2700) watts over approximately the last one-half portion of the dryer cycle (plot 290 ). Once again, the drum inlet air temperature is at approximately two hundred forty degrees (240°) F., as evidenced by plot 292 in FIG. 8 , and the outlet air temperature from the drum ranges from approximately ninety degrees (90°) F. to an end value of approximately one hundred forty (140°) F. as represented by plot 294 . The relative moisture content also decreases over time, i.e., the clothes dry in response to the heated air and airflow, and the curve is more akin to the relative moisture content curve 286 of FIG. 7 , ultimately reaching what would be deemed a “dry clothes” at the end of the cycle (plot 296 ).
[0046] Still another arrangement is to reduce the inlet air drum temperature by periodically stepping-down the input power as represented in plot line 300 in FIG. 9 . The initial wattage is approximately five thousand four hundred (5400) watts, and then reduced by approximately one-quarter about one-third of the way through the cycle, and reduced another one-quarter to the two thousand seven hundred (2700) watt level two-thirds of the way through the cycle. As is evident, the corresponding drum inlet air temperature plot 302 tracks the periodic reduction in the heater power, beginning at a temperature of approximately two hundred forty degrees (240°) F., and reducing to a level around two hundred twenty five degrees (225°) F. approximately one-third of the way through the cycle, and further reducing to about two hundred degrees (200°) F. for approximately the last third of the drying cycle. The inlet air temperatures in FIGS. 6-8 stay constant with varying heater wattage due to non-fluctuating or constant inlet air thermistor set points (plot 262 in FIG. 6 , plot 282 in FIG. 7 and plot 292 in FIG. 8 ). In FIG. 9 , however, the inlet air thermistor set points fluctuate (see plot 302 in FIG. 9 ). The outlet air temperature from the drum shown in plot 304 , on the other hand, slowly increases from about ninety degrees (90°) F. to approximately one hundred twenty degrees (120°) F. over this same time period, while the relative moisture content (plot 306 ) drops from the original level to a “dry” level by the termination of the drying cycle. Once again, the reduction in heater power, even if the airflow is maintained the same, will result in a significant energy savings, and may be reduced even more depending on how airflow is altered under such an arrangement.
[0047] Each of FIGS. 7-9 demonstrate that reducing the amount of electrical heater power results in energy savings over what is deemed a typical drying cycle as exhibited in FIG. 6 of a constant heater power over the entire dryer cycle time period. By monitoring the outlet dryer temperature and/or the dampness of the load, i.e., by sensor rods contacting the clothes, the heater power can be reduced as the outlet temperature increases. This will, in turn, cause less wasted heat and save energy over the drying cycle. Monitoring either the outlet dryer temperature or the dampness of the load via the sensor rods also permits the inlet thermistor to be set in response thereto to reduce the heater power, or the fan speed, or both. Again, this will cause less wasted heat over the cycle and result in an energy savings. The controller monitors outlet and inlet air temperatures and, in response, reacts with different wattage outputs.
[0048] FIG. 10 represents another potential energy savings feature. Particularly, a fan 320 is located in the attic 322 that includes an attic vent 324 , or possibly outside the building or home. Warm air is drawn through air filter 326 disposed in the attic into the dryer housing from an outside source such as the attic or outside air. This eliminates the need to pull warm air from inside the house to the dryer. Air from the dryer is then directed outside the house. This arrangement will also reduce the energy needed to heat the air from ambient temperature. Such an energy savings kit would include, for example, a variable speed fan, pressure switches 330 , temperature sensors 332 , and associated duct work 334 . The remotely located fan will be controlled by the pressure switch and the dryer controller uses the remote temperature sensor as an input to determine whether air should be blown into the cabinet from the remote outside source. It will also be appreciated that taking heat out of the attic will result in an energy savings for the house, not just an improvement in savings associated with reduced dryer energy. For example, in the summer months, the air conditioner load could be reduced with a lower attic temperature.
[0049] FIGS. 11 and 12 illustrate a multi-tube transition duct assembly 340 that may be used to efficiently transfer heat away from internal ducting, which can then be reintroduced into the inlet of the dryer. More particularly, the heat recovery assembly 340 may include a module or housing 342 that receives a multi-tube transition duct 344 associated with the blower 346 which receives exhaust air from the dryer. By this arrangement, air vented from the dryer reaches the blower 346 at blower inlet 348 , and is then directed into dryer passages or tubes 350 that direct the elevated temperature air in the passages 350 toward outside vent 352 . The individual passages 350 are received within a shell 354 having an inlet 356 that permits air from inside the dryer cabinet, for example at a temperature of approximately eighty (80°) F., to pass over external surfaces of the individual dryer passages 350 toward the outlet 358 and includes a blower 360 driven by a motor (not shown) to draw the air into the inlet 356 of the shell and across the dryer passages where the heat exchange results in an increase of air temperature of approximately twenty degrees (20°) F. to about one hundred degrees (100°) F., where the heat recovered air is then directed toward the heater intake 362 of the dryer. As will be appreciated, since the heat exchange takes place across the surface of the dryer tubes, residual condensate may collect at drain tube 370 and directed toward a drain, while the remaining exhaust air is directed toward the outside vent as represented at 352.
[0050] The disclosure has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. For example, it will be appreciated that the particular temperature ranges, time periods, heater power levels, air flow rates, relative moisture contents, etc. may vary from those numerical values used in the described embodiments without departing from the scope and intent of the energy savings features. It is intended that the disclosure be construed as including all such modifications and alterations. | Energy efficiencies are achieved in a dryer or washer/dryer by selectively varying temperature ranges, time periods, heater power levels, and air flow rates. Efficiency improvements on the order of 16% were obtained over typical constant power, constant temperature, timed drying cycles by varying one or more of these parameters. Efficiencies can also be improved by drawing air from alternative warm sources such as an attic or warm external environment, or by heat recovery from dryer exhaust passages. | 3 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/973,885, filed Apr. 2, 2014, the disclosure and teachings of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a system and method for determining levels of a substance in a patient's body based on the patient's skin coloration. The invention provides a device such as a smartphone coupled to a light source and optical detector that receives data regarding the skin coloration and uses that data to calculate the concentration of the substance in the body.
BACKGROUND OF THE INVENTION
[0003] During the first week of life, most newborns develop a visible yellow coloring of the skin—jaundice—due to an increase in a chemical called bilirubin. Moderate levels of bilirubin are benign, but very high levels—called severe hyperbilirubinemia—can cause a condition called kernicterus, which is a severe and life-long severe form of athetoid cerebral palsy with hearing dysfunction, dental-enamel dysplasia, and intellectual handicaps.
[0004] In order to reduce the likelihood of kernicterus, the American Academy of Pediatrics recommends that all infants be evaluated for jaundice with systematic measurement of bilirubin, and treated according to specific algorithms. Measurement of bilirubin levels is most accurately done by chemical analysis of a blood specimen, but hand-held instruments have also been developed to estimate bilirubin levels by optical measurement of subcutaneous skin coloration. Because of prohibitively high cost, such instruments are only practical in a hospital setting, rather than in a doctor's office or for home application. There are no currently available technologies for estimating the bilirubin level at a price level consistent with use in a doctor's office or in the home. Accordingly, it is often necessary for infants to return to the hospital to have the bilirubin level checked.
[0005] The present invention described herein builds upon the functions of smartphones, tablets, computers, digital cameras connected to computers and other home devices to give parents and clinicians a noninvasive, rapid, and relatively easy to implement tool to monitor bilirubin through changes in the skin color of the infant. The invention further provides an affordable method of estimating bilirubin levels in the home or doctor's office that will simplify and vastly improve the outpatient management of hyperbilirubinemia in babies during the first week at home.
DESCRIPTION OF PRIOR ART
[0006] To the Applicant's knowledge, no prior art exists that provides a system or method for determining the levels of a substance in a patient's body based on subcutaneous skin coloration using a smartphone, tablet, personal computer, digital camera, or other personal device.
SUMMARY OF THE INVENTION
[0007] The present invention provides a system and method for determining bilirubin levels in an individual based on subcutaneous skin coloration using a smartphone or other personal device and an attached ancillary apparatus. The device, such as a smartphone or tablet, is capable of storing and running software. The device is also coupled to both a camera and light source to obtain data regarding the skin's subcutaneous coloration. Software is installed on the device to control the light source and calculate bilirubin levels in the individual based on the input received from the camera.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a diagram depicting the system architecture of the preferred embodiment.
[0009] FIG. 2A provides a top perspective view of the ancillary device in a smartphone embodiment having one or more physical filters or light-transmitting pathways as well as safety features and utilizing the smartphone's on-board flash and the on-board camera to capture an image and an ancillary module that has incorporated that prevent misuse;
[0010] FIG. 2B provides a cross sectional view along section A-A of the ancillary device provided in FIG. 2A ;
[0011] FIG. 2C provides a angled elevational view of the ancillary device provided in FIG. 2A ;
[0012] FIG. 2D provides a top perspective view of the ancillary device in an alternative smartphone embodiment having one or more physical filters or light-transmitting pathways as well as safety features and utilizing the smartphone's on-board flash and the on-board camera to capture an image and an ancillary module that has incorporated that prevent misuse;
[0013] FIG. 2E provides a cross sectional view along section D-D of the ancillary device provided in FIG. 2D ;
[0014] FIG. 2F provides a angled elevational view of the ancillary device provided in FIG. 2D ;
[0015] FIG. 3A provides a graph disclosing the distribution of the light source on the Nokia Lumia 1020 smartphone showing the emission of light at both the 450 nm and 550 nm wavelengths for use with the present invention;
[0016] FIG. 3B provides a graph disclosing the distribution of the light source on the iPhone 5s smartphone showing the emission of light at both the 450 nm and 550 nm wavelengths for use with the present invention;
[0017] FIG. 3C provides a graph disclosing the distribution of the light source on the Samsung Galaxy S4 Mini smartphones showing the emission of light at both the 450 nm and 550 nm wavelengths for use with the present invention;
[0018] FIG. 4A depicts a side view of an embodiment of the ancillary module disclosed in FIG. 2 attached to the smartphone;
[0019] FIG. 4B depicts a rear view of a smartphone attached to an embodiment of the ancillary module disclosed in FIGS. 2A-2E ;
[0020] FIG. 4C depicts a detailed cross sectional view of section C-C of the embodiment of the ancillary module disclosed in FIG. 4B ;
[0021] FIG. 4D depicts a detailed cross sectional view of section D-D of the embodiment of the ancillary module disclosed in FIG. 4B ;
[0022] FIG. 4E depicts a detailed view of section E shown in FIG. 4D ;
[0023] FIG. 5A is a portion of a flowchart illustrating the functions of the software of the preferred embodiment.
[0024] FIG. 5B is a portion of a flowchart continuing from FIG. 5A illustrating the functions of the software of the preferred embodiment.
[0025] FIG. 5C is a portion of a flowchart continuing from FIGS. 5A and 5B illustrating the functions of the software of the preferred embodiment.
DETAILED DESCRIPTION
[0026] A detailed description will now be given of the invention with reference to the attached FIGS. 1-5 . It should be understood that these Figures are exemplary in nature and in no way serve to limit the scope of the invention.
[0027] The present invention describes a system and method for measuring the level of bilirubin in a patient based on subcutaneous skin coloration by using a known light source to generate reflected light that is then recorded and analyzed. This system and method utilizes optical imaging methods for obtaining tissue properties based on the emissions of known light sources 60 , such as those demonstrated in FIGS. 3A-3C , and the sensing of light refraction 70 and 80 caused by tissue interactions. The difference in the optical densities found in the various pathways allows the effect of the dermal layers to be removed through analysis to obtain values for the transcutaneous bilirubin in the subcutaneous layer. At the highest level the invention consists of a user 10 , a patient 50 , hardware 40 , such as a smartphone, a software application 30 , and an ancillary module 20 as shown in FIG. 1 . To use the system, a user connects the ancillary module 20 to the hardware 40 , and places the ancillary module onto the patient's skin. In some applications, the user and patient are the same person. The user then, using the software 30 on the hardware 40 , emits light 60 from a light source through the ancillary module onto the patient's skin. The emitted light 60 strikes the cutaneous membranes of the user 50 . A fraction of the incident energy is reflected at the tissue boundary, and a fraction is transmitted inside the tissue. A portion of the transmitted light is further absorbed and scattered by the tissue. The light distribution in the tissue is affected by the refractive index and absorption scattering characteristics of the tissue. The scattered light is then transmitted through single or multiple optical pathways and detected by a sensor. The optical sensor transmits this data to the software on the device and the software uses this data to calculate the level of bilirubin or other substance in the patient.
[0028] The detailed description elaborates the methods by which the ancillary module 20 and the accompanying software application 30 will interface between the hardware 40 and the patient 50 . The safety features and methods by which the module and software protects the patient, by reducing the possibility of user error, are also described.
[0029] As seen in FIGS. 1 and 4 A- 4 D, the invented system is based around hardware or a device 40 , such as a smartphone, computer, iPod, digital camera, tablet, or other device. The device 40 provides a user interface, a light source, and an optical sensor. It also stores energy to provide power to these different components. In the preferred embodiment, the device is a smartphone such as the Nokia Lumia 1020, iPhone 5S, and the Samsung Galaxy 4, although tablets, personal computers, and other electronics will serve as well. In the preferred embodiments, the native flash of the camera is used as the source of light emission, although in other embodiments, the smartphone may control an external electronics module that emits light as well. The spectral distribution of the light source on the Nokia Lumia 1020, iPhone 5S, and the Samsung Galaxy 4 are shown in FIGS. 3A , 3 B, and 3 C, respectively. These Figure shows that both of the preferred 450 nm and 550 nm wavelengths are emitted by standard smartphone flashes. In preferred embodiments the camera of the smartphone is used as optical sensor, although the optical sensor may be ancillary sensors that evaluate light. Device 40 also contains a memory for storing software and data as well as a processor to execute the software. Additional sensors for detecting environmental data, such as ambient light may be included in the hardware as well.
[0030] The software 30 connects the various aspects of the invention and allows the user to interact with the controls as well as visualize the outputs of the analysis. The software controls the intensity, duration and timing sequence of the light source as well as the activation and parameters of the camera and/or sensor. It additionally can take inputs from additional sensors such as an ambient light sensor to be utilized in analysis. The software in some embodiments can analyze passive or active input from the camera to ensure the module is appropriately adhered to the hardware as well as appropriately contacting the skin substrate. The software further might prevent a calculated value to be obtained under certain constraints. In even further embodiments, it might provide visual, audible or tactile feedback to the user until the appropriate constraints are met. Once the software obtains data, it can utilize the input from the camera or sensor(s) to calculate concentrations of substances such as bilirubin within the cutaneous layer. Preferably, the software includes an algorithm that separates and analyzes the output from the return optical pathways to negate the effects of ambient light. Additionally the software could store these concentration values to provide a logged history to the user, patient, or caregivers, either directly or through wireless communications, to monitor changes and trending and to provide clinical recommendations to the patient and/or caregiver. In some embodiments, the software 30 may additionally upload and forward concentration values to a caregiver such as a doctor, nurse, or a hospital. This can be done automatically in real time or at regular intervals, or, only when requested or approved by the user possibly by way of a pop up window or side option. The software 30 may further provide reminders. For example, the software may alert a user if a reading was not been taken recently. Even further, in some embodiments, the software 30 will report device failure.
[0031] The invention also includes an ancillary module 20 as shown in FIGS. 1 , 2 A- 2 F, and 4 A- 4 E. The ancillary module attaches to the light source and optical sensor to create a light-tight, non-transmissive barrier between these components and the patients skin. The ancillary module 20 may be attached by any known means including adhesives or interlocking parts. The light-tight feature is a vital feature of the present invention because it protects the integrity of the interface to the patient by ensuring it is appropriately in contact with the skin or other measurement substrate within acceptable pressure ranges to obtain the most accurate data. This function could be achieved through the compression of elastomeric elements 2 b , 2 c such as a rigid housing biased by spring loaded mechanical elements. Other possible light-tight barrier mechanisms can include inclined, ramped, or snap locking features, cases, pressure sensitive adhesives or other methods of attachment that would allow for sufficient compression of the light tight gasket(s) or seal. In some embodiments, the ancillary module further includes a mechanism for monitoring the quality of the seal. In some embodiments, the mechanism may be entirely electrical, such as a pressure sensitive touchscreen. In these embodiments, the mechanism will communicate with the software by way of the headphone jack or other input location. In other embodiments, it may be entirely mechanical. In FIG. 2 , a small spring 2 i loaded light sealed 2 j articulating toggle 2 k reacts within the appropriate pressure range to remove a shutter blocking the lightpath to the camera, as further described below, such that the software shall recognize that the ancillary module 20 is properly sealed and ready for use. The toggle 2 k is hinged within the housing allowing for rotational movement. Alternatively, it may be captured within a vertical cavity of the housing and could be held in place through retention features either in the housing or the toggle. In this embodiment, prior to applying the ancillary module 20 to the skin, the tip of the retention feature would extend distally from the housing. When the user begins to place the ancillary module 20 on the patient's skin, surface tension would result in a normal force being applied on the tip of the feature, exceeding the spring force of the feature, and causing it to recoil back into the housing. The spring force of the feature could be created by a plastic molded spring arm, a compression spring, a torsional spring or through other known force, proximity, transmittance or other sensor driven actuators. The articulation of this arm would then either insert or remove a portion of the arm either into or out of a path of light returning from the skin to the camera. This aberration or lack of aberration in the light could be sensed by the phone camera and recognized as an input to the software program. A similar mechanism could also be utilized to detect the appropriate attachment of the ancillary module to the hardware, which could also be achieved through image analysis as further described in the software section below or by utilizing other sensors or actuated aberrations
[0032] The ancillary module also acts as a housing to provide a light pathway 2 f to enable the light source of the hardware to be directly transferred to the patient's skin. The ancillary module may contain one or more intermediate optical features such as a lens or high, low and bandpass filtering elements 2 g . These options could allow light transmitted from the light source to be filtered to controlled wavelengths and transmitted with controlled losses in amplitude without interference from external sources due to the dimensional and optical characteristics of the housing components. The module could also have voids, gaps or additional light pathways or pipes 2 h to allow sensors such as an ambient light sensor to have direct or indirect access to external light sources that would also influence the tissue properties and be able to be incorporated into software algorithms.
[0033] The module may further provide one or more return light pathways 2 l , 2 m that allow light refracted within the skin to return to the camera sensor feature. For example, the invention might include multiple parallel return light paths that capture light from two or more different dimensional pathways. These pathways may vary in size and spacing to accommodate different devices and brands. This may be accomplished by a threaded connection between the camera section and the light source section with detends set for different devices as well as additional threaded adjustment(s) to adust the elevantion exis between the sections if desired. The several different pathways may direct light through various thicknesses of skin and allow the light to be transferred to the camera without the influence of other external sources due to the dimensional and optical characteristics of the housing components such as cavities or light pipes 2 h.
[0034] The invention can be used in a multitude of embodiments, two of which are further described below. Although each embodiment is described through methods most optimal for that particular embodiment, the majority of the methods disclosed can be combined or used in parallel with other embodiments envisioned.
[0035] In the preferred embodiment the ancillary module is affixed to the device and is contacted to the skin. This is due to the fact that the alignment with the mobile device flash and camera is more critical than the alignment to the skin substrate within a jaundice patient population. The role of the interfaces could be reversed to instead adhere the ancillary module to the patient substrate or a particular target area of a substrate through a pressure sensitive adhesive patch. This would then require the hardware device to be connected to the module just during time of use, which could be accomplished through a similar light obscuring mechanism that is used on either side of the preferred embodiment or can be accomplished through other means of mechanical alignment and connection. In another embodiment, portions of the hardware utilized within the preferred embodiment could also be stored in a separate device or as part of the ancillary module to allow for additional filters or sensors not available on the hardware. The ancillary hardware could then be connected by various means of electrical connection such as through utilizing a stereo, dock or USB connection.
[0036] It will be understood by those of ordinary skill in the art that various changes may be made and equivalents may be substituted for elements without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular feature or material to the teachings of the invention without departing from the scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed, but that the invention will include all embodiments falling within the scope of the claims. | The present invention provides a system and method for determining bilirubin levels in an individual based on skin coloration using a smartphone or other personal device and an attached ancillary apparatus. The device, such as a smartphone or tablet, is capable of storing and running software. The device is also coupled to both a camera and light source to obtain data regarding the skin's coloration. Software is installed on the device to control the light source and calculate bilirubin levels in the individual based on the input received from the camera. The ancillary apparatus is a mechanism surrounding the light source and camera that is placed on the skin of the individual when the system is in use. The ancillary apparatus thus creates a light tight seal between the skin, light source and camera, enabling the system to receive the most accurate data from the camera. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to sterilization devices and more particularly to a hand-held ultraviolet radiation sterilization device and a method of using the same.
2. Background
UV radiation is a form of electromagnetic radiation that contains measurable wavelengths in the 4-400 nanometer range. Ultraviolet (UV) radiation is a well-known sterilization agent. The use of UV light for germicidal, bactericidal and pathogenicidal effects is well known. Suitable wavelengths for this effect is 300-200 nanometers.
Ultraviolet light is effective at eradicating germs, bacteria, viruses and other pathogens. Ultraviolet light has been used in a number of applications, including low level uses in dermatology, tanning, dental procedures, and small-scale sterilization of objects or instruments. However, to date large scale usage of ultraviolet light in hospitals or other large areas has been limited, principally because exposure to ultraviolet light at an intensity necessary for effective and efficient eradication or sterilization of pathogenic agents is very harmful to the human body. Specifically, the ultraviolet radiation required to effectively and efficiently eradicate pathogenic agents should be an intensity ranging from 2000-6000 microwatts/cm 2 . Human contact with ultraviolet light in this range requires protective clothing, including covering the skin and eyes. UV light has been used in operating rooms, wards, and nurseries of hospitals, generally by being fixed to the walls or ceilings. The danger to humans posed by ultraviolet radiation requires these UV light sources to be shielded to prevent direct or reflected UV light from striking humans. The stationary and shielded light fixture is therefore only partially effective eradicating pathogens or of micro-organisms because there are many surfaces and hidden areas that can escape direct contact by the UV radiation.
In order for UV radiation to eradicate or kill micro-organisms, it is generally believed that the UV rays must directly strike the micro-organisms. The exposure to UV light necessary to kill bacteria (or the "kill" factor) is a product of time and intensity.
U.S. Pat. No. 2,215,635 issued to Collins (Sep. 24, 1940) discloses an adjustable ultraviolet light fixture apparatus for hospital operating rooms for treating bacteria. Collins describes maintaining the intensity of the radiation "at the highest value to which the uncovered viscera of a patient may be exposed without harmful adhesions or other undesired results ensuing." Col. 1, lines 35-38. The device includes a conventional light source and an ultraviolet radiation source attached to a positional support arm, the device fixedly mounted above an operating table to direct the light and UV radiation at the patient. The UV radiation was believed to possess bactericidal and therapeutic effects.
U.S. Pat. No. 4,952,369 issued to Belilos (Aug. 28, 1990) describes a portable, pocket-size, ultraviolet flashlight that can be used by ordinary individuals to kill germs and viruses on objects like toilet seats, flatware, and telephones. The flashlight includes a housing, an ultraviolet light source, an on/off switch, and a gravity switch that limits the activation of the ultraviolet light source to the position wherein the light source is facing downward. By limiting the activation of the UV source to when the device faces downward the device sought to reduce harm to eyes. The UV lamp utilized by Belilos can be any type of light source generating UV light in sufficient intensity to disinfect objects at relatively short distances. Col. 2, lines 6-9.
U.S. Pat. Nos. 4,786,812, 5,029,252, and 5,446,289 describe devices for sterilizing air and instruments by passing the air or instruments through the sterilization devices. U.S. Pat. No. 4,786,812 issued to Humphreys (Nov. 22, 1988) describes a device with a fan and ultraviolet light source in a housing whereby the fan draws unsterilized air into the housing and the air is sterilized and then return to its environment. U.S. Pat. No. 5,029,252 issued to Ameseder (Jul. 2, 1991) describes an apparatus with a housing containing an ultraviolet light source and the housing has openings for instrumental devices, like toothbrushes. The instrumental device is placed in the housing and sterilized by the ultraviolet light. U.S. Pat. No. 5,466,289 issued to Shodeen et al. (Aug. 29, 1995) describes a pass-through sterilization chamber where items are placed in the sterilization chamber and subjected to ultraviolet radiation.
There is a need for a UV sterilization device with sufficient intensity to kill germs, bacteria, viruses, and other pathogens and microorganisms efficiently in a large area like a hospital room. There is also a need for a hand-held device that supplies sufficient intensity to a surface or object to destroy most pathogens or microorganisms. There is further a need for a device that is capable of sterilizing rooms like, hospital operating rooms, wherein the device can reach all corners or all surfaces of the room.
SUMMARY OF THE INVENTION
The invention relates to a hand-held sterilization device that emits ultraviolet radiation in a range sufficient to destroy germs, bacteria, viruses, and other pathogens and microorganisms, by exposing surfaces and objects to unshielded, high intensity ultraviolet radiation. The device includes a housing containing an UV light source, a power source, and an electronic safety mechanism. The UV light source operates in a wavelength spectra effective to have germicidal, bactericidal, and pathogenicidal effects. The power source supplies the UV light source with sufficient intensity to effectively and efficiently destroy germs, bacteria, pathogens and microorganisms. The intensity of the UV light source is such that the radiation is unsafe to the exposed, unprotected human anatomy. An electronic safety mechanism is therefore included to regulate the power source so that only a skilled and protected operator can use the device. Further, the UV light emitted from the hand-held sterilization device is not shielded. Therefore, the light can come into direct contact with all surfaces or objects in a room. The hand-held device is simply directed throughout the room at all surfaces and objects to expose the surfaces and objects to intense UV light for a given period of time to sterilize the room.
The invention also relates to a method for sterilizing objects, the method comprising providing a hand-held sterilization device with an unshielded UV light source operating in a wavelength effective to have germicidal, bactericidal and pathogenicidal effects, supplied by a power source with sufficient intensity to be unsafe to the unprotected human anatomy but effective to have significant germicidal, bactericidal and pathogenicidal effects at significant distances from the UV light source, and passing the device over objects and surfaces of a room for a sufficient period of time.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a perspective side view of the hand-held sterilization device of the invention.
FIG. 2 is a perspective top view of the hand-held sterilization device of the invention illustrating the electronic safety mechanism.
FIG. 3 is a logic diagram of the operation of the electronic safety mechanism for the hand-held sterilization device of the invention.
FIG. 4 is a perspective top view of the bottom side of the hand-held sterilization device of the invention.
FIG. 5 is a perspective front view of the operation of the hand-held sterilization device of the invention.
DETAILED DESCRIPTION OF THE INVENTION
A hand-held sterilization device and a method for sterilizing objects utilizing a hand-held sterilization device is described herein. In the following detailed description, reference is made to specific embodiments containing particular mechanisms. These embodiments and mechanisms are to be read in an illustrative rather than a restrictive sense.
FIG. 1 illustrates the hand-held sterilization device that is the invention. The device in FIG. 1 includes a housing 10 containing an unshielded ultraviolet light source 30. The hand-held device and ultraviolet light source are powered by a power supply. In FIG. 1, the power supply is the standard power supplied to a building or hospital. In the United States, that power source is either a 110v alternating current or 220v alternating current power supply. The hand-held sterilization device 5 of FIG. 1 is coupled to the power supply through a power cord 40. The power cord 40 is of sufficient length to allow an operator of the device to maneuver throughout the room to be sterilized. It is to be understood that the power cord 40 is a conventional power cord sufficient to supply the necessary current to the hand-held sterilization device 5. It is also to be understood that coupling the device 5 to the common power source of a building is only one alternative of supplying power to the device 5. Another alternative includes a battery power supply coupled to the device 5.
The power supplied to the hand-held sterilization device 5 of FIG. 1 must be sufficient to provide the device 5 with the necessary intensity or power to have the effective germicidal, bactericidal, and pathogenicidal effects. The invention contemplates that the necessary intensity of the ultraviolet light is approximately 2000-6000 microwatts/cm 2 . Thus, the device must be coupled to a power supply that yields the necessary measure of intensity.
The hand-held sterilization device 5 of FIG. 1 includes a handle 20 coupled to the housing. The handle 20 allows an operator to manipulate the hand-held sterilization device 5 to the necessary locations to eradicate any pathogens or microorganisms. Holding the device 5 approximately 6-18 inches over an area for approximately 1-2 seconds will be sufficient to eradicate most pathogens and microorganisms.
FIG. 2 presents a perspective top view of the hand-held sterilization device of the invention. The device 5 in FIG. 2 includes a housing 10, a handle 20 coupled to the housing, and a power cord 40 that may be connected to a power source. The device 5 in FIG. 2 further includes an electronic safety mechanism 50. The electronic safety mechanism 50 includes a switch lock 60 actuated by a key 65. The electronic safety mechanism 50 also includes a digital lock circuit made up of a numerical or alphabetical keypad 70 wherein a required numerical or alphabetical code is needed to open or turn on the power to the digital lock circuit. The digital lock circuit also includes a display 80 with prerecorded messages to prompt the user of the device as to the operation of the device 5. For example, the display pad prompts the user with queries such as, "Is the room sealed?" or "Has the room been cleared?". The electronic safety mechanism further includes a speaker 90 to provide audible signals or statements to the user regarding the use of the device 5. For example, the speaker can audiblize the query "Is the room sealed?" or "Has the room been cleared?".
FIG. 3 illustrates a logic block diagram of the electronic safety mechanism 50 of the hand-held sterilization device of the invention. To operate the device, a user must first actuate the switch lock 60 to close the circuit. Next, the user must enter the appropriate numerical or alphabetical code on the keypad 70. Entry of the proper code actuates the digital lock circuit 100 to send a control signal to actuate a switch 110 that is, for example, a relay or a transistor. The digital lock circuit 100 is, for example, a microcontroller. According to the state of the digital lock circuit 100, corresponding signals are sent to the digital display 80, that, for example, contains a light emitting diode, to visually prompt the user and the audio speaker 90 to audibly prompt the speaker of the proper use of the device. Once the proper numerical or alphabetical code is entered into the keypad 70 to actuate the digital lock circuit 100 and turn on the switch 110, power then is directed from the power supply to the light source 30 to operate the device.
FIG. 4 illustrates a perspective top view of the back side of the hand-held sterilization device. FIG. 4 shows the device 5 with a housing 10 and a handle 20 coupled to the housing 10. The device 5 shown in FIG. 4 includes a retractable hood 120 that is a pair of doors that open to reveal the ultraviolet light source. In FIG. 4, the doors are opened by actuating a key lock 130. The key lock is actuated by a key 65. The key 65 is the same key that actuates the switch lock on the electronic safety mechanism in FIG. 2. Thus, the invention contemplates that the same key 65 is used to expose the ultraviolet light source and to turn the light source on. The hood 120 doors are pivotably coupled to the housing by hinges 140 extending the length of the device housing 10. When the device 5 is operated and the UV radiation directed at the area to be sterilized, the hood doors are open and do not interfere with the path of the UV radiation. It should be appreciated that the hood 120 can also be electrically connected to the digital lock circuit 100 so that the hood 120 opens to reveal the light source only when the digital lock circuit 100 is actuated, for example, by an electromagnetic coupling.
FIG. 5 illustrates the use of the hand-held sterilization device 5 to sterilize a room. In FIG. 5, the operator of the device 5 wears protective clothing 170 to protect the operator from exposure to ultraviolet light. The protective clothing includes goggles 150. The goggles include a tether 160 that is attached to the key 65 that operates the electronic safely mechanism. Thus, the key 65 attached to the goggles 150 ensures that the operator will use the goggles 150 when the ultraviolet device 5 is operated.
In the preceding detailed description, the invention is described with reference to specific exemplary embodiments thereof. It will however be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention as set forth in the claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. | A hand-held sterilization device that emits ultraviolet radiation in a range sufficient to eradicate germs, bacteria, viruses, and other pathogens and microorganisms is disclosed. The device includes a housing containing an ultraviolet light source, a power source, and an electronic safety mechanism, wherein the electronic safety mechanism includes both a switch lock circuit and a digital lock circuit that must be actuated to close an electric circuit and actuate the device. A method of using the hand-held sterilization device is also disclosed. | 0 |
BACKGROUND
[0001] Field of the Disclosure
[0002] The present disclosure relates to a safety apparatus for a sliding door for a vehicle.
[0003] Description of the Related Art
[0004] The operation of a sliding door for a vehicle can be inconvenient for its user. For example, an object of the user, e.g. a bag, may be caught between the sliding door and the vehicle body. Such kinds of inconveniences are prone to happen when the sliding door has an open window through which the object of the user can be passed. Furthermore when the door is vigorously opened, the object caught between the open window and the body of the vehicle can be severely damaged.
[0005] In order to prevent such kinds of inconveniences from occurring safety apparatuses that are actuated by the opening of the window have been available.
[0006] Such available apparatuses are based on complex designs relying on open and large mechanisms operating long and protruding parts that can interfere with each other.
[0007] Though such apparatuses have achieved some success in preventing such kinds of inconveniences, they have numerous shortcomings.
[0008] Unfortunately, due to their complex and cumbersome designs, these apparatuses are prone to fail. Notably, these apparatuses may be easily deformed and rendered inoperative by stepping on them or slamming the sliding door too vigorously. The main elements of these apparatuses may not be well protected and exposed to external elements such as grease or dust and ends up not working properly. In addition, such apparatuses may be bulky and difficult to hide resulting in unpleasing appearance for the vehicle.
[0009] Thus, a safety apparatus for opening a sliding door of a vehicle solving the aforementioned problems of design complexity, reliability, compactness and aesthetic is desired.
SUMMARY
[0010] Accordingly, the object of the present disclosure is to provide a safety apparatus for a sliding door of a vehicle which overcomes the above-mentioned limitations.
[0011] The safety apparatus of the present disclosure ensures reliability, compactness and aesthetic due to a more integrated and directly operated mechanism. The apparatus of the present disclosure directly utilizes the support structure of the sliding door as a way to protect the main elements and functionalities of the apparatus. In addition, the apparatus of the present disclosure relies on a direct connection and a positioning between its main elements avoiding interferences and complexity.
[0012] In one non-limiting illustrative example, a safety apparatus for a sliding door of a vehicle includes a lower rail including a mid stopper bracket; and an arm affixed at an external extremity to the sliding door and connected at an internal extremity to the lower rail, the arm including a mid stopper lever that is rotatable. In an open position, the mid stopper lever contacts the mid stopper bracket and contacts a tongue of the internal extremity of the arm to prevent the sliding door from exceeding a mid open position..
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] A more complete appreciation of the disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
[0014] FIG. 1 is a perspective view of a sliding door assembly mounted within a side of a vehicle, according to certain aspects of the disclosure;
[0015] FIG. 2A is a perspective view of a lower roller assembly and a lower rail in a mid open position, according to certain aspects of the disclosure.
[0016] FIG. 2B is a perspective view of a lower roller assembly and a lower rail in a fully open position, according to certain aspects of the disclosure;
[0017] FIG. 3 is an exploded perspective view of the lower roller assembly, according to certain aspects of the disclosure;
[0018] FIG. 4 is a perspective view of a D-shaped pin, according to certain aspects of the disclosure; and
[0019] FIG. 5 is an exploded perspective view of a roller sub assembly, according to certain aspects of the disclosure.
DETAILED DESCRIPTION
[0020] In the drawings, like reference numerals designate identical or corresponding parts throughout the several views. Further, as used herein, the words “a”, “an” and the like generally carry a meaning of “one or more”, unless stated otherwise. The drawings are generally drawn to scale unless specified otherwise or illustrating schematic structures or flowcharts.
[0021] Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views.
[0022] FIG. 1 is a perspective view of a sliding door assembly 1000 mounted within a side 2002 of a vehicle 2000 , according to certain aspects of the disclosure.
[0023] The side 2002 of the vehicle 2000 includes a floor 2014 , a roof 2016 and an opening 2004 with a front edge 2006 opposite to a rear edge 2008 and a top edge 2010 opposite to bottom edge 2012 . As used herein, the term “front” refers to the region of the vehicle 2000 closest to the front edge 2006 , the term “rear” refers to the region of the vehicle 2000 closest to the rear edge 2008 , the term “top” refers to the region of the vehicle 2000 closest to the top edge 2010 , and the term “bottom” refers to the region of the vehicle 2000 closest to the bottom edge 2012 .
[0024] The opening 2004 may be placed in the rear region of the side 2002 , as illustrated in FIG. 1 , or anywhere on the vehicle 2000 and have any size.
[0025] The sliding door assembly 1000 includes a sliding door 1002 , a center rail assembly 3000 mounted on the side 2002 of the vehicle 2000 and affixed to the sliding door 1002 by the interior, and a lower roller assembly 4000 linking the bottom part of the sliding door 1002 to a lower rail 4200 mounted on the floor 2014 of the vehicle 2000 .
[0026] The sliding door 1002 has a door front edge 1002 a opposite to a door rear edge 1002 b and a door top edge 1002 c opposite to a door bottom edge 1002 d. The sliding door 1002 includes a frame 1004 , a door window 1006 with a door glass panel 1008 inserted into a door opening 1010 . The door opening 1010 is characterized by front window edge 1010 a opposite to rear window edge 1010 b and a top window edge 1010 c opposite to a bottom window edge 1010 d. The door window 1006 is moveable from a closed position, where the glass panel 1008 is adjacent to the top window edge 1010 c, to an open position, where the glass panel 1008 is separated from the top window edge 1010 c.
[0027] The center rail assembly 3000 includes a center rail 3002 extending longitudinally along the side 2002 of the vehicle 2000 and from the rear edge 2008 of the opening 2004 as well as a center guide 3004 affixed to the rear of the sliding door 1002 on one end and inserted into the center rail 3002 on another end.
[0028] The lower roller assembly 4000 includes an arm 4020 with an external extremity 4022 affixed to the sliding door 1002 and an internal extremity 4024 ended by a roller sub assembly 4100 with a roller guide 4110 , see FIG. 3 , inserted into the lower rail 4200 .
[0029] The lower rail 4200 has an S-shape extending longitudinally on the floor 2014 of the vehicle 2000 between the front edge 2006 and the rear edge 2008 of the opening 2004 . The rear part of the lower rail 4200 is delimited by a full stopper bracket 4202 ending the lower rail 4200 , see FIG. 2A .
[0030] In addition, an upper floor 2014 a may cover the internal extremity 4024 of the arm 4020 with the roller sub assembly 4100 and the lower rail 4200 to provide protection against the external elements, e.g., tar, grease, gravel, and hazards, e.g. unintentional stepping or hitting.
[0031] The center rail assembly 3000 , the lower roller assembly 4000 and the lower rail 4200 enable the displacement of the sliding door 1002 along the side 2002 of the vehicle 2000 . The center guide 3004 slides in the center rail 3002 while the roller sub assembly 4100 rolls in the lower rail 4200 . The sliding motion of the sliding door 1002 may be performed by manual actions of a user or via motorized mechanical actions using electrical motors or hydraulic systems or by any other technique known by a person having ordinary skill in the art.
[0032] The sliding door 1002 may be displaced from a fully closed position, where the front window edge 1010 a of the sliding door 1002 is affixed to the front edge 2006 of the vehicle 2000 , to a fully open position, where the front window edge 1010 a of the sliding door 1002 is placed adjacent to the rear edge 2008 of the vehicle 2000 . The sliding door 1002 is maintained in the fully open position through a latch lever 4172 displaced by the latch mechanism 4170 , see FIGS. 3A-3C , and hooked onto an anchor point of the side 2002 .
[0033] When the door window 1006 is placed in the open position, the roller sub assembly 4100 is actuated to disable the fully open position of the sliding door 1002 and to block the sliding door 1002 in a mid open position, where a spacing between the rear edge 2008 of the opening 2004 and the front window edge 1010 a of the side opening 1010 is maintained.
[0034] Blocking the sliding door 1002 in the mid open position prevents objects or body parts protruding through the door window 1006 from being caught between the rear edge 2008 of the opening 2004 and the front window edge 1010 a z of the door window 1006 .
[0035] FIGS. 2A-2B are perspective views of the lower roller assembly 4000 and the lower rail 4200 in the mid open position and in the fully open position, respectively, according to certain aspects of the disclosure.
[0036] The lower roller assembly 4000 includes a mid stopper lever 4144 and a mid stopper bracket 4142 mounted on the lower rail 4200 .
[0037] The mid stopper bracket 4142 is mounted on the lower rail 4200 or on the upper floor 2014 a with a predetermined distance d from the full stopper bracket 4202 , see FIG. 2A . The mid stopper bracket 4142 includes a body 4046 with half tubular shapes surmounted by a flat head 4048 . The full stopper bracket 4202 may be molded or machined in one or several pieces assembled together and fastened onto the lower rail 4200 or onto the floor 2014 using fastening devices such as bolts, adhesives or the combination thereof.
[0038] The mid stopper lever 4144 may be formed by a plate having a crescent shape with a raised part 4145 and a lowered part 4144 b. The raised part 4145 is characterized by a main flat part 4145 a opposite to a minor flat part 4145 b, and a curved part 4145 c joining the major flat part 4145 a and the minor flat part 4145 c.
[0039] When the door window 1006 is moved from the closed position to the open position the mid stopper lever 4144 is rotated to an open position and when the door window 1006 is moved from the open position to the closed position the mid stopper lever 4144 is rotated back to a closed position.
[0040] The connection between the mid stopper lever 4144 and the door window 1006 may be electrical, mechanical or the combination thereof. For example, the rotation of the mid stopper lever 4144 may be actuated by a cable 4026 inserted into a cable housing 4026 a actioned by a window regulator, wherein the window regulator controls the opening or closing of the door window 1006 . The cable 4026 and the cable housing 4026 a may be lodged into a groove of the arm 4020 for space saving purposes.
[0041] When the mid stopper lever 4144 is rotated in the open position, as illustrated in FIG. 2A , the raised part 4145 of the mid stopper lever 4144 protrudes over the internal extremity 4024 of the arm 4020 while the lowered part 4144 b lies on a bumper 4148 , e.g. a fixed pin circled with a rubber washer.
[0042] In addition, the minor flat part 4145 b rests of the raised part 4145 of the mid stopper lever 4144 slightly touches a tongue 4030 formed by the internal extremity 4024 of the arm 4020 . The raised part 4145 of the mid stopper lever 4144 protrudes such that the main flat part 4145 a hits the flat head 4048 of the mid stopper bracket 4142 and prevents the arm 4020 from contacting the full open stopper bracket 4202 . When the mid stopper lever 4144 hits the mid stopper bracket 4142 , the sliding door 1002 is blocked in the mid open position and cannot be forced into the full open position. When the user tries to place the sliding door 1002 in the full open position the lowered part 4144 b of the lever 4144 compresses the bumper 4148 and the raised part 4145 is pushed against the tongue 4030 .
[0043] Since the arm 4020 is a strong and rigid structure, the tongue 4030 represents a robust blockage preventing the sliding door 1002 from being placed into the fully open position.
[0044] The predetermined distance d, see FIG. 2A , between the full stopper bracket 4202 and the mid stopper bracket 4142 is chosen such that a spacing between the rear edge 2008 of the opening 2004 and the front window edge 1010 a of the window door 1006 is large enough to prevent an accident from occurring.
[0045] When the mid stopper lever 4144 is rotated back into the closed position, as illustrated in FIG. 2B , the main flat part 4145 a of the raised part of the 4145 of the mid stopper lever 4144 is folded against the internal extremity 4024 of the arm 4020 and position on top of the bumper 4148 . In the closed position, the mid stopper lever 4144 is no longer able to contact the mid stopper bracket 4142 and to prevent the arm 4020 from contacting the full open stopper bracket 4202 . The arm 4020 passes over the mid stopper bracket 4142 and contact the full open stopper bracket 4202 to have the sliding door 1002 placed in the fully open position. In addition, the curved part 4145 c of the raised part 4145 facilitates the passage of the arm 4020 over the mid stopper bracket 4142 .
[0046] FIG. 3 is an exploded perspective view of the lower roller assembly 4000 , according to certain aspects of the disclosure.
[0047] The lower roller assembly 4000 includes the arm 4020 , the roller sub assembly 4100 , and the roller guide 4110 . The roller guide 4110 and the roller sub assembly 4100 are supported by a support plate 4120 affixed below the internal extremity 4024 of the arm 4020 through a plurality of bolts.
[0048] The mid stopper lever 4144 is affixed on top of the support plate 4120 via a D-shaped pin 4180 , see detailed descriptions in the following paragraphs, while the latch mechanism 4170 is affixed below the support plate 4120 . By not having the stopper lever 4144 and the latch lever 4172 in the vicinity of each other, interferences between the stopper lever 4144 and the latch lever 4172 are avoided, resulting in a more robust mechanism.
[0049] The mid stopper lever 4144 is covered in part by an embossment 4028 formed by the internal extremity 4024 of the arm 4020 . The embossment 4028 protects the mid stopper lever 4144 and the D-shaped pin 4180 . Since the arm 4020 is a strong and rigid structure, the embossment 4028 represents a robust protection for the mid stopper lever 4144 and the D-shaped pin 4180 against external stress loads such as stepping.
[0050] The spacing between the mid stopper lever 4144 and the latch mechanism 4170 , as well as the embossment 4028 , minimizes the thickness of the lower roller assembly 4000 and consequently minimizes the necessary distance between the floor 2014 and the upper floor 2014 a. Minimizing the distance between the floor 2014 and the upper floor 2014 a reduces the exposure of the internal extremity 4024 of the arm 4020 , the roller sub assembly 4100 , and the lower rail 4200 to external elements as well as to improve the aesthetics of the vehicle 2000 .
[0051] FIGS. 4-5 are a perspective view of the D-shaped pin 4180 and an exploded perspective view of the roller sub assembly 4100 , respectively, according to certain aspects of the disclosure.
[0052] The roller sub assembly 4100 includes the D-shaped pin 4180 , an intermediate lever 4152 placed bellow the support plate 4120 and an trigger 4162 placed on a lower support plate 4164 localized below the support plate 4120 .
[0053] The D-shaped pin 4180 , the intermediate lever 4152 and the trigger 4162 are used to affix the mid stopper lever 4144 to the support plate 4120 and to articulate the mid stopper lever 4144 via the cable 4026 , controlled by a window regulator.
[0054] The D-shaped pin 4180 enables to link the mid stopper lever 4144 with the intermediate lever 4152 in a direct fashion such that the intermediate lever 4152 rotates with the mid stopper lever 4144 around an axis z perpendicular to the support plate 4120 . In other words, the D-shaped pin 4180 prevents the mid stopper lever 4144 and the intermediate lever 4152 from rotating independently.
[0055] The D-shaped pin 4180 may include a male body 4182 b that can be inserted, e.g. by screwing, into a female body 4182 a. The female body 4182 a may include a waist 4184 a with a circular cross section, a female D-shaped shoulder 4186 a, e.g. a larger circular cross section that has been cut to form a flat part, or any non-circular cross section, and a head 4188 a. The male body 4182 b may include a male D-shaped shoulder 4186 b, similar to the female D-shaped shoulder 4186 a, surmounted by a male head 4188 b.
[0056] The female waist 4184 a may be inserted through a circular hole 4190 of the support plate 4120 while the female D-shaped shoulder 4186 a may be inserted through a first D-shaped hole 4192 of the mid stopper lever 4144 with the female head 4188 a resting on top of the mid stopper lever 4144 . The first D-shaped hole 4192 has a shape and dimensions to tightly fit the female D-shaped shoulder 4186 a.
[0057] The male D-shaped shoulder 4186 b may be inserted through a second D-shape hole 4152 a of the intermediate lever 4152 with the male head 4188 b resting on the bottom of the intermediate lever 4152 while the male body 4182 b may be inserted into the female waist 4184 a. The second D-shaped hole 4152 a has a shape and dimensions to fit tightly the male D-shaped shoulder 4186 b.
[0058] Alternatively, the D-shaped pin 4180 may be any kind fastening devices preventing the mid stopper lever 4144 and the intermediate lever 4152 from rotating independently, such as a keyed joint, a flanged bolt with a lock nut, or any other devices known by someone having ordinary skills in the art.
[0059] By affixing the mid stopper lever 4144 and the intermediate lever 4152 to the support plate 4120 and by directly linking the mid stopper lever 4144 and the intermediate lever 4152 together, the D-shaped pin 4180 minimizes the number of elements, e.g. springs, holes, used to actuate the mid stopper lever 4144 and increase the robustness as well as compactness of the roller sub assembly 4100 .
[0060] When the intermediate lever 4152 is rotated, the second D-shaped hole 4152 holds onto the male D-shaped shoulder 4186 b and rotates the female waist 4184 a inside the circular hole 4190 of the support plate 4120 . The rotation of the female waist 4184 a results in a rotation of the mid stopper lever 4144 via the connection between the female-shaped shoulder 4186 a and the first D-shaped hole 4192 .
[0061] When the door window 1006 is moved by the user from the closed position to the open position, the cable 4026 actuates the trigger 4162 , the trigger 4162 engages the intermediate lever 4152 and forces the D-shaped pin 4180 to rotate and move the mid stopper lever 4144 from the closed position to the open position.
[0062] When the stopper lever 4144 is placed in the open position, the raised part 4145 of the mid stopper lever 4144 protrudes over the arm 4020 and leans on the tongue 4030 while the lowered part 4144 b leans on the bumper 4148 . The open position of the mid stopper lever 4144 prevents the sliding door 1002 from being placed into the fully open position by having the raised part 4145 of the mid stopper lever 4144 hitting the mid stopper bracket 4142 and blocking the sliding door 1002 into the mid open position.
[0063] When the door window 1006 is moved by the user from the open position to the closed position, the cable 4026 releases the trigger 4162 , the trigger 4162 disengages the intermediate lever 4152 and forces, the D-shaped pin 4180 to rotate back the mid stopper lever 4144 from the open position to the closed position, under a bias force that may be generated by at least one spring.
[0064] When the stopper lever 4144 is placed in the closed position, the raised part 4144 is folded back against the internal extremity 4024 of the arm 4020 and is no longer able to hit the mid stopper bracket 4142 and to prevent the sliding door 1002 from being placed into the fully open position.
[0065] The foregoing discussion discloses and describes merely exemplary embodiments of an object of the present disclosure. As will be understood by those skilled in the art, an object of the present disclosure may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Accordingly, the present disclosure is intended to be illustrative, but not limiting of the scope of an object of the present disclosure as well as the claims.
[0066] Numerous modifications and variations on the present disclosure are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the disclosure may be practiced otherwise than as specifically described herein. | A safety apparatus for a sliding door of a vehicle, including a lower rail including a mid stopper bracket; and an arm affixed at an external extremity to the sliding door and connected at an internal extremity to the lower rail, the arm including a mid stopper lever that is rotatable. In an open position, the mid stopper lever contacts the mid stopper bracket and contacts a tongue of the internal extremity of the arm to prevent the sliding door from exceeding a mid open position. | 4 |
RELATED APPLICATION
This application is a 35 U.S.C. §371 national stage filing of International Application No. PCT/US2011/050138, filed on Sep. 1, 2011, which, in turn claims priority to U.S. Provisional Application No. 61/379,182, filed on Sep. 1, 2010. The entire contents of each of the foregoing applications are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
The (R)M-1 metabolite of pentoxifylline is known as lisofylline and is known to have similar properties to pentoxifylline.
Deuterated (R) M-1 metabolites of pentoxifylline and related compounds have been reported as having therapeutic utility in WO2009/108383. There is a need for commercially feasible methods for producing such deuterated (R)-M-1 metabolites, as well as other deuterated (R)-alcohols.
SUMMARY OF THE INVENTION
Applicants have solved this problem by employing certain commercially available ketoreductases and carbonyl reductases to produce deuterated (R)-alcohols from the corresponding prochiral deuterated ketone in a highly stereoselective manner without loss of deuterium incorporation.
The present invention provides a process for the preparation of a compound of Formula I:
comprising reacting a compound of formula II:
with a hydride source or a deuteride source in the presence of a ketoreductase or carbonyl reductase to form a compound of formula I with an enantiomeric excess of at least 80%, wherein:
Y is H when a compound of Formula II is reacted with a hydride source; or
Y is D when a compound of Formula II is reacted with a deuteride source;
R 1 is —CH 3 or —CD 3 ;
R 2 is a C 2 -C 10 alkylene-X wherein X is H, D, or R 3 and the C 2 -C 10 alkylene portion of R 2 is optionally substituted with a group independently selected from the group consisting of (i) one or more deuterium, and (ii) one R 3 ; and
R 3 is (i) C 6 -C 10 aryl, 5-10-membered heteroaryl, C 3 -C 8 cycloalkyl, or saturated heterocyclyl, wherein R 3 is optionally substituted with one or more substituent independently selected from deuterium, C 1 -C 2 alkyl optionally substituted with deuterium, and —OH; or (ii) a tautomer thereof;
wherein at least one of R 1 and the C 2 -C 10 alkylene portion of R 2 is substituted with deuterium; and
wherein the amount of deuterium incorporation at each deuterium in R 1 and the C 2 -C 10 alkylene portion R 2 in the compound of formula I is substantially equal to the amount of deuterium incorporation at corresponding deuterium atoms in R 1 and R 2 in the compound of formula II.
The process of this invention is particularly useful to reduce deuterated forms of pentoxifylline to their corresponding deuterated alcohols.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
“The term “alkyl” refers to a monovalent, saturated hydrocarbon group having the indicated number or range of carbon atoms. For example, C 2 -C 10 alkyl is an alkyl having from 2 to 10 carbon atoms. An alkyl may be linear or branched. Examples of alkyl groups include methyl; ethyl; propyl, including n-propyl and isopropyl; butyl, including n-butyl, isobutyl, sec-butyl, and t-butyl; pentyl, including, for example, n-pentyl, isopentyl, and neopentyl; and hexyl, including, for example, n-hexyl, 2-methylpentyl and heptyl.
The term “cycloalkyl” refers to a monovalent monocyclic or bicyclic saturated group containing only carbon ring atoms. The term “C 3 -C 8 cycloalkyl” refers to a monocyclic saturated group containing between 3 and 7 carbon ring atoms. Examples of cycloalkyl include cyclopropyl, cyclobutyl, cyclopentyl, and cyclohexyl, cycloheptyl, cis- and trans-decalinyl, and norbornyl.
The term “aryl” refers to an aromatic carbocycle. The term “C 6 -C 10 aryl” refers to a monocyclic or bicyclic, aromatic carbocycle containing between 6 and 10 ring carbon atoms. Examples of aryl are phenyl and naphthyl.
The term “saturated heterocyclyl” refers to a monovalent monocyclic or bicyclic saturated group containing between 3 and 8 ring atoms, wherein one or more ring atoms is a heteroatom independently selected from N, O, and S. Examples of saturated heterocycles include azepanyl, azetidinyl, aziridinyl, imidazolidinyl, morpholinyl, oxazolidinyl, piperazinyl, piperidinyl, pyrazolidinyl, pyrrolidinyl, tetrahydrofuranyl, and thiomorpholinyl.
The term “heteroaryl” refers to a monovalent monocyclic or bicyclic aromatic group, wherein one or more ring atoms is a heteroatom independently selected from N, O, and S. A 5-10 membered heteroaryl is a monocyclic or bicyclic heteroaryl that contains between 5 and 10 ring atoms. Examples of heteroaryl groups include furanyl, thiazolyl, isothiazolyl, isoxazolyl, oxazolyl, pyrimidinyl, pyrazolyl, pyridazinyl, pyridinyl, pyrrolyl, thiadiazolyl, thiophenyl, triazinyl, triazolyl, quinolinyl, quinazolinyl, indolyl, isoindolyl, 3,7-dihydro-1H-purine-2,6-dion-yl; xanthinyl, hypoxanthinyl, theobrominyl, uric acid, isoguaninyl, thymine, and uracilyl.
The term “ketoreductase or carbonyl reductase” refers to an enzyme belonging to Enzyme Classification Class 1.1.1.184, which, in the presence of which a hydride source, is capable of converting a methyl ketone into a secondary alcohol. The term “methyl ketone” refers to a ketone of the formula:
wherein R A is C n H 2n+1 and n is an integer between 2 and 10.
The term “substituted” refers to the replacement of one or more hydrogen atoms with the indicated substituent. For avoidance of doubt, substitutions may occur on the terminus of a moiety. For example, the terminal —CH 3 group on R 2 may be substituted with an R 3 . “Substituted with deuterium” refers to the replacement of one or more hydrogen atoms with a corresponding number of deuterium atoms.
When a position is designated specifically as “D” or deuterium, the position is understood to have deuterium at an abundance that is at least 1000 times greater than the natural abundance of deuterium, which is 0.015% (i.e., at least 15% incorporation of deuterium). In certain embodiments, when a position is designated as “D” or deuterium that position has at least 50.1% incorporation of deuterium, at least 75% incorporation of deuterium; at least 80% incorporation of deuterium, at least 85% incorporation of deuterium; at least 90% incorporation of deuterium; at least 95% incorporation of deuterium; at least 98% incorporation of deuterium; at least 99% incorporation of deuterium; or at least 99.5% incorporation of deuterium.
When a position is designated specifically as “H” or hydrogen, the position is understood to have hydrogen at its natural isotopic abundance.
The amount of deuterium incorporation at a deuterium atom in a compound of Formula I is said to be “substantially equal” to the amount of deuterium incorporation at the corresponding deuterium atom in a compound of Formula II if the difference in the amount of deuterium incorporation between them is no more than about 5%, as an example no more than about 3%; no more than about 2%; no more than about 1%; or no more than about 0.5%.
Ketones Useful as Compounds of Formula II
It will be understood that each of R 1 and R 2 in a compound of Formula I,
is structurally identical to the corresponding R 1 and R 2 in a compound of Formula II,
Notwithstanding this, according to the present invention, the amount of deuterium incorporation at any deuterium present in R 1 and R 2 of a compound of Formula I is substantially equal to the amount of deuterium incorporation at the corresponding deuterium atoms in a compound of Formula II.
In one embodiment, R 2 is substituted with one or two R 3 .
In one embodiment, at least one of R 1 and R 2 comprises a deuterium bound to the carbon atom adjacent the carbonyl carbon.
In one embodiment, each of R 1 and R 2 is substituted with one or more deuterium. In one aspect of this embodiment at least one of R 1 and R 2 comprises a deuterium bound to the carbon atom adjacent the carbonyl carbon.
In one embodiment, R 1 is CH 3 .
In another embodiment, R 1 is CD 3 .
In one embodiment, R 2 is C 2 -C 6 alkyl optionally substituted with one or more deuterium and optionally substituted with one or two R 3 . In one aspect of this embodiment, R 2 is —CH 2 —(C 1 -C 5 alkyl optionally substituted with one or more deuterium and optionally substituted with one R 3 . In another aspect of this embodiment, R 2 is —CH 2 —(C 1 -C 5 alkyl optionally substituted with one or more deuterium and optionally substituted with one R 3 ).
In one embodiment, R 3 is (i) 5-10-membered heteroaryl optionally substituted with one or more substituents independently selected from deuterium, C 1 -C 2 alkyl optionally substituted with deuterium, and —OH; or (ii) a tautomer thereof.
In one embodiment, a compound of Formula II has structural Formula II-A:
or a salt thereof, wherein:
each of R 4 , R 6 and R 7 is independently selected from —CH 3 and —CD 3 ;
R 5 is hydrogen or deuterium or a combination thereof;
each Z 2 is the same and is hydrogen or deuterium;
each Z 3 is the same and is hydrogen or deuterium;
each Z 4 is the same and is hydrogen or deuterium;
each Z 5 is the same and is hydrogen or deuterium; and
either R 7 is —CD 3 or at least one of Z 2 , Z 3 , Z 4 and Z 5 is deuterium. In such an embodiment, the corresponding compound of Formula I has structural Formula I-A:
wherein R 4 , R 5 , R 6 , R 7 , Z 2 , Z 3 , Z 4 and Z 5 are as defined for Formula II-A; and Y is as defined for Formula I.
In one embodiment of Formula I-A and II-A, each R 7 is —CD 3 .
In one embodiment of Formula I-A and II-A, each Z 2 is deuterium.
In another embodiment of Formula I-A and II-A, each Z 2 is hydrogen.
In one embodiment of Formula I-A and II-A, each R 5 is deuterium.
In one embodiment of Formula I-A and II-A, each R 5 is hydrogen.
In one embodiment of Formula I-A and II-A, each Z 3 , Z 4 and Z 5 is hydrogen. In one aspect of this embodiment each R 6 is —CH 3 and each R 7 is —CD 3 . In a more specific aspect, each R 4 is —CH 3 , each R 6 is —CH 3 ; and each R 7 is —CD 3 . In another aspect of this embodiment each R 6 is —CD 3 and each R 7 is —CD 3 .
In one embodiment of Formula I-A and II-A, each Z 3 , Z 4 and Z 5 is deuterium.
In one embodiment of Formula I-A and II-A, each R 6 and each R 4 is —CD 3 .
In one embodiment of Formula II-A, the compound is selected from any one of:
In one embodiment of Formula I-A, the compound is selected from the following:
In one specific aspect, the compound of Formula II-A is
(Compound 407) and the compound of Formula I-A is
(Compound 437(R)).
In one embodiment, Compound 437 (R) is further converted to Compound 137(R) by treatment with K 2 CO 3 and water. Thus, maintenance of the deuteration at that position during the enzymatic conversion to Compound 437(R) is unimportant:
In one embodiment, compound 137(R) is substantially free of 437(R). “Substantially free” means that the amount of 437(R) is equal to or less than 5%, more preferably equal to or less than 1%, or more preferably equal to or less than 0.1%, of the amount of 137(R).
In one embodiment, any compound of formula I-A having a group
may be further converted to a compound having the same structure except for having a group
by treating with a suitable base and a proton source, such as water.
Applicants have discovered that the use of a ketoreductase or carbonyl reductase to reduce a deuterium-containing ketone compound of Formula II, in particular a compound of Formula II-A, allows for both high enantiomeric enrichment and substantially no loss of deuterium incorporation. In particular, the amount of deuterium incorporation at each deuterium in R 1 and R 2 in the compound of formula I is substantially equal to the amount of deuterium incorporation at corresponding deuterium atoms in R 1 and R 2 in the compound of formula II. This is particularly surprising in that it was unexpected that one could provide buffer conditions that (1) allowed the ketoreductase or carbonyl reductase to efficiently reduce the ketone without also allowing the enzyme to catalyze deuterium-to-hydrogen exchange on the existing deuterium atoms; (2) would not result in an acidic pH which would be expected to cause deuterium-to-hydrogen exchange on the existing deuterium atoms; and (3) would not require for activity sufficiently basic or acidic conditions that would also be expected to cause deuterium-to-hydrogen exchange.
In a related embodiment the invention provides a method of making Compound 133(R)
comprising the step of reacting pentoxifylline:
with a deuteride source in the presence of a ketoreductase or carbonyl reductase and an appropriate catalytic co-factor at a pH between 6.5 and 7.3 to form a compound of formula I with an enantiomeric excess of at least 90% and deuterium incorporation of at the hydroxy carbon of Compound 133(R) of least 90%.
Any ketoreductase or carbonyl reductase that produces a 90% or greater enantiomeric excess of the (R)—OH stereoisomer of Formula II may be utilized in the method of this invention. Commercially available kits containing different ketoreductases or carbonyl reductases are available from multiple vendors. A determination of whether or not a particular ketoreductase or carbonyl reductase produces a 90% or greater enantiomeric excess of the (R)—OH stereoisomer of Formula II may be achieved by standard techniques well-known in the art. For example, a compound of Formula II may be incubated with the ketoreductase or carbonyl reductase to be screened in the presence of a hydride or deuteride source.
In one embodiment, the ketoreductase is a naturally occurring ketoreductase selected from the group consisting of Candida magnoliae ketoreductase, Candida parapsilosis ketoreductase, and Sporobolomyces salmicolor ketoreductase.
In one embodiment, the ketoreductase or carbonyl reductase is selected from any one or ALMAC Carbonyl Reductases CRED A161, CRED A291, CRED A311, or CRED A601 (each commercially available from ALMAC Group Ltd, Craigavon, England), any one of CODEXIS Ketoreductases KRED-NADP-118, or KRED-NAD 1110 (each commercially available from Codexis Inc., Redwood City, Calif.), or SYNCORE Ketoreductases ES-KRED-120, ES-KRED-126, or ES-KRED-131 (each commercially available from Syncore Labs, Shanghai, China). In one aspect of this embodiment, the enzyme is selected from CRED A291, CRED A311, or CRED A601. In a more specific aspect, the enzyme in CRED A311.
In one embodiment, the amount of enzyme used in the reaction ranges from 0.05 wt % to 10 wt % as a percentage of the weight of the substrate, such as 0.5 wt % to 5 wt %. In one embodiment, the amount of enzyme is between 1.0 wt % and 2.0 wt %. In a more specific aspect, the amount of enzyme is about 1.0 wt %.
In one embodiment, the compound of formula I is formed with an enantiomeric excess of at least 90%. In one aspect of this embodiment, the enantiomeric excess is at least 94%. In a more particular aspect of this embodiment, the enantiomeric excess is at least 96%. In a more particular aspect of this embodiment, the enantiomeric excess is at least 98%.
The process of this invention requires the presence of a hydride source or a deuteride source. The term “hydride source” refers to a compound or mixture that is capable of providing a hydride anion or a synthetic equivalent of a hydride anion. Similarly, the term “deuteride source” refers to a compound or mixture that is capable of providing a deuteride anion or a synthetic equivalent of a deuteride anion. A hydride or deuteride source comprises a co-factor, which may be in catalytic or stoichiometric amounts. When the co-factor is in a catalytic amount, the hydride or deuteride source comprises a co-factor regeneration system.
A co-factor used with the ketone reductase or carbonyl reductase in the process of this invention is selected from NAD, NADP, NADH, NADPH, NAD 2 H and NADP 2 H. The choice of co-factor may be based upon (a) the presence or absence of a co-factor regeneration system; (b) the requirement for a hydride versus a deuteride source; and (c) compatibility with the specific ketone reductase or carbonyl reductase employed. In embodiments where the hydride or deuteride source does not comprise a co-factor regeneration system, the co-factor is in a stoichiometric amount and is a reduced co-factor which is therefore selected from NADH and NADPH for a hydride source, or NAD 2 H and NADP 2 H for a deuteride source. It is well known in the art—or information is available from the commercial supplier of the specific ketone reductase or carbonyl reductase—whether NADH or NADPH is the appropriate co-factor for a given ketone reductase or carbonyl reductase. In this embodiment, the reduced co-factor is present in stoichiometric amounts as compared to the compound of Formula II.
In another embodiment, the hydride or deuteride source additionally comprises a co-factor regeneration system. The high cost of co-factors, in particular the deuterated co-factors, makes their use on a stoichiometric basis impractical. A low-cost co-factor regeneration system continually produces and regenerates the reduced form of the co-factor, requiring the co-factor to be present in only catalytic amounts. Moreover, the use of a co-factor regeneration system eliminates the need to use a reduced co-factor or a deuterated co-factor. The co-factor regeneration system produces the required reduced or reduced and deuterated co-factor in situ. Accordingly, any cofactor or combinations of cofactors compatible with the chosen ketone reductase or carbonyl reductase can be employed with a co-factor regeneration system. In this embodiment, therefore, NAD is interchangeable with NADH and NAD 2 H; and NADP is interchangeable with NADPH and NADP 2 H. Similarly, the designations “-NAD” and “-NADH”, and “-NADP” and “-NADPH”, respectively, are used interchangeably herein in conjunction with enzymes that use, respectively, NADH and NADPH as co-factors.
When used in conjunction with a co-factor regeneration system the amount of co-factor can range from 0.1 wt % to 5 wt %. In one aspect of this embodiment, the amount of co-factor is between 1 wt % and 3 wt %. In an alternate aspect of this embodiment, the amount of cofactor is between 0.1 wt % and 1.1 wt %.
A typical co-factor regeneration system consists of a dehydrogenase and a substrate for that dehydrogenase. Without being bound by theory or mechanism, Applicants believe that upon catalysis by the dehydrogenase, its substrate provides a hydride or deuteride anion to regenerate (reduce) the cofactor. The newly reduced cofactor can then subsequently donate a hydride or deuteride atom to the compound of Formula II to provide a compound of Formula I. In certain embodiments, the substrate for the dehydrogenase may be generated in situ from the corresponding ketone and a reducing agent. A second co-factor regeneration system takes advantage of the fact that certain ketoreductases and carbonyl reductases both possess alcohol dehydrogenase activity. In this system an alcohol dehydrogenase substrate is used and upon catalysis donates the hydride or deuteride ion to the co-factor.
Examples of hydride cofactor regeneration systems include, but are not limited to, reducing sugars and their corresponding hydrogenase, e.g., glucose and glucose dehydrogenase (“GDH”), glucose-6-phosphate and glucose-6-phosphate dehydrogenase, etc.; formate and formate dehydrogenase; a secondary (e.g., isopropanol) alcohol and a secondary alcohol dehydrogenase; phosphite and phosphite dehydrogenase; molecular hydrogen and hydrogenase; and ethanol, aldehyde dehydrogenase and an alcohol dehydrogenase.
Examples of deuteride co-factor regeneration systems include, but are not limited to, deuterated reducing sugars and their corresponding dehydrogenase, e.g., deuterated glucose and GDH, deuterated glucose-6-phosphate and glucose-6-phosphate dehydrogenase, etc.; deuterated formate and formate dehydrogenase; a secondary deuterated (e.g., deuterated isopropanol) alcohol alone or together with a secondary alcohol dehydrogenase; deuterated phosphite and phosphite dehydrogenase; molecular deuterium and hydrogenase; and deuterated ethanol and aldehyde dehydrogenase optionally together with an alcohol dehydrogenase.
In one embodiment of the process, the deuteride co-factor regeneration system comprises a substrate having a —C(D)OH functional group and its associated dehydrogenase. In a related embodiment, the substrate having a —C(D)OH functional group is generated in situ. In this related embodiment, the deuteride co-factor regeneration system comprises (a) a compound having a C═O functional group; (b) a metal deuteride or a mixed metal deuteride, such as a borodeuteride or aluminum deuteride of a metal such as sodium or lithium, capable of reducing the C═O functional group to a —C(D)OH functional group; and (c) a dehydrogenase that acts upon the —C(D)OH functional group. As an example, the substrate having a —C(D)OH functional group is a C 1 -C 6 alcohol such as CH 3 C(D)(OH)CH 3 . As another example, the substrate having a —C(D)OH functional group is carbohydrate of the formula C 6 H 11 DO 6 , such as deuterated glucose (shown below in its open chain and pyranose forms):
As yet another example the deuterated glucose is generated in situ from D-glucono-δ-lactone and NaBD 4 . This embodiment is advantageous in that an otherwise expensive deuterated glucose substrate is generated in situ from relatively inexpensive D-glucono-δ-lactone and NaBD 4 .
Moreover, the inventors have discovered that the use of deuterated glucose (or D-glucono-δ-lactone and NaBD 4 ) as part of the deuteride source consistently produced high deuterium incorporation (>90%) at the Y position of a compound of Formula I and in particular a compound of Formula I-A. The use of deuterated glucose in the deuteride source in the production of
from pentoxifylline:
in accordance with this invention will also result in a surprisingly high deuterium incorporation at the indicated position of Compound 133(R).
When a combination of (a) GDH, glucose and a co-factor; (b)(i) GDH, deuterated glucose and a cofactor; or (b)(ii) GDH, D-glucono-δ-lactone, a metal deuteride or a mixed metal deuteride, and a cofactor is used as (a) the hydride source or (b) the deuteride source, respectively, the amount of GDH in the reaction can range from 0.01 wt % to 5 wt %. The term “wt %” means the amount of substance that is the recited percent of the amount of substrate present on a wt/wt basis. In one embodiment, the amount of GDH is between 0.05 wt % and 0.15 wt %. In an alternate embodiment, the amount of GDH is between 0.1 wt % and 0.2 wt %.
An appropriate pH to perform the method according to the present invention means buffer conditions that maintain the pH at between 6.0 and 7.5 throughout the reaction. In one embodiment, the pH of the reaction was maintained at between 6.5 and 7.3. In another embodiment, the pH of the reaction was maintained between 6.0 and 7.0. Typically dropwise addition of KOH is used to maintain the desired pH because the enzymatic reaction generates acid. In one aspect, the pH of the reaction is maintained between 6.90 and 7.05. If the pH of the reaction is allowed to drop below the desired range, the enzyme will typically become irreversibly inactivated and the compound of Formulae I and II subject to acid-catalyzed deuterium-to-hydrogen exchanged.
In one embodiment of the process of the invention, the process is performed at a temperature of about 20° C. to 37° C. In one aspect of this embodiment, the temperature is about 29° C. to 32° C.
In one embodiment of the process of the invention, the process is performed over a time period of about 12 hours to about 24 hours. In one embodiment, the time period is about 24 hours to about 40 hours. In one embodiment, the time period is about 40 hours to about 72 hours. In one embodiment, the time period is a time period sufficient for less than about 5% of the initial amount of compound of formula (II) to be present.
Example 1
Preparation of Compound 407
In a 50-L Jacket Glass Reactor, pentoxifylline (900 g) was reacted with deuterium oxide (99% of “D”, 2.7 L) in the presence of potassium carbonate (0.25 equiv) in toluene (18 L) at 85-87° C. (refluxing) over four hours. The reaction mixture was cooled to 55° C. and the agitation was stopped to allow the layers to separate. The reaction mixture was held overnight at 55° C. 1 H NMR analysis of an IPC sample of the organic layer showed the deuterium incorporation was 94.4% “D” at the methyl position. The bottom aqueous layer was collected. Following the same exchange conditions, a second exchange was conducted with a solution of potassium carbonate (0.25 equiv) in deuterium oxide (99% of “D”, 2.7 L). After separation, a third exchange was conducted with a solution of potassium carbonate (0.25 equiv) in deuterium oxide (99.8% of “D”, 2.7 L). 1 H NMR analysis of an IPC sample of the organic layer showed the deuterium incorporation was 99.6% “D” at the methyl position after three exchanges. The organic layer was concentrated to ca. 5.5 L (6 vol) at 60° C. (Batch temperature) and cooled slowly. The solids were formed at 36° C. and n-heptane (1.8 L) was added to form a thin slurry. The slurry was stirred at 25° C. over the weekend and filtered to provide white solids (825 g, wet). The solids were dried in vacuum oven (28.5 inch Hg) at 45-48° C. over night to afford Compound 407 (778.5 g, 84.6% yield). 1 H NMR analysis of Compound 407 showed that the deuterium incorporation was 99.7% “D” at the methyl position. An HPLC purity check by area showed that the purity was 99.96%.
Example 2
Screening of Carbonyl Reductases and Ketoreductases
ALMAC Carbonyl Reductases
The ability of the 40 individual carbonyl reductases in the ALMAC Carbonyl Reductase (CRED) Screening Kit to convert Compound 407 to Compound 421(R)
was tested as follows:
Into a vial was added 1 mL of a 15 mg/mL solution of the CRED to be tested in 0.1M K 2 HPO 4 , pH 7.0. To that vial was added 100 μL of a 300 mg/mL solution of glucose; 100 μL of a 10 mg/mL solution of the appropriate co-factor NAD or NADP (as indicated in the table below) in 0.1M K 2 HPO 4 , pH 7.0; 100 μL of a 20 mg/mL solution of glucose dehydrogenase in 0.1M K 2 HPO 4 , pH 7.0; and approximately 20 mg of Compound 407 in 50-150 μL of DMSO or MTBE. The sample was shaken or stirred overnight at 30° C. The sample was then extracted with METE or EtOAc and analyzed by TLC and certain select samples by chiral GC/HPLC to determine conversion to Compound 421(R) and enantiomeric enrichment. The results are set forth in Table 1.
TABLE 1
Screening of ALMAC Carbonyl Reductases
Estimated
Conversion
Conversion
S/R Ratio of
Enzyme
Cofactor
By TLC
By HPLC
Alcohol
A101
NADP
10%
N/A
N/A
A201
NADP
0%
N/A
N/A
A301
NADP
5%
N/A
N/A
A401
NADP
10%
N/A
N/A
A501
NADP
0%
N/A
N/A
A601
NADP
100%
99.90%
0.2/99.8
A701
NADP
0%
N/A
N/A
A801
NADP
20%
8.20%
92.4/7.6
A901
NADP
50%
32.10%
96.5/3.5
A121
NADP
10%
N/A
N/A
A131
NAD
100%
99.70%
99.7/0.3
A141
NADP
5%
N/A
N/A
A151
NAD
35%
20.10%
35.0/65.0
A161
NAD
100%
99.90%
2.6/97.4
A171
NAD
0%
N/A
N/A
A181
NADP
10%
N/A
N/A
A191
NAD
0%
N/A
N/A
A211
NADP
0%
N/A
N/A
A221
NAD
0%
N/A
N/A
A231
NADP
5%
N/A
N/A
A241
NADP
0%
N/A
N/A
A251
NAD
100%
99.90%
99.9/0.1
A261
NADP
0%
N/A
N/A
A271
NADP
45%
36.50%
99.4/0.6
A281
NADP
40%
36.70%
73.2/26.8
A291
NADP
90%
97.20%
0.1/99.9
A311
NADP
100%
99.80%
0.1/99.9
A321
NADP
0%
N/A
N/A
A331
NADP
5%
N/A
N/A
A341
NADP
10%
N/A
N/A
A351
NADP
0%
N/A
N/A
A361
NADP
0%
N/A
N/A
A371
NADP
50%
51.60%
73.0/27.0
A381
NADP
0%
N/A
N/A
A391
NADP
0%
N/A
N/A
N501
NADP
0%
N/A
N/A
N701
NADP
0%
N/A
N/A
N121
NADP
0%
N/A
N/A
N131
NADP
5%
N/A
N/A
N151
NADP
10%
N/A
N/A
The results of this experiment demonstrated that ALMAC Carbonyl Reductase CRED A291, CRED A311, CRED A161, or CRED A601 were useful in the process of this invention.
Codexis Ketoreductases.
The CODEXIS Ketoreductase (KRED) Enzyme Screening Kit contained 34 enzymes that used either NADP (Kit KRED-22000) or NAD (Kit KRED-12000) as a co-factor. The screening Kit KRED-22000 contained 22 KRED-NADP enzymes and their screening test results were carried out according to manufacturer's directions using approximately 5 mg of KRED-NADP enzyme and 71 mg of Compound 407 and the appropriate CODEXIS buffer system (KRED-NADPH Recycle Mix A or KRED-NADH Recycle Mix A) for each reaction. Reactions were tested by TLC (data not shown) and selected reactions were tested by chiral HPLC after 40 hours. These results are set forth in Tables 2 and 3. Results indicated by a dash (“-”) indicate an insufficient amount of Compound 421(R) or its stereoisomer were produced by TLC to warrant detection by HPLC.
TABLE 2
Screening of Codexis Ketoreductases in Kit KRED-22000.
KRED-
S/R
NADP
Conversion By
Ratio of
Enzyme
HPLC
Alcohol
KRED-101
26.30%
29.8/70.2
KRED-102
—
—
KRED-103
—
—
KRED-107
—
—
KRED-112
23.80%
27.2/72.8
KRED-113
—
—
KRED-118
52.80%
7.8/92.2
KRED-119
99.70%
91.6/8.4
KRED-121
—
—
KRED-128
41.80%
72.0/28.0
KRED-129
—
—
KRED-130
99.50%
78.7/21.3
KRED-131
—
—
KRED-137
25.60%
96.4/3.6
KRED-140
—
—
KRED-142
—
—
KRED-147
—
—
KRED-148
76.70%
99.5/0.5
KRED-149
—
—
KRED-164
—
—
KRED-169
65.10%
98.9/1.1
KRED-174
73.90%
99.2/0.8
TABLE 3
Screening of Codexis Ketoreductases in Kit KRED-12000.
S/R
KRED-NADH
Conversion
Ratio of
Enzyme
By HPLC
Alcohol
101
100%
100/0
102
100%
100/0
107
—
—
108
—
—
109
—
—
110
100%
1.5/98.5
112
99.90%
99.8/0.2
113
—
—
119
—
—
121
—
—
124
—
—
126
100%
>99.9/0.1
The above results indicated that CODEXIS Ketoreductases KRED-118 and KRED-NADH 110 were useful in the process of this invention.
Syncore Ketoreductases
SYNCORE Ketoreductase (ES-KRED) Enzyme Screening Kit contained 75 enzymes. Twenty-one ketoreductases (NADH dependent) were tested for the reduction of Compound 407 on 100 mg scale. The CODEXIS buffer system (KRED-NADH Recycle Mix A) was used for these screening tests. The reduction was conducted with 5 wt % of enzyme loading in 50 vol of buffer at 30° C. The reactions were checked by TLC (data not shown) and selected reaction mixtures were checked by chiral HPLC and worked up. Results indicated by a dash (“-”) indicate an insufficient amount of Compound 421(R) or its stereoisomer were produced by TLC to warrant detection by HPLC. The results are summarized in Table 4.
TABLE 4
Screening of Syncore NADH-dependent Ketoreductases.
S/R Ratio of
Enzyme
Conversion By HPLC
Alcohol
ES-KRED-121
99.62%
100/0
ES-KRED-122
—
ES-KRED-125
—
ES-KRED-126
100.00%
0/100
ES-KRED-128
99.42%
99.83/0.17
ES-KRED-129
—
ES-KRED-130
100.00%
100/0
ES-KRED-132
—
ES-KRED-133
—
ES-KRED-134
—
ES-KRED-137
—
ES-KRED-138
—
ES-KRED-141
—
ES-KRED-142
100.00%
100/0
ES-KRED-143
—
ES-KRED-144
—
ES-KRED-155
—
ES-KRED-159
—
ES-KRED-165
—
ES-KRED-166
—
ES-KRED-175
22.71%
100/0
The remaining 54 NADPH dependent ketoreductases from Syncore were also tested for the reduction of Compound 407 (100 mg) using the CODEXIS buffer system (KRED-NADPH Recycle Mix A). The reduction was conducted with 5 wt % of enzyme loading in 50 vol of buffer at 30° C. The reactions were checked by TLC (data not shown) and selected reaction mixtures were checked by chiral HPLC and worked up. Results indicated by a dash (“-”) indicate an insufficient amount of Compound 421(R) or its stereoisomer were produced by TLC to warrant detection by HPLC. The results are summarized in Table 5.
TABLE 5
Screening of Syncore NADPH-dependent Ketoreductases.
Conversion By
S/R Ratio of
Enzyme
HPLC
Alcohol
ES-KRED-101
—
—
ES-KRED-102
—
—
ES-KRED-103
—
—
ES-KRED-104
—
—
ES-KRED-105
—
—
ES-KRED-106
—
—
ES-KRED-107
—
—
ES-KRED-108
—
—
ES-KRED-109
—
—
ES-KRED-110
—
—
ES-KRED-111
—
—
ES-KRED-112
—
—
ES-KRED-113
—
—
ES-KRED-114
—
—
ES-KRED-115
—
—
ES-KRED-116
—
—
ES-KRED-117
—
—
ES-KRED-118
—
—
ES-KRED-119
—
—
ES-KRED-120
99.30%
0.18/99.82
ES-KRED-123
—
—
ES-KRED-124
—
—
ES-KRED-127
—
—
ES-KRED-131
99.90%
0.06/99.94
ES-KRED-135
—
—
ES-KRED-136
—
—
ES-KRED-139
—
—
ES-KRED-140
—
—
ES-KRED-145
—
—
ES-KRED-146
—
—
ES-KRED-147
—
—
ES-KRED-148
—
—
ES-KRED-149
—
—
ES-KRED-150
—
—
ES-KRED-151
—
—
ES-KRED-152
—
—
ES-KRED-153
—
—
ES-KRED-154
—
—
ES-KRED-156
—
—
ES-KRED-157
—
—
ES-KRED-158
—
—
ES-KRED-160
—
—
ES-KRED-161
—
—
ES-KRED-162
—
—
ES-KRED-163
—
—
ES-KRED-164
—
—
ES-KRED-167
—
—
ES-KRED-168
—
—
ES-KRED-169
99.96%
99.94/0.06
ES-KRED-170
—
—
ES-KRED-171
100%
98.70/1.30
ES-KRED-172
—
—
ES-KRED-173
—
—
ES-KRED-174
—
—
From the above experiments, it was determined that SYNCORE Ketoreductases ES-KRED-120, ES-KRED-126, and ES-KRED-131 were suitable for use in the present invention.
Example 3
Preparation of Compound 437(R) from Compound 407 Using CRED-A311 and Deuterated Glucose Generated In Situ
a) In Situ Generation of Deuterated Glucose:
Deuterated glucose (D-[1- 2 H 1 ] Glucose) was prepared according to the procedure described in Liebigs Ann. Chem. 1992, 1201-1203. D-Glucono-δ-lactone (5 g, 28.09 mmoles) was added in one portion to ice-cold water (35 mL, 0-3° C.) and stirred for 10 min. A freshly prepared, ice-cold solution of NaBD 4 (0.294 g, 7.02 mmoles, 99% D) in 10 mL of water was added slowly during 10 min. The reaction is slightly exothermic (2° to 10° C.) and the pH of the reaction was 7.42. Stirring was continued for 30 min, keeping the temperature by cooling to 0-3° C. Acetic acid (0.32 mL, 5.61 mmoles) was added and stirring was continued further 30 min.
b) Preparation of Compound 437(R) from Compound 407:
The reaction mixture obtained in step (a) was diluted with 18 ml of water and the solution was heated to 25-30° C. KH 2 PO 4 (0.85 g) was added to the mixture and the pH was adjusted to 7 with 4M KOH solution. To this was added 2.5 g (8.8 mmoles) of 407. A solution of NADP (15 mg), GDH (2.5 mg), CRED A311 (25 mg) in 12.5 mL of 0.1 KH 2 PO 4 buffer was added. The resulting solution was stirred at 25-30° C. The pH of the reaction mixture was maintained between 6 and 7 by adding 4M KOH solution drop-wise. The reaction was monitored by HPLC and was complete after 12 hours with 99.97% conversion by HPLC. Sodium chloride (12.5 g) was added and stirred for 30 min. The mixture was extracted with ethyl acetate (3×25 mL). The organic layer was separated, filtered through celite pad and concentrated to a small volume (˜5 vol) and product solids were precipitated. Heptanes (20 mL) were added to the slurry (at 40-60° C.) over 10 minutes. The slurry was stirred overnight at 20-25° C. and filtered. The wet cake was dried at 50° C. for 12 hours to afford 437(R) as a white solid. (2.12 g, 85% yield). The isolated product purity was >99.95% by HPLC and as a single enantiomer by chiral HPLC.
Compound 437 (R) may be further converted to Compound 137(R) by treatment with K 2 CO 3 and water, as follows:
Preparation of Compound 137(R) from Compound 437(R).
In a 3-L 3-necked RB flask, Compound 437(R) (100 g) was charged followed by water (1.0 L) and K 2 CO 3 (0.25 equiv). The reaction mixture was heated to 80±5° C. and monitored by 1 H NMR. The reaction was complete after 24 hours and worked up after 65 hours. The resulting product was extracted with three times with EtOAc and the solid products from the three extractions combined and re-dissolved in 5 volumes of EtOAc at 60-65° C. n-heptane (5.5 vol.) was added at 60-65° C. over 15 minutes and cooled to 20° C. over night (16 hrs). The slurry was filtered and the wet cake was washed with n-heptane (2×1 vol. to afford product Compound 137(R) after drying at 40-50° C. A total of 92.4 g of Compound 137(R) was isolated. HPLC purity was 99.92% (AUC) and chiral selectivity was 100% to “S” enantiomer. The 1 H NMR analysis showed 99.2% of “H” at the 8-position in the 3,4,5,7-tetrahydro-1H-purine-2,6-dione ring and 99.4% of “D” at the methyl position.
Example 4
Preparation of Compound 421(R) from Compound 407 Using CRED A131
A 100 mL 3-necked RB flask equipped with a heating mantle, a J-Kem thermocouple, magnetic stir bar, a reflux condenser, and a pH probe was charged with CTP-499-A (500 mg, 1.75 mmol), D(+) Glucose (750 mg, 1.5 wt) in 10 mL buffer (0.1M KH 2 PO 4 , pH=7.0) and heated to 25-30° C. A solution of NADP (15 mg, 3 wt %), GDH (3 mg, 0.6 wt %), ALMAC CRED A311 (30 mg, 6 wt %) in 0.1 M KH 2 PO 4 buffer was added and maintained reaction temperature 25-30° C.
To this added 1 mL of methyl-t-butyl ether (MTBE). The pH of the reaction mixture was maintained between 6 and 7 adding 4M KOH solution drop-wise. The reaction was monitored by HPLC and was complete after 29 hours with 99.87A % conversion by HPLC. Sodium chloride (2.5 g, 5 wt) was added and stirred for 20 min. The reaction mixture was extracted with ethyl acetate (3×15 mL). The organic layer was separated, filtered through celite pad and concentrated to a small volume (˜5 vol) and product solids were precipitated. Heptanes (5 mL) was added to the slurry (at 40-60° C.) over 5 minutes. The slurry was stirred at 20-25° C. and filtered. The wet cake was dried at 50° C. for 12 hours to afford CTP-499-G as a white solid. (0.422 g, 84% yield). The isolated product purity was >99.5% by HPLC and single enantiomer by chiral HPLC. | The present invention provides a convenient and efficient process for the preparation of enantiomerically enriched, deuterated secondary alcohols without reducing deuterium incorporation. | 2 |
The government may own certain rights in the present invention pursuant to grants by the Defense Advanced Research Projects Agency, Contract Nos. N00014-86-K-0769 and N00014-90-J-1320.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to transition metal bis(dithiolene) complex polymers and copolymers, and their preparation by polymerization of bifunctionalized transition metal bis(dithiolene) complexes.
2. Description of Related Art
Over the past 30 years, there has been a considerable effort devoted to the synthesis and understanding of transition metal bis(dithiolenes) 1 and structurally related complexes 2 which possess interesting electrochemical, optical, magnetic, liquid crystalline, 3 electrically conductive, superconductive 4 , and near-infrared ("NIR") absorption properties. 5-7
A number of electroactive and conductive polymers and oligomers based on the square planar MS 4 center have also been prepared. These include poly(metal tetrathiooxalates), 8 poly(metal ethylenetetrathiolates), 9 poly(metal tetrathiosquarates), 10 poly(metal tetrathiafulvalenetetrathiolates), 11 , 12 poly(metal tetrathianaphthalenes), 13 and poly(metal benzenetetrathiolates). 14
Although many of these polymers are potentially useful because of their electroactive and conductive properties, most of them are insoluble and infusible solids due to their ribbonlike rigid structure. During synthesis some of these systems possess solubility that may be attributed to the high charge density along the polymer backbone, but precipitation to insoluble and infusible powders prohibits processing of the polymer for practical application.
In order to address the low solubility of these fully conjugated polymers, the inventors herein have discovered the possibility of incorporating square planar metal complexes [i.e. metal bis(dithiolenes)] into the main chain of polymers that contain flexible units. The inventors previously reported 15-18 on the synthesis of a novel metal complex polymer, poly[[1,1'-oxybis[4-(1,2-dithiolatoethenyl)benzene]] nickel(II)], having the following structure: ##STR1## where X is oxygen.
Although this polymer, in its reduced form, is generally soluble in a variety of both aqueous and organic solvents, and exhibits electrochemical properties analogous to transition metal bis(dithiolenes), it tends to be generally insoluble in its oxidized and neutral forms. Thus, its potential application is limited. In addition, low molecular weights were obtained due to intrinsic problems of the metal complexation polymerization technique used.
It can be hypothesized that solubility and processability of compound (I) could be improved by introducing a flexible linkage X into the main chain. The synthesis of this polymer, as previously reported by the inventors, involved complexation of a tetrathiolate ligand precursor prepared via a bis(dithiocarbonate) (shown below), with a stoichiometric amount of Ni 2+ . ##STR2##
This type of synthesis tends to become problematical as the flexible linkage X becomes longer, due to the difficulty in preparing the precursor (2). For example, when the linkage is docosane, the synthesis of the ligand generally requires multiple steps and therefore the overall yield tends to be low. As a general rule in organic chemistry, increasing the substrate size and flexible side chain length significantly reduces the reactivity of the functional group in the compound due to steric blocking of the active site. From a kinetic viewpoint, the number of effective collisions between molecules may also be reduced. Typically, long reaction times, severe reaction conditions and low yields are encountered in reactions involving large molecules. Long flexible chains along the polymer backbone are generally needed in order to further increase the solubility of the polymers. However, this tends to further increase synthetic difficulties, as well as lead to added expense, lower yields, and increased time constraints. Time consuming, highly involved multistep syntheses may be required to produce products that possess little synthetic versatility. Another problem associated with such a synthesis is in maintaining stoichiometric balance between the two reactants.
Thus, there is a need to develop improved classes of polymers based on square planar MS 4 centers, and improved syntheses of such polymers. It is an object of this invention to provide such polymers and syntheses which address at least some of the shortcomings of the prior art.
SUMMARY OF THE INVENTION
One aspect of the present invention provides a broad class of transition metal bis(dithiolene) complex polymers and copolymers having improved characteristics. The class of polymers of the invention can be represented generally as having the following formula: ##STR3## wherein: --A-- is derived from a reactive functional group;
--R-- is an organic substituent derived from a bifunctional molecule capable of reacting with the reactive functional group;
M is a transition metal;
q is the oxidation state of the transition metal complex; and
n is the chain length of the polymer.
The class of copolymers provided by the present invention have the following general random formula: ##STR4## wherein: --A-- is derived from a reactive functional group;
--R"-- is an organic substituent derived from a molecule bifunctionalized with reactive functional groups;
--R-- is an organic substituent derived from a bifunctional molecule capable of reacting with the reactive functional groups;
M is a transition metal;
q is the oxidation state of the transition metal complex;
n is the chain length of the copolymer segments having bifunctionalized transition metal complex comonomer units and is a varying positive integer;
m is the chain length of the copolymer segments having --R"-- comonomer units and is a varying positive integer; and
x is the overall chain length of the copolymer.
Other aspects of the invention provide methods of preparing the polymers (3) and copolymers (4), NIR filters comprising such compounds, and methods of filtering NIR radiation using such compounds.
In a preferred embodiment, the transition metal is one which provides a square planar transition metal complex center, such as Ni, Pd, or Pt. Such a structure may provide NIR absorptive properties to the resulting polymer or copolymer.
Preferably, the chain length of the polymer (3) or copolymer (4) is greater than about 5, most preferably, greater than about 20. This may provide the polymer or copolymer with sufficient molecular weight to attain useful mechanical properties.
In a preferred embodiment of the copolymer (4), --R"-- is an alkyl unit, an aryl unit, or an organic oligomer, such as a methylene, oxymethylene, or oxyethylene chain.
Preferred syntheses of transition metal bis(dithiolene) complex polymers and copolymers as provided by this invention will now be discussed. A preferred method of preparing the polymer generally comprises the steps of preparing a transition metal bis(dithiolene) complex which is bifunctionalized, and linking the bifunctional transition metal bis(dithiolene) complex with an organic compound which is bifunctionalized with functional groups capable of reacting with the bifunctional metal bis(dithiolene) complex.
The analogous preferred method of preparing the copolymer comprises the steps of preparing a transition metal bis(dithiolene) complex which is bifunctionalized; providing a comonomer compound which is also bifunctionalized; and copolymerizing the bifunctional transition metal bis(dithiolene) complex and bifunctional comonomer compound with an organic compound which is bifunctionalized with functional groups capable of reacting with said bifunctional complex and compound.
In preferred embodiments of these methods, the bifunctional metal bis(dithiolene) complex includes proton donating end groups, and the bifunctional organic compound includes functional groups capable of reacting with the proton donating end groups (e.g. active halide or isocyanate end groups).
Examples of proton donating end groups suitable for use are:
--OH;
--NH 2 ; ##STR5## --(CH 2 ) p --OH; --(CH 2 ) p --NH 2 ; and ##STR6## where p (hereinafter) is a positive integer.
Examples of suitable bifunctional organic compounds for reaction with such groups include: ##STR7## OCN--R'--NCO; R' (hereinafter) preferably being an alkyl or an aryl.
Alternatively, the bifunctional metal bis(dithiolene) complex may include active halide end groups, while the bifunctional organic compound may include functional groups capable of reacting with the active halide end groups (e.g. proton donating end groups).
Examples of active halide end groups suitable for use are: ##STR8##
Suitable bifunctional organic compounds for reaction with such groups include, for example:
H 2 N--R'13 NH 2 ; and
HO--R'--OH
In order to attain ambient stability, the metal complex centers of the resulting polymers and copolymers can be oxidized or reduced to different oxidation states by conventional methods, such as exposure to air or reaction with an oxidizing agent, such as I 2 or NOPF 6 .
As will be apparent, the methods described above may be used to yield polymers and copolymers of the class represented by formulas (3) and (4) above. Using one of the preferred embodiments discussed above, the resulting polymer (3) or copolymer (4) can be designed such that --A-- is derived from a proton donating functional group. For example, --A-- may be: ##STR9## In this embodiment, --R-- in formula (3) or (4) may be derived from a bifunctional molecule having active halide end groups. For example, --R-- may be: ##STR10##
Alternatively, --A-- may be derived from an active halide functional group, examples of --A-- being ##STR11## while --R-- may be derived from a bifunctional molecule having proton donating end groups, examples of --R-- being --O--R'--O-- and --NH--R'--NH--.
The oxidation state of the transition metal complex may be adjusted, as desired, to attain ambient stability. Preferably, the oxidation state is -2, -1, 0, or +1.
Polymer (3) or copolymer (4) may be designed to serve as a NIR filter. If desired, such a NIR filter may take the form of a film of the polymer or copolymer on a surface of a transparent substrate or as freestanding film. Radiation may be directed through the polymer or copolymer to filter NIR light.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart illustrating the synthesis of a nickel bis(dithiolene) complex diol, which may be used as a precursor in the polymerization and copolymerization schemes provided by this invention.
FIG. 2 is a flow chart illustrating polyester formation with the nickel bis(dithiolene) complex product of FIG. 1.
FIG. 3 is a flow chart illustrating polyester copolymer formation with the nickel bis(dithiolene) complex product of FIG. 1 and a second diol.
FIG. 4 is a flow chart illustrating polycarbonate copolymer formation with the nickel bis(dithiolene) complex of FIG. 1 and a second diol.
FIG. 5 is a flow chart illustrating polyurethane copolymer formation with the nickel bis(dithiolene) complex of FIG. 1 and a second diol.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The metal bis(dithiolene) complex-based polymers and copolymers provided by this invention can be used in a variety of contexts due to their optical and electrochemical properties. They can be designed for use as NIR filters, sensors (e.g. for detecting toxic gases), charge storage, and other applications. The properties of the polymers can be designed for the particular application, by controlling the number and positioning of the metal complex centers and flexible linkages within the polymer chain.
A preferred embodiment of this invention relates to preparation of a transition metal bis(dithiolene) complexcontaining polymer. According to this embodiment, a transition metal bis(dithiolene) complex is first prepared having two functional groups, then reacted with another bifunctional compound to synthesize the polymer. Particularly preferred reaction schemes are analogous to conventional esterification, carbonate formation, and urethane formation.
An advantage associated with this type of synthesis is that a wide variety of flexible linkages can be incorporated into the polymer chain via the bifunctional reactant. Also, standard polymerization techniques can be used to prepare high molecular weight polymers. The functional groups in this reaction can be varied for different reactivities.
In another preferred embodiment, a third bifunctional reactant can be added to the reaction to run a copolymerization that can bring even more variety to the resulting polymer. In this way, the physical properties of the polymer products can be varied and designed for particular applications. The molecular weight and solubility of the polymer may also be increased significantly. A copolymer prepared in this manner may possess the desired properties to fit the requirements of practical applications.
Polymers based on nickel bis(dithiolene) (sometimes referred to hereinafter as "Ni-BDT") complexes will be used in the discussion below to exemplify the general polymerization and copolymerization schemes provided by this invention.
First, synthesis of a nickel bis(dithiolene) complex diol can be carried out as shown in FIG. 1. In the scheme shown, an alcoholic hydroxy group serves as a functional group on the Ni-BDT complex. The alcoholic hydroxy group tends to be stable during the metal complexation reaction, and it has only a minimum possibility of interfering with the complexation reaction. Also, the hydroxy groups are easily protected and deprotected during the synthetic steps if necessary.
In the scheme shown in FIG. 1, the starting material is phenethyl alcohol, containing a hydroxy group which behaves as a regular aliphatic alcohol. The first step of this embodiment involves a Friedel-Crafts acylation, though with the presence of alcohol and acyl chloride in the reaction mixture, esterification is an obvious side reaction. If desired, the alcohol group may be protected. Upon considering the reaction conditions however, low temperature (-10° C.) and excess AlCl 3 present, it is seen that the AlCl 3 will complex with the hydroxy group, thus reducing its reactivity. By careful control of the reaction conditions the acylation may be the major reaction route and the esterification may be reduced to a minimum. Thus, the protection of the hydroxy group may be omitted in this acylation reaction.
The next step in FIG. 1 is a substitution reaction with O-ethylxanthic acid potassium. Though compound 7 may be used directly for the complexation reaction (the acetyl group can be cleaved by sodium ethoxide), an initial deprotection may give cleaner products. In order to avoid the possible complications caused by deacylation, compound 7 may be deprotected by aqueous K 2 CO 3 solution to compound 8 before the complexation reaction.
The diol 9 can then be reacted with a diacid chloride (e.g. sebacoyl chloride or terephthaloyl chloride) to give the corresponding polyester, as illustrated in FIG. 2. Polyester formation involves a low temperature, acyl chloride, and solution reaction conditions. The nickel complex may be thermally unstable, therefore, a high temperature ester-exchange polymerization method is not preferred for this reactant. The acyl chloride method has the advantage of simplicity, mild conditions, and high reaction equilibrium constant. The interfacial method is also not preferred for this synthesis because the Ni-BDT monomer is an alcoholic diol which has a low K a value so it may not provide enough alkoxide anion in the reaction. In order to have the reaction carried out in high concentration, a good solvent for the nickel complex, e.g. DMF, may be employed.
As illustrated in FIG. 3, other diols can be introduced to give a polyester copolymer. Examples of diols which can be used as the comonomer include ethylene glycol and bisphenol A. When both the diol and the diacid moiety are alkyl, a highly flexible polymer can be obtained. If part of the diol or diacid moiety is aryl, the polymer will tend to have a more rigid structure, and the mechanical properties of the polymer may be enhanced.
An alternative preferred reaction scheme yields Ni-BDT functionalized polycarbonates and polycarbonate copolymers, as illustrated in FIG. 4, and explained in detail in Example III below.
Yet another alternative embodiment yields Ni-BDT functionalized polyurethanes and polyurethane copolymers, as illustrated in FIG. 5, and explained in detail in Example IV below.
The polycarbonates containing Ni-BDT generally have high solubility in common organic solvents, and films can typically be cast from them. The polyurethanes containing Ni-BDT generally have high solubility in polar solvents such as DMF and DMSO. The high Ni-BDT content polymer (20%) shows decreased solubility. Both the Ni-BDT containing polycarbonates and polyurethanes are generally electroactive.
EXAMPLES
The following examples are designed to illustrate certain aspects of the present invention. The examples are not intended to be comprehensive of all features and all embodiments of the present invention, and should not be construed as limiting the disclosure presented herein.
EXAMPLE I: Preparation of Bifunctionalized Transition Metal Complex Comonomer
Step 1: Preparation of 4-(chloroacetyl)phenethyl alcohol (5)
Finely ground AlCl 3 (92.0 g, 0.69 mol) was mixed with dichloromethane (120 ml) in a flask and cooled to -10° C. Chloracetyl chloride (37.3 g, 0.33 mol) was added to the mixture as it was kept cool. Phenethyl alcohol (36.6 g, 0.30 mol) was dissolved in dichloromethane (20 ml) and charged to a dropping funnel. The phenethyl alcohol solution was added slowly dropwise to the mixture over 2 hours while stirring and keeping the temperature at about 10° C. At the end of the addition, the mixture was allowed to warm to room temperature and stirred overnight. The red color solution was poured into a large quantity of ice (about 300 g). The organic layer was separated and the aqueous layer was extracted with dichloromethane (200 ml), and the dichloromethane portions were washed with water until neutral. The organic phase was then dried (magnesium sulfate), concentrated, recrystallized (ether), and dried to give 48.8 g (81.9%) of compound 5. Analysis of the products gave the following results: mp 41°-45° C.; NIR (KBr) 3477, 3355, 2947, 1702, 1693, 1606, 1218, 1044, 818 cm -1 ; 1 H NMR (60 MHz) δ 1.96 (s, 1H), 2.92 (t, 2H, J=6.5 Hz), 3.90 (t, 2H, J=6.5 Hz), 4.67 (s,2H), 7.2-7.4 (m, 2H), 7.8-8.0 (m, 2H).
Step 2: Preparation of 4 -(o-ethylxanthateacetyl)phenethyl alcohol (6)
A mixture of compound 5 (48.5 g, 0.244 mol) and o-ethylxanthic acid potassium salt (39.1 g, 0.244 mol) in acetone (250 ml) was heated to reflux for 3 hours. The mixture was allowed to cool to room temperature and filtered. The precipitate was washed with dichloromethane (50 ml). The combined organic phase was concentrated to give crude compound 6. The crude compound 6 was dissolved in dichloromethane (200 ml) and washed with water (100 ml). The solution was dried (magnesium sulfate), concentrated, and cooled to give a light yellow solid. The solid was crushed and washed with hexane to give 65.9 g (95.0%) of compound 6. Analysis of the product gave the following results: mp 53°-55° C.; NIR (KBr) 3329, 2891, 1672, 1605, 1224, 1113, 1054 cm -1 ; 1 H NMR (60 MHz) δ 1.33 (t, 3H, J=7 Hz), 2.90 (t, 2H, J=6.8 Hz), 3.85 (t, 2H, J=6.8 Hz), 4.60 (s, 2H), 4.60 (q, 2H, J=7 Hz), 7.2-7.4(m, 2H), 7.8-8.0 (m, 2H).
Step 3: Preparation of 4-(2-oxo- 1,3-dithiolyl)phenethyl acetate (7)
A mixture of compound 6 (63.4 g, 0.223 mol) and acetyl chloride (70 ml, 0.98 mol) was stirred at room temperature for 24 hours. Chloroform (200 ml) was added to the flask and the mixture was poured into ice (300 g). The chloroform solution was separated and washed with water until neutral, concentrated, recrystallized (ethanol), and dried to give 54.0 g (86.4%) of compound 7. Analysis of the product gave the following results: mp 55°-56° C.; NIR (KBr) 3079, 2964, 1728, 1632, 1256, 1042, 784 cm -1 ; 1 H NMR (300 MHz) δ 2.03 (s, 3H), 2.95 (t, 2H, J=6.8 Hz), 4.28 (t, 2H, J=6.8 Hz), 6.81 (s, 1H), 7.24-7.37 (m, 4H); 13 C NMR (75 MHz) δ 192.29, 170.76, 139.20, 134.58, 130.92, 129.57, 126.30, 111.28, 64.28, 34.62, 20.78. Anal. Calcd. for C 13 H 12 O 3 S 2 : C, 55.69; H, 4.31; Found: C, 55.30; H, 3.97.
Step 4: Preparation of 4-(2-oxo-1,3-dithiolyl)phenethyl alcohol (8)
A mixture of compound 7 (40.0 g, 0.143 mol) dissolved in 500 ml methanol and 40 g K 2 C03 dissolved in 300 ml water was stirred at room temperature for 1 hour. The mixture was extracted with 300 ml chloroform. The chloroform solution was washed with water, concentrated, recrystallized (methanol/ether), and dried to give 23.8 g (70.0%) of compound 8. Analysis of the product gave the following results: mp 92°-94° C.; NIR (KBr) 3258, 3060, 2927, 1697, 1632, 1503, 1055, 1046, 868 cm -1 ; 1 H NMR (300 MHz) δ 1.55 (s, 1H), 2.89 (t, 2H, J=6.8 Hz), 3.88 (t, 2H, J=6.8 Hz), 6.79 (s, 1H), 7.26-7.38 (m, 4H); 13 C NMR (75 MHz) δ 192.52, 140.08, 134.80, 130.89, 129.79, 126.43, 111.19, 63.27, 38.75. Anal. Calcd. for C.sub. 11 H 10 O 2 S 2 : C, 55.44; H, 4.23; Found: C, 56.32; H, 4.56.
Step 5: Preparation of 1,1'bis[2-hydroxyethyl[4-(1,2-dithiolatoethenyl)benzene]] nickel (II) (9)
A mixture of compound 8 (1.500 g, 6.294 mmol) and sodium ethoxide (1.285 g, 18.88 mmol) in ethanol (100 ml) was heated at 60° C. with stir for 40 min. Nickel bromide (0.687 g, 3.147 mmol) dissolved in ethanol (200 ml) was added to the mixture via cannula. The resulting mixture was heated at 60° C. for 4 hours and then cooled to room temperature. The ethanol was removed and 200 ml acetone was added to the residue. After filtering and washing the solid residue with more acetone (2×100 ml), the acetone solution was collected and a solution of 50 ml water with 1 ml 37% HCI was added to the acetone solution. Removing the solvent gave the product which was washed with water and chloroform, then dried under vacuum to give 1.034 g (68.6%) of compound 9. Analysis of the product gave the following results: NIR (KBr) 3366, 3022, 2933, 1414, 1371, 1193, 1043, 1017, 864, 793 cm -1 ; UV-Vis-NIR (THF) λ max (ε) 295 (24,500), 365 (sh, 9100), 835 (10,150) nm. Anal. Calcd. for C 20 H 20 NiO 2 S 4 : C, 50.11; H, 4.21; Found: C, 49.84; H, 3.84.
EXAMPLE II: Polyester and Polyester Copolymer Formation
Preparation of Polyester
Poly[1-oxyethyl[4-(1,2-dithiolatoethenyl)benzene]nickel(II)[(1',2,'-dithiolatoethenyl)4'-benzene]1 '-ethyloxysebacoyl] (FIG. 2). In a 50 ml flask, compound 9 (0.479 g, 1 mmol) and sebacoyl chloride (0.239 g, 1 mmol) were dissolved in 10 ml DMF. 2 ml pyridine was added and the mixture was purged with nitrogen and kept under nitrogen atmosphere. The mixture was stirred at room temperature for 3 days. The DMF solution was precipitated into 100 ml methanol with vigorous stirring. The polymer was collected by filtration and washed thoroughly with water and methanol. The product was then dried in a vacuum oven at 70° C. for 24 hours to give 0.225 g (39.5%):IR (KBr) 3023, 2928, 2852, 1728, 1603, 1370, 1194, 1170, 863, 795 cm -1 ; UV-Vis-NIR (THF) λ max (ε) 840 (6450) nm. Anal. Calcd. for (C 30 H 34 NiO 4 S 4 ) n : C, 55.82; H, 5.31. Found: C, 57.24; H, 5.54.
Preparation of Polyester Copolymer
Copoly{1oxyethylene[4-(1,2-dithiolatoethenyl)benzene]nickel (II)[1',2'-dithiolatoethenyl)4'-benzene]1'-ethyleneoxysebacoyl]}-{poly(oxyethyleneoxy-sebacoyl) (FIG. 3). The procedure described for the synthesis of the polyester above was followed. Compound 9 (0.240 g, 0.5 mmol), ethyleneglycol (0.155 g, 2.5 mmol) and sebacoyl chloride (0.717 g, 3 mmol) were used. 0.540 g (60.5%) of polyester copolymer was isolated as a black tar material: IR (KBr) 3031, 2930, 2854, 1738, 1708, 1379, 1197, 1164, 868 cm -1 .
EXAMPLE III: Polycarbonate Copolymer Formation
Copolymerizations were carried out via the reaction scheme shown in FIG. 4 to prepare a series of polycarbonates containing different compositions of Ni-BDT complex along the polymer main chain. The mole percentage of the Ni-BDT complex in the feed ranged from 1% to 20% as indicated.
The general procedure for this example was as follows: A 50 ml three neck flask was charged with a certain amount of compound 9 (see Example I), along with bisphenol A or poly(ethylene glycol), total weight about 0.8 g, and 10 ml pyridine. The mixture was then purged with nitrogen for 10 min. Phosgene was admitted into the vapor space of the reaction flask while keeping thorough stirring. The temperature was maintained at about 25° C. Addition time for phosgene was about 1.5 hours, during which time the viscosity of the solution increased and pyridium hydrochloride precipitated.
The end point for the co-polymerization was determined by visual observation until the viscosity of the solution no longer increased as phosgene addition was continued. Sometimes a gel like mixture was formed.
The copolymer solution was then diluted with 10 ml chloroform and precipitated into 100 ml methanol with vigorous stirring. The copolymer was redissolved in 20 ml THF and filtered, although sometimes a portion of the polymer was insoluble as a gel, presumably due to very high molecular weight or crosslinking of the copolymer. The THF copolymer solution was reprecipitated into 100 ml methanol. The copolymer was filtered and dried at 65° C. in a vacuum oven overnight. The final yield of pure copolymer was about 40-70%.
EXAMPLE IV--Polyurethane Copolymer Formation
For the purpose of exploring the possibility of incorporating Ni-BDT complex units into polyurethanes, a series of polyurethane compounds containing Ni-BDT complex along the polymer main chain were prepared, via the reaction scheme shown in FIG. 5.
A modified literature procedure was adopted, and a series of polyurethanes prepared with a varied Ni-BDT content.
The general procedure was as follows. A 50 ml three neck flask with mechanical stirrer was charged with tolylene 2,4-diisocyanate (TDI) dissolved in 5 ml DMSO. Compound 9 and 1,10-decanediol were dissolved in 5 ml DMSO and charged into an additional funnel. The flask was heated to 60° C. and the DMSO solution of the diol was drop added to the flask with stirring over 10 min. After the completion of the addition, 5 drops of dibutyltin dilaurate were added as catalyst. The mixture was stirred for 4 hours at 60° C. The polymer solution was then diluted with 5 ml DMSO and precipitated into 200 ml methanol with vigorous stirring. The rubbery product was then cut to small pieces, washed with water and methanol, and dried at 70° C. in a vacuum oven overnight.
Samples 17-19 could not be completely dissolved in THF, suggesting possible crosslinking present in these polymers.
The instant invention has been disclosed in connection with specific embodiments. However, it will be apparent to those skilled in the art that variations from the illustrated embodiments may be undertaken without departing the spirit and scope of the invention.
BIBLIOGRAPHY
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18. Reynolds et al, ACS PMSE Proceedings (Fall 1989). | A new class of transition metal bis(dithiolene) complex polymers having improved physical characteristics. These polymers are generally prepared by first preparing a bifunctionalized transition metal bis(dithiolene) complex, then reacting the bifunctionalized complex with one or more other bifunctional compounds. A wide variety of flexible linkage can be incorporated into the polymer chain via the bifunctional reactant to vary the physical properties of the resulting polymer. The polymers can be used as near infrared filters, both as supported and freestanding films. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates primarily to a data transfer apparatus, a data transfer method, and an information processing system and, more particularly, to a data transfer apparatus such as a server machine in a client-server system, a data transfer method and a program for data transfer or the like from a server machine to a client machine, and an information processing system such as a client-server system.
2. Related Background Art
In recent years, increasing efforts have been put into the development of client-server systems as the information processing systems for use on internets or other types of networks. A client-server system is configured so that a server machine (hereinafter referred to as a “server”) retains and manages major data in a unified manner and a client machine (hereinafter referred to as a “client”) can access such data at any time. For example, when a server and a client are connected on an internet for the purpose of accessing information by a world wide web (WWW), which serves as a wide area information system, a server creates document data in a hypertext described in a hyper text markup language (HTML), while the client receives the document data by means of a communication protocol called “hyper text transfer protocol” (HTTP). Thus the document data is displayed on a display unit of the client.
Most document data transferred from the server to the client are usually composed of a plurality of objects including embedded objects and linked objects. More specifically, as shown in FIG. 8, for example, a page A is composed of an embedded object b and c, and the data on a page D to which the page A is linked, i.e., a link object d, in addition to a main text a indicative of main contents. Furthermore, the page D to which the link object d is linked frequently has an embedded object f in addition to a main text e.
In general, the embedded objects b and c, or the link object d are retained in a separate file from that on the page A. Hence, in many cases, the portion corresponding to the embedded objects b and c, or the link object d in the page A includes only the information for referring to the embedded objects b and c, or the link object d. For this reason, the data on the page A is sequentially transferred time-wise from the server to the client according to the procedure illustrated in FIG. 9 .
More specifically, when the client issues a connection request to the server and the connection between the client and the server is implemented, the client first reads in all data contained in the page A, then analyzes the contents of the data to check for the presence of the embedded objects b and c, or the link object d. The client then issues three connection requests to the server at the same time in order to read in the embedded objects b and c, and the data on the page D to which the link object d is to be linked that are retained in a separate file.
On the other hand, data transfer from the server to the client on the network is performed on a basis of packet of a predetermined length of data. Therefore, to implement data transfer to a plurality of connections (three connections in this case), the network is evenly used for the respective connections, the embedded objects b and c, and the data on the page D are read in time-sharing mode.
To be more specific, when each datum consists of three packets, as shown in FIG. 9, an embedded object b 1 , an embedded object c 1 , and data D 1 on the page D are first read in sequence into the client. Then, an embedded object b 2 , an embedded object c 2 , and data D 2 on the page D are read in, and further, an embedded object b 3 , an embedded object c 3 , and data D 3 on the page D are read in. When all the data on the page D that is divided into three sections has been read in, the client issues a connection request to the server in order to read in an embedded object f that is embedded in the page D and retained in a separate file from that of the page D.
Page A and the embedded object f are also transferred from the client to the server by being divided in a plurality of sections based on packets. There is no other network connected to the server at the same time, so that the network is monopolistically used for transferring the data.
In the data transfer method described above, however, the embedded objects b and c, and the data on the page D to which the link object d is to be linked are read in sequence according to the reading order in units of packets, so that no particular portion of data can be preferentially taken out. For example, the embedded objects b and c may be image data providing cut-in illustration for decorating the main text a of the page A. In such a case, a request for giving a higher priority to referring to the main text e of the page D than the embedded objects b and c may be made. Since the conventional data transfer method is adapted to read data on a basis of packet in the time-sharing mode as discussed above, it has been impossible to refer preferentially to the data of the main text e of greater significance.
The use of networks based on radio transmission has been becoming widespread these days; however, disconnection of lines during data transfer based on the radio transmission may happen due to radio waves failing to reach in the middle of transfer. In this case, if, for example, the line between a client and a server is disconnected at time T 1 of FIG. 9, then the client must send a request for reconnection to the page D to the server so as to read the data of the page D, or restart from reading the data of the page A, depending on a situation, thus posing a problem of inconvenience.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a data transfer apparatus, a data transfer method, and an information processing system that are capable of preferentially acquiring data of greater significance.
It is another object of the present invention to provide a data transfer apparatus, a data transfer method, and an information processing system that are capable of obviating the need of reconnection for rereading as much as possible even if a line is disconnected in the middle of communication.
According to one aspect, the present invention which achieves these objectives relates to a data transfer apparatus including: priority setting means for assigning a priority to each of a plurality of transferable data; and transfer means for transferring a plurality of data for which a transfer request has been issued to a terminal according to an order based on the priorities assigned to the respective data by the priority setting means.
According to another aspect, the present invention which achieves these objects relates to a data transfer method including the steps of: assigning a priority to each of a plurality of transferable data; and transferring a plurality of data for which a transfer request has been issued to a terminal according to an order based on the priorities assigned to the respective data.
According to still another aspect, the present invention which achieves these objectives relates to a computer-readable storage medium storing a data transfer program for controlling a data transfer apparatus to perform data transfer to a terminal via a network, the program including codes for causing the computer to perform the steps of assigning a priority to each piece of a plurality of transferable data, and transferring a plurality of data for which a transfer request has been issued to a terminal according to an order based on the priorities assigned to respective data.
According to yet another aspect, the present invention which achieves these objectives relates to an information processing system having a data transfer apparatus and a terminal connected via a network, wherein: the data transfer apparatus includes priority setting means for assigning a priority to each of a plurality of transferable data, transfer means for transferring a plurality of data for which the terminal has issued a transfer request to the terminal according to an order based on the priorities assigned to the respective data by the priority setting means; and the terminal includes requesting means for issuing a request for transfer of a plurality of data to the data transfer apparatus, and receiving means for receiving data transferred from the data transfer apparatus.
Other objectives and advantages besides those discussed above shall be apparent to those skilled in the art from the description of a preferred embodiment of the invention which follows. In the description, reference is made to accompanying drawings, which form a part thereof, and which illustrate an example of the invention. Such example, however, is not exhaustive of the various embodiments of the invention, and therefore reference is made to the claims which follow the description for determining the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a data transfer system of an embodiment.
FIG. 2 is a flowchart illustrative of a connection task processing procedure.
FIG. 3 is a flowchart illustrative of a processing procedure of a data transfer task in accordance with a first embodiment.
FIG. 4 is a diagram showing an example of a transfer order of the embodiment.
FIG. 5 is a flowchart illustrative of a processing procedure of a data transfer task in accordance with a second embodiment.
FIG. 6 is a diagram showing the configuration of major data in a document data storage area in accordance with a third embodiment.
FIG. 7 is a flowchart illustrative of a processing procedure of a data display task in accordance with the third embodiment.
FIG. 8 is a diagram showing an example of the configuration of document data.
FIG. 9 is a diagram showing an example of a conventional transfer order.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferable embodiment in accordance with the present invention will be described in detail with reference to the accompanying drawings.
FIG. 1 is a block diagram showing an embodiment of a data transfer system in accordance with the present invention. The server serving as a data transfer apparatus has: an input unit 1 such as a keyboard; a communication control unit 3 that controls communication with a network 2 such as an internet; a ROM 4 wherein a predetermined control program including a program for a processing procedure to be hereinafter described in conjunction with a flowchart has been stored; a RAM 5 used for temporarily storing computation results or used as a work area; and a CPU 7 that executes the program in the ROM 4 and is connected to the foregoing constituents via a bus 6 to control the entire apparatus. The server is connected to a client via the network 2 to transfer data to the client so as to provide services requested from the client.
The RAM 5 has a slot data storage area 8 for storing slot data (SL data) to, for example, respond to a request for connection to the client, and a document data storage area 9 for storing document data corresponding to the contents stored in the slot data storage area 8 .
The slot data storage area 8 has a connection table 11 consisting of a plurality of slots (SL) 10 corresponding to the number of connection requests from the client, and each slot 10 has a slot number storage section 12 for storing a predetermined slot number SN (i) (i=1, 2, . . . , n) corresponding to a request from the client, and a first data number storing section 13 for storing a data number DN (i) (i=1, 2, . . . , n). The slot data storing area 8 further has a selected slot number storing section 14 . A current slot number (CS) selected from the slots 10 stored in the connection table 11 is stored in the selected slot number storing section 14 .
The document data storage area 9 has a second data number storing section 15 wherein a data number D (i) (i=1, 2, . . . , n) corresponding to the data number DN (i) in the first data number storing section 13 has been stored, a data significance storing section 16 wherein a priority of data P (i) (i=1, 2, . . . , n) is stored, and a data main body storing section 17 wherein a data main body B (i) (i=1, 2, . . . , n) such as document data or image data is stored. The data number D (i), the data priority P (i), and the data main body B (i) that are associated with each other are formed as a set, and a plurality of such sets are stored in sequence. It is assumed that the data priority P (i) has been set and stored beforehand when a user registers data in the server. To be more specific, the data priority P (i) in this embodiment is set such that the value of “i” is set to a greater number like 1, 2, . . . , n as the significance increases.
The client serving as a data receiving apparatus has: an input device 21 such as a keyboard; a communication control unit 23 that controls communication with the network 2 such as an internet; a ROM 24 wherein a predetermined control program including a program for a data display task processing procedure to be hereinafter described in conjunction with a flowchart has been stored; a RAM 25 used for temporarily storing computation results or received data or used as a work area; and a CPU 27 that executes the program in the ROM 24 and is connected to the foregoing constituents via a bus 26 to control the entire apparatus. The client is connected to the server via the network 2 to send requests for data to the server and to receive the data transferred from the server.
FIG. 2 is a flowchart illustrative of a processing procedure for a connection task.
In a step S 1 , the server waits until it receives a connection request from the client. When the server is notified by the communication control unit 3 to the effect that the connection request has been received from the client, it updates the contents of the connection table 11 in a step S 2 . More specifically, when a new connection request is received from the client, a single empty slot 10 stored in the connection table 11 is allotted a slot number SN (i) and a data number DN (i) associated with the slot number SN (i), and stored in the connection table 11 . Each slot 10 includes the address of the client and various other data such as a connection state.
Thus, after the connection table 11 has been updated, the server issues, in a step S 3 , a transfer service instruction to the data transfer task by means of inter-task communication based on a message or a signal. Then, the server returns to the step S 1 to wait until it receives another new connection request from the client.
FIG. 3 is a flowchart illustrative of the processing procedure for the data transfer task in accordance with the first embodiment.
In a step S 11 , the server waits until it receives a data transfer instruction from the connection task (the step S 3 of FIG. 2 ). When the server receives the data transfer instruction, it advances to a step S 12 to select a slot number SN (i) of a high priority from the connection table 11 . To be more specific, the server finds the data number DN (i) requested for each slot 10 stored in the connection table 11 from the first data number storing section 13 , and finds the data number D (i) associated with the data number DN (i) from the second data number storing section 15 in the document data storage area 9 to select the data number D (i) associated with the P (i) of the highest data priority and the slot number SN (i) associated with the data number D (i). Then, the server stores the selected slot number SN (i) in the selected slot number storing section 14 .
Subsequently, the server proceeds to a step S 13 wherein it sends out the data main body B (i) corresponding to the slot number SN (i) stored in the slot number storing section 14 from the communication control unit 3 to the network 2 to transfer it to the client. In a step S 14 , the server releases or cuts the connection, then returns to the step S 11 wherein it waits until it receives another new data transfer request from the connection task.
Thus, according to the first embodiment, the priorities are assigned in advance to the data stored in the server, and the data is transferred in sequence to the client according to the priorities, starting with the data with the highest priority.
For instance, to receive the document data of FIG. 8, the client first reads all the data contained in a page A, and analyzes the contents of the data to detect the presence of embedded objects b and c, and a link object d as in the case of the conventional art. The client then issues three connection requests at the same time to the server in order to read the embedded objects b and c stored in a separate file, and the data of a page D to which the link object d is linked. In this case, if the degrees of significance or the priorities have been set in the order of the page D, the embedded object b, and the embedded object c, then these data are transferred according to the order of their priorities as shown in FIG. 4 . Hence, even if the line is disconnected at time T 1 , the user or the client can acquire the data in the page D with the highest priority before the time at which the disconnection occurred.
Therefore, if the embedded object b or c is unnecessary, then there will be no need for reconnection. Even if the embedded object b or c is necessary, there will be no need to reread all data requested at the same time as in the case of the conventional art since the data in the page D has already been obtained. This minimizes the efforts for rereading or the like, contributing greatly to improved convenience to the users.
FIG. 5 is a flowchart illustrative of the processing procedure for the data transfer task in accordance with a second embodiment. In the first embodiment, the data priority P (i) is statically assigned and registered when the data is registered in the server. In the second embodiment, the data priority P (i) is dynamically assigned according to the operation status of the server; to be more specific, priorities are assigned according to the frequencies of transfer requests.
In the second embodiment, the data priority P (i) in the document data storage area 9 is initialized to, for example, “0” denoting the lowest significance, at the time of registering data in the server.
In steps S 21 through S 23 , the server carries out the same processing as that in the steps S 11 through S 13 of FIG. 3 and transfers data to the client. In the following step S 24 , the information regarding the frequency is updated. In this case, the transferred data D (i) is the data that has been transferred in response to an actual request for the data; therefore, it is determined that the priority has been increased, and the data priority P (i) is updated by adding 1, namely, P (i)+1. After updating the information regarding the frequency, the server releases or disconnects the line in a step S 25 , then returns to the step S 21 .
According to the second embodiment, the priority of data that is requested by the client more frequently is set to a greater value, thereby enabling the data with higher request frequencies to be preferentially transferred. With this arrangement, the priorities can be set according to the current state while checking the operational state, thus obviating the need of statically presetting the priorities.
FIG. 6 shows the configuration of major data in the document data storage area 9 in accordance with a third embodiment. In this figure, it is assumed that the data size is large. A data main body 18 has been subdivided, and each piece of data resulting from the subdivision is independently assigned a priority. To be more specific, in the third embodiment, a subdivided data number d (i, j) (i=1, . . . n; j=1, . . . m), a priority of subdivided data p (i, j) (i=1, . . . n; j=1, . . . m), and a subdivided data main body b (i, j) (i=1, . . . n; j=1, . . . m) are assigned to the data number D (i) and the data priority P (i), respectively.
As the data size is increased, variations tend to take place in the priority. Normally, however, the data for one object is likely to be stored in one file; therefore, one piece of data cannot be divided, causing data not required by the user to be inevitably transferred in some cases. On the other hand, document data is usually composed of paragraphs, chapters, sections, etc., and information can be identified by means of these paragraphs, chapters, sections, etc. This makes it possible to subdivide, for example, document data in units of paragraphs. In the third embodiment, therefore, each datum is subdivided, a data priority is assigned to each subdivided data, and data with higher priorities is transferred preferentially to the client, thus achieving further improved convenience for the client.
To subdivide data, there is a method available whereby the data is automatically subdivided, and the subdivided data numbers d (i, j) and the subdivided data priorities p (i, j) are assigned by embedding the subdivided data numbers d (i, j) and the subdivided data priorities p (i, j) in the data itself beforehand, or by running a parser program that analyzes the structure of a prepared document.
The procedure for the connection to the client and the procedure for transferring data to the client are the same as those of the first and second embodiments, and the description thereof will not be repeated.
FIG. 7 is a flowchart illustrative of the processing procedure for the data display task in accordance with the third embodiment. As shown in the flowchart of FIG. 7, in the third embodiment, received data is reconstructed on the client side and displayed on a screen.
First, in a step S 31 , the client waits for incoming data from the server. Upon receipt of data, the server reconstructs the data in a step S 32 . More specifically, the subdivided data that has been transferred according to the priority order is rearranged in a proper order according to the subdivided data numbers d (i, j). In a step S 33 , the rearranged data is shown on a display screen.
Subsequently, in a step S 34 , the client determines whether the data received is the last data or not. If the determination result is negative (No), then the client returns to the step S 31 to repeat the aforesaid processing; or if the determination result is affirmative (Yes), then it advances to a step S 35 to disconnect the line. After the client returns to the step S 31 , it waits for another data from the server.
For instance, if the data number of the subdivided data transferred first to the client is the data of the third paragraph, then it means that the data of the first and second paragraphs has not yet been transferred; hence, only the data of the third paragraph is shown on the display screen. When the data of the first paragraph is received, the paragraph data is reconstructed to so that the data of the first paragraph is displayed before the data of the third paragraph, and the reconstruction result is shown on the display screen. In this way, the data of the first paragraph is shown first on the display screen, then the data of the third paragraph is shown on the display screen.
Thus, according to the third embodiment, the client is allowed to quickly obtain the data of a desired page regardless of the transfer order of the contents of a document, by reconstructing the data each time new subdivided data arrives.
As explained in detail above, the embodiment is adapted to assign priorities to data and the data is transferred in order of precedence, enabling the user to more quickly refer to the data that the client is more interested in. Furthermore, even if the line is disconnected in the middle of data transfer, the need of reconnection for rereading can be minimized, contributing to improved convenience for the user.
The present invention may be applied to a system constructed of a plurality of units (e.g. a computer main unit, an interface, a display, and so on) or to an apparatus constructed of a single unit, within the range where the functions of the foregoing embodiments can be implemented.
The present invention also includes a modification wherein, in order to operate various devices to implement the functions of the foregoing embodiments, the program codes of software for implementing the functions of the embodiments are supplied to a computer in an apparatus or a system connected to the various devices, and the various devices are operated by the computer (or a CPU or MPU) of the system or the apparatus in accordance with the supplied program. In this case, the program codes themselves read out from a storage medium carry out the functions of the embodiments; hence, the program codes themselves, and the means for supplying the program codes to the computer, e.g. the storage medium for storing the program codes, constitute the present invention.
Storage medium for supplying the program codes includes a floppy disk, a hard disk, an optical disk, a magneto-optical disk, a CD-ROM, a CD-R, a magnetic tape, a nonvolatile memory card, and a ROM.
It is needless to say that, when the computer executes the program codes that it reads to implement the functions of the embodiments, or when the functions of the embodiments are implemented in cooperation with an operating system (OS) running on the computer or other application software or the like in accordance with the instructions of the program codes, the program codes are included in the scope of the present invention.
Further, the present invention scope also includes a case wherein program codes read out from a storage medium are written to a memory provided on a feature expansion board inserted in a computer or a feature expansion unit connected to the computer, then a CPU or the like provided on the feature expansion board or the feature expansion unit carries out a part or all of actual processing in accordance with the instructions of the program codes so as to implement the functions of the embodiments.
To apply the present invention to the foregoing storage medium, the program code corresponding to the flowcharts, which have been discussed above, may be stored in the storage medium.
Although the present invention has been described in its preferred form with a certain degree of particularity, many apparently widely different embodiments of the invention can be made without departing from the spirit and the scope thereof. It is to be understood that the invention is not limited to the specific embodiments thereof except as defined in the appended claims. | In an information processing system in which a server supplying document data and a client requesting the server to transfer the document data are connected via a network, the server assigns priorities to respective data constituting the document data. When the client requesting the transfer of a particular document datum detects the presence of a plurality of data embedded in the document data or linked to the document data, the client further requests the transfer of a plurality of such data. Upon receipt of the request for the transfer of a plurality of data, the server transfers the respective data in order of precedence, starting with a datum with the highest priority among the data. This enables the client to obtain data with higher priorities sooner. Further, even if a line is disconnected in the middle of transfer, the amount of data that must be reread by restoring the line connection can be minimized. | 7 |
CROSS-REFERENCE
[0001] This application claims priority to U.S. application Ser. No. 14/273,522, filed May 8, 2014 entitled “METHOD AND APPARATUS FOR RAPID SCALABLE UNIFIED INFRASTRUCTURE SYSTEM MANAGEMENT PLATFORM”, which claims the benefit of Provisional Patent Application Numbers:
[0000] 61/820,703 filed May 8, 2013 entitled “METHOD AND APPARATUS TO REMOTELY MONITOR INFORMATION TECHNOLOGY INFRASTRUCTURE”; 61/820,704 filed May 8, 2013 entitled “METHOD AND APPARATUS TO ORCHESTRATE ANY-VENDOR IT INFRASTRUCTURE (COMPUTE) CONFIGURATION”; 61/820,705 filed May 8, 2013 entitled “METHOD AND APPARATUS TO ORCHESTRATE ANY-VENDOR IT INFRASTRUCTURE (NETWORK) CONFIGURATION”; 61/820,706 filed May 8, 2013 entitled “METHOD AND APPARATUS TO ORCHESTRATE ANY-VENDOR IT INFRASTRUCTURE (STORAGE) CONFIGURATION”; 61/820,707 filed May 8, 2013 entitled “METHOD AND APPARATUS TO ENABLE LIQUID APPLICATIONS”; 61/820,708 filed May 8, 2013 entitled “METHOD AND APPARATUS TO ENABLE LIQUID APPLICATIONS”; 61/820,709 filed May 8, 2013 entitled “METHOD AND APPARATUS TO ENABLE CONVERGED INFRASTRUCTURE TRUE ELASTIC FUNCTION”; 61/820,712 filed May 8, 2013 entitled “METHOD AND APPARATUS FOR OPERATIONS BIG DATA ANALYSIS AND REAL TIME REPORTING”; and 61/820,713 filed May 8, 2013 entitled “METHOD AND APPARATUS FOR RAPID SCALABLE UNIFIED INFRASTRUCTURE SYSTEM MANAGEMENT PLATFORM”; and this application also claims the benefit of U.S. Provisional Patent Application Numbers 61/827,560 filed May 24, 2013 entitled “METHOD AND APPARATUS FOR A PREDICTABLE CLOUD INFRASTRUCTURE ASSURANCE MODEL”;
61/827,612 filed May 26, 2013 entitled “METHOD AND APPARATUS FOR DYNAMIC CORRELATION OF LARGE NETWORK COMPUTE FAULT EVENT STREAM”;
61/827,613 filed May 26, 2013 entitled “METHOD AND APPARATUS FOR DYNAMIC CORRELEATION OF LARGE CLOUD LOAD BALANCING FAULT EVENT STREAM”, the contents of which are all herein incorporated by reference in its entirety.
FIELD
[0002] The disclosure generally relates to enterprise cloud computing and more specifically to a seamless cloud across multiple clouds providing enterprises with quickly scalable, secure, multi-tenant automation.
BACKGROUND
[0003] Cloud computing is a model for enabling on-demand network access to a shared pool of configurable computing resources/service groups (e.g., networks, servers, storage, applications, and services) that can ideally be provisioned and released with minimal management effort or service provider interaction.
[0004] Software as a Service (SaaS) provides the user with the capability to use a service provider's applications running on a cloud infrastructure. The applications are accessible from various client devices through either a thin client interface, such as a web browser or a program interface. The user does not manage or control the underlying cloud infrastructure including network, servers, operating systems, storage, or even individual application capabilities.
[0005] Infrastructure as a Service (IaaS) provides the user with the capability to provision processing, storage, networks, and other fundamental computing resources where the user is able to deploy and run arbitrary software, which can include operating systems and applications. The user does not manage or control the underlying cloud infrastructure but has control over operating systems, storage, and deployed applications; and possibly limited control of select networking components (e.g., host firewalls).
[0006] Platform as a Service (PaaS) provides the user with the capability to deploy onto the cloud infrastructure user-created or acquired applications created using programming languages, libraries, services, and tools supported by the provider. The user does not manage or control the underlying cloud infrastructure including network, servers, operating systems, or storage, but has control over the deployed applications and possibly configuration settings for the application-hosting environment.
[0007] Cloud deployment may be Public, Private or Hybrid. A Public Cloud infrastructure is provisioned for open use by the general public. It may be owned, managed, and operated by a business, academic, or government organization. It exists on the premises of the cloud provider. A Private Cloud infrastructure is provisioned for exclusive use by a single organization comprising multiple users (e.g., business units). It may be owned, managed, and operated by the organization, a third party, or some combination of them, and it may exist on or off premises. A Hybrid Cloud infrastructure is provisioned for exclusive use by a single organization comprising multiple users (e.g., business units). It may be owned, managed, and operated by the organization, a third party, or some combination of them, and it may exist on or off premises.
[0008] The promise of enterprise cloud computing was supposed to lower capital and operating costs and increase flexibility for the Information Technology (IT) department. However lengthy delays, cost overruns, security concerns, and loss of budget control have plagued the IT department. Enterprise users must juggle multiple cloud setups and configurations, along with aligning public and private clouds to work together seamlessly. Turning up of cloud capacity (cloud stacks) can take months and many engineering hours to construct and maintain. High-dollar professional services are driving up the total cost of ownership dramatically. The current marketplace includes different ways of private cloud build-outs. Some build internally hosted private clouds while others emphasize Software-Defined Networking (SDN) controllers that relegate switches and routers to mere plumbing.
[0009] The cloud automation market breaks down into several types of vendors, ranging from IT operations management (ITOM) providers, limited by their complexity, to so-called fabric-based infrastructure vendors that lack breadth and depth in IT operations and service. To date, true value in enterprise cloud has remained elusive, just out of reach for most organizations. No vendor provides a complete Cloud Management Platform (CMP) solution.
[0010] Therefore there is a need for systems and methods that create a unified fabric on top of multiple clouds reducing costs and providing limitless agility.
SUMMARY OF THE INVENTION
[0011] Additional features and advantages of the disclosure will be set forth in the description which follows, and will become apparent from the description, or can be learned by practice of the herein disclosed principles by those skilled in the art. The features and advantages of the disclosure can be realized and obtained by means of the disclosed instrumentalities and combinations as set forth in detail herein. These and other features of the disclosure will become more fully apparent from the following description, or can be learned by the practice of the principles set forth herein.
[0012] A Cloud Management Platform is described for fully unified compute and virtualized software-based networking components empowering enterprises with quickly scalable, secure, multi-tenant automation across clouds of any type, for clients from any segment, across geographically dispersed data centers.
[0013] In one embodiment, systems and methods are described for sampling of data center devices alerts; selecting an appropriate response for the event; monitoring the end node for repeat activity; and monitoring remotely.
[0014] In another embodiment, systems and methods are described for discovery of compute nodes; assessment of type, capability, VLAN, security, virtualization configuration of the discovered compute nodes; configuration of nodes covering add, delete, modify, scale; and rapid roll out of nodes across data centers.
[0015] In another embodiment, systems and methods are described for discovery of network components including routers, switches, server load balancers, firewalls; assessment of type, capability, VLAN, security, access lists, policies, virtualization configuration of the discovered network components; configuration of components covering add, delete, modify, scale; and rapid roll out of network atomic units and components across data centers.
[0016] In another embodiment, systems and methods are described for discovery of storage components including storage arrays, disks, SAN switches, NAS devices; assessment of type, capability, VLAN, VSAN, security, access lists, policies, virtualization configuration of the discovered storage components; configuration of components covering add, delete, modify, scale; and rapid roll out of storage atomic units and components across data centers.
[0017] In another embodiment, systems and methods are described for discovery of workload and application components within data centers; assessment of type, capability, IP, TCP, bandwidth usage, threads, security, access lists, policies, virtualization configuration of the discovered application components; real time monitoring of the application components across data centers public or private; and capacity analysis and intelligence to adjust underlying infrastructure thus enabling liquid applications.
[0018] In another embodiment, systems and methods are described for analysis of capacity of workload and application components across public and private data centers and clouds; assessment of available infrastructure components across the data centers and clouds; real time roll out and orchestration of application components across data centers public or private; and rapid configurations of all needed infrastructure components.
[0019] In another embodiment, systems and methods are described for analysis of capacity of workload and application components across public and private data centers and clouds; assessment of available infrastructure components across the data centers and clouds; comparison of capacity with availability; real time roll out and orchestration of application components across data centers public or private within allowed threshold bringing about true elastic behavior; and rapid configurations of all needed infrastructure components.
[0020] In another embodiment, systems and methods are described for analysis of all remote monitored data from diverse public and private data centers associated with a particular user; assessment of the analysis and linking it to the user applications; alerting user with one line message for high priority events; and additional business metrics and return on investment addition in the user configured parameters of the analytics.
[0021] In another embodiment, systems and methods are described for discovery of compute nodes, network components across data centers, both public and private for a user; assessment of type, capability, VLAN, security, virtualization configuration of the discovered unified infrastructure nodes and components; configuration of nodes and components covering add, delete, modify, scale; and rapid roll out of nodes and components across data centers both public and private.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] In order to describe the manner in which the above-recited and other advantages and features of the disclosure can be obtained, a more particular description of the principles briefly described above will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. Understanding that these drawings depict only exemplary embodiments of the disclosure and are not therefore to be considered to be limiting of its scope, the principles herein are described and explained with additional specificity and detail through the use of the accompanying drawings in which:
[0023] FIG. 1 is a block diagram of an exemplary hardware configuration in accordance with the principles of the present invention;
[0024] FIG. 2 is a block diagram describing a tenancy configuration wherein the Enterprise hosts systems and methods within its own data center in accordance with the principles of the present invention;
[0025] FIG. 3 is a block diagram describing a super tenancy configuration wherein the Enterprise uses systems and methods hosted in a cloud computing service in accordance with the principles of the present invention;
[0026] FIG. 4 is a logical diagram of the Enterprise depicted in FIG. 1 in accordance with the principles of the present invention;
[0027] FIG. 5 illustrates a logical view that an Enterprise administrator and Enterprise user have of the uCloud Platform depicted in FIG. 1 in accordance with the principles of the present invention;
[0028] FIG. 6 illustrates a flow diagram of a service catalog classifying data center resources into service groups; selecting a service group and assigning it to end users;
[0029] FIG. 7 illustrates a flow diagram of mapping service group categories to user groups that have been given access to a given service group, in accordance with the principles of the present invention;
[0030] FIG. 8 illustrates the Cloud administration process utilizing the tenant cloud instance manager as well as the manager of manager and the ability of uCloud platform to logically restrict and widen scope of Cloud Administration, as well as monitoring;
[0031] FIG. 9 illustrates a hierarchy diagram of the Cloud administration process utilizing the tenant cloud instance manager as well as the manager of manager and the ability of uCloud platform to logically restrict and widen scope of Cloud Administration in accordance with the principles of the present invention;
[0032] FIG. 10 illustrates the logical flow of information from the uCloud Platform depicted in FIG. 1 to a Controller Node in a given Enterprise for compute nodes;
[0033] FIG. 11 illustrates the logical flow of information from the uCloud Platform depicted in FIG. 1 to the Controller Node in a given Enterprise for network components;
[0034] FIG. 12 illustrates the logical flow of information from the uCloud Platform to the Controller Node in a given Enterprise for storage devices;
[0035] FIG. 13 illustrates the application-monitoring component of the uCloud Platform in accordance with the principles of the present invention;
[0036] FIG. 14 illustrates the application-orchestration component of the uCloud Platform in accordance with the principles of the present invention;
[0037] FIG. 15 illustrates the integration of the application-orchestration and application-monitoring components of the uCloud Platform in accordance with the principles of the present invention;
[0038] FIG. 16 illustrates the big data component of the uCloud Platform depicted in FIG. 1 and the relationship to the monitoring component of the platform
[0039] FIG. 17 illustrates the process of deploying uCloud within an Enterprise environment;
[0040] FIG. 18 illustrates a flow diagram in accordance with the principles of the present invention;
[0041] FIG. 19 illustrates a flow diagram in accordance with the principles of the present invention;
[0042] FIG. 20 illustrates a flow diagram in accordance with the principles of the present invention;
[0043] FIG. 21 illustrates a flow diagram in accordance with the principles of the present invention;
[0044] FIG. 22 illustrates a block diagram in accordance with the principles of the present invention;
[0045] FIG. 23 illustrates a combined block and flow diagram in accordance with the principles of the present invention;
[0046] FIG. 24 illustrates a combined block and flow diagram in accordance with the principles of the present invention;
[0047] FIG. 25 illustrates a block diagram in accordance with the principles of the present invention;
[0048] FIG. 26 illustrates a combined block and flow diagram in accordance with the principles of the present invention;
[0049] FIG. 27 illustrates a block diagram in accordance with the principles of the present invention; and
[0050] FIG. 28 illustrates a combined block and flow diagram in accordance with the principles of the present invention.
DETAILED DESCRIPTION
[0051] The FIGURES and text below, and the various embodiments used to describe the principles of the present invention are by way of illustration only and are not to be construed in any way to limit the scope of the invention. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims. A Person Having Ordinary Skill in the Art (PHOSITA) will readily recognize that the principles of the present invention maybe implemented in any type of suitably arranged device or system. Specifically, while the present invention is described with respect to use in cloud computing services and Enterprise hosting, a PHOSITA will readily recognize other types of networks and other applications without departing from the scope of the present invention.
[0052] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by a PHOSITA to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, a limited number of the exemplary methods and materials are described herein.
[0053] All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited. The publications discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided may be different from the actual publication dates, which may need to be independently confirmed.
[0054] Reference is now made to FIG. 1 that depicts a block diagram of an exemplary hardware configuration in accordance with the principles of the present invention. A uCloud Platform 100 combining self-service cloud orchestration with a Layer 2 - and Layer 3 -capable encrypted virtual network may be hosted by a cloud computing service such as but not limited to, Amazon Web Services or directly by an enterprise such as but not limited to, a service provider (e.g. Verizon or AT&T), provides a web interface 104 with a Virtual IP (VIP) address, a Rest API interface 106 with a Virtual IP (VIP), a RPM Repository Download Server and, a message bus 110 , and a vAppliance Download Manager 112 . Connections to and from web interface 104 , Rest API interface 106 , RPM Repository Download Server, message bus 110 , and vAppliance Download Manager 112 are preferably SSL secured. Interfaces 104 , 106 , 107 and 109 are preferably VeriSign certificate based with Extra Validation (EV), allowing for 128-bit encryption and third party validation for all communication on the interfaces. In addition to SSL encryption on Message BUS 110 , each message sent across on interface 107 to a Tenant environment is preferably encrypted with a Public/Private key pair thus allowing for extra security per Enterprise/Service Provider communication. The Public/Private key pair security per Tenant prevents accidental information leakage to be shared across other Tenants. Interfaces 108 and 110 are preferably SSL based (with self-signed) certificates with 128-bit encryption. In addition to communication interfaces, all Tenant passwords and Credit Card information stored are preferably encrypted.
[0055] Controller node 121 performs dispatched control, monitoring control and Xen Control. Dispatched control entails executing, or terminating, instructions received from the uCLoud Platform 100 . Xen control is the process of translating instructions received from uCLoud Platform 100 into a Xen Hypervisor API. Monitoring is performed by the monitor controller by periodically gathering management plane information data in an extended platform for memory, CPU, network, and storage utilizations. This information is gathered and then sent to the management plane. The extended platform comprises vAppliance instances that allow instantiation of Software Defined clouds. The management, control, and data planes in the tenant environment are contained within the extended platform. RPM Repository Download Server 108 downloads RPMs (packages of files that contain a programmatic installation guide for the resources contained) when initiated by Control node 121 . The message bus VIP 110 couples between the Enterprise 101 and the uCloud Platform 100 . A Software Defined Cloud (SDC) may comprise a plurality of Virtual Machines (vAppliances) such as, but not limited to a Bridge Router (BR-RTR, Router, Firewall, and DHCP-DNS (DDNS) across multiple virtual local area networks (VLANs) and potentially across data centers for scale, coupled through Compute node (C-N) nodes (aka servers) 120 a - 120 n . The SDC represents a logical linking of select compute nodes (aka servers) within the enterprise cloud. Virtual Networks running on Software Defined Routers 122 and Demilitarized Zone (DMZ) Firewalls are referred to as vAppliances. All Software defined networking components are dynamic and automated, provisioned as needed by the business policies defined in the Service Catalogue by the Tenant Administrator.
[0056] The uCloud Platform 100 supports policy-based placement of vAppliances and compute nodes ( 120 a - 120 n ). The policies permit the Tenant Administrator to do auto or static placement thus facilitating creation of dedicated hardware environment Nodes for Tenant's Virtual Machine networking deployment base.
[0057] The uCloud Platform 100 created SDC environment enables the Tenant Administrator to create lines of businesses or in other words, department groups with segregated networked space and service offerings. This facilitates Tenant departments like IT, Finance and development to all share the same SDC space but at the same time be isolated by networking and service offerings.
[0058] The uCloud Platform 100 supports deploying SDC vAppliances in redundant pair topologies. This allows for key virtual networking building block host nodes to be swapped out and new functional host nodes be inserted managed through uCloud Platform 100 . SDCs can be dedicated to data centers, thus two unique SDCs in different data centers can provide the Enterprise a disaster recovery scenario.
[0059] SDC vAppliances are used for the logical configuration of SDC's within a tenants private cloud. A Router Node is a physical server, or node, in an tenant's private cloud that may be used to host certain vAppliances relating SDC networking. Such vAppliances may include the Router, DDNS, and BR-RTR (Bridge Router) vApplications that may be used to route internet traffic to and from an SDC, as well as establish logical boundaries for SDC accessibility. Two Router Nodes exist, an active Node (-A) and a standby Node (-S), used in the event that the active node experiences failure. The Firewall Nodes, also present in an active and standby pair, are used to filter internet traffic coming into an SDC. There is a singular vAppliance that uses the Firewall Node, that being the Firewall vAppliance. The vAppliances are configured through use of vAppliance templates, which are downloaded and stored by the tenant in the appliance store/Template store.
[0060] Reference is now made to FIG. 2 depicting a block diagram describing a tenancy configuration wherein the Enterprise hosts systems and methods within its own data center in accordance with the principles of the present invention. The uCloud platform 100 is hosted directly on an enterprise 200 which may be a Service Provider such as, but not limited to, Verizon FIOS or AT&T uVerse, which serves tenants A-n 202 , 204 and 206 , respectively. Alternatively, enterprise 200 may be an enterprise having subsidiaries or departments 202 , 204 and 206 that it chooses to keep segregated.
[0061] Reference is now made to FIG. 3 depicting a block diagram of a super tenancy configuration wherein the Enterprise uses systems and methods hosted in a cloud computing service 300 in accordance with the principles of the present invention. In this configuration, the uCloud platform is hosted by a cloud computing service 300 that services Enterprises 302 , 304 and 306 . It should be understood that more or less Enterprises could be serviced without departing from the scope of the invention. In the present example, Enterprise C 306 has sub tenants. Enterprise C 306 may be a service provider (e.g. Verizon FIOS or AT&T u-Verse) or an Enterprise having subsidiaries or departments that it chooses to keep segregated.
[0062] Reference is now made to FIG. 4 depicting a block diagram describing permutations of a Software Defined Cloud (SDC) in accordance with the principles of the present invention. The SDC can be of three types namely Routed 400 , Public Routed 402 and Public 404 . Routed and Routed Public SDC types 400 and 402 respectively are designed to be reachable through the Enterprise IP address space, with the caveat that the Enterprise IP address space cannot be in the same collision domain as these types of SDC IP network space. Furthermore, Routed and Public Routed SDC 400 and 402 respectively can re-use same IP network space without colliding with each other. The Public SDC 404 is Internet 406 facing only, it can have overlapping collision IP space with the Enterprise network. Public SDC 404 further provides Internet facing access only. SDC IP schema is automatically managed by the uCloud platform 100 and does not require Tenant Administrator intervention.
[0063] SDC Software Defined Firewalls 408 are of two/one type, Internet gateway (for DMZ use). The SDC vAppliances (e.g. Firewall 408 , Router 410 ) and compute nodes ( 120 a - 120 n ) provide a scalable Cloud deployment environment for the Enterprise. The scalability is achieved through round robin and dedicated hypervisor host nodes. The host pool provisioning management is performed through uCloud Platform 100 . The uCloud Platform 100 manages dedicated nodes for the compute nodes ( 120 a - 120 n ), it allows for fault isolation across the Tenant's Virtual Machine workload deployment base.
[0064] Referring back to FIG. 1 , an uCloud Platform administrator 102 A, an Enterprise administrator 102 B, and an Enterprise User 102 C without administrator privileges are depicted. To deploy uCloud platform 100 , Enterprise administrator 102 B grants uCloud Platform administrator 102 A information regarding the enterprise environment 101 and the hardware residing within it (e.g. compute nodes 120 a - n ). After this information is supplied, platform 100 creates a customized package that contains a Controller Node 121 designed for the Enterprise 101 . Enterprise administrator 102 B downloads and install Controller Node 121 into the Enterprise environment 101 . The uCloud Platform 100 then generates a series of tasks, and communicates these tasks indirectly with Controller Node 121 , via the internet 111 . The communication is preferably done indirectly so as to eliminate any potential for unauthorized access to the Enterprise's information. The process preferably requires uCloud platform 100 to leave the tasks in an online location, and the tasks are only accessible to the unique Controller Node 121 present in an Enterprise Environment 101 . Controller Node 121 then fulfills the tasks generated by uCloud platform 100 , and thus configures the compute 122 , network 123 , and storage 120 a - n capability of the Enterprise environment 101 .
[0065] Upon completion of the hardware configuration, uCloud platform 100 is deployed in the Enterprise environment 101 . The uCloud platform 100 monitors the Enterprise environment 101 and preferably communicates with Controller Node 121 indirectly. Enterprise administrator 102 B and Enterprise User 102 C use the online portal to access uCloud platform 100 and to operate their private cloud.
[0066] Software defined clouds (SDCs) are created within the uCloud platform 100 configured Enterprise 101 . Each SDC contains compute nodes that are logically linked to each other, as well as certain network and storage components (logical and physical) that create logical isolation for those compute nodes within the SDC. As discussed above, an enterprise 101 may create three types of SDC's: Routed 400 , Public Routed 402 , and Public 404 as depicted in FIG. 4 . The difference, as illustrated by FIG. 4 , is how each SDC is accessible to an Enterprise user 102 C.
[0067] Reference is now made to FIG. 5 that depicts a logical view of the uCloud Platform 100 that the Enterprise administrator 102 B and Enterprise user 102 C have in accordance with the principles of the present invention. Resources compute 502 , network 504 and storage 506 residing in a data center 507 are coupled to the service catalog 508 that classifies the resources into service groups 510 a - 510 n . A monitor 512 is coupled to the service catalog 508 and to a user 514 . User 514 is also coupled to service catalog 508 . Service catalog 508 is configured to designate various data center items (compute 502 , network 504 , and storage 506 ) as belonging to certain service groups 510 a - 510 n . The Service catalog 508 also maps the service groups to the appropriate User. Additionally, monitor 512 monitors and controls the service groups belonging to a specific User.
[0068] The service catalog 508 allows for a) the creation of User defined services: a service is a virtual application, or a category/group of virtual applications to be consumed by the Users or their environment, b) the creation of categories, c) the association of virtual appliances to categories, d) the entitlement of services to tenant administrator-defined User groups, and e) the Launch of services by Users through an app orchestrator. The service catalog 508 may then create service groups 510 a - 510 n . A service group is a classification of certain data center components e.g. compute Nodes, network Nodes, and storage Nodes.
[0069] Monitoring in FIG. 5 is done by periodically gathering management plane information data in the extended platform for memory, CPU, network, storage utilizations. This information is gathered and then sent to the management plane.
[0070] FIG. 6 illustrates a flow diagram of a service catalog classifying data center resources into service groups; selecting a service group and assigning it to end users. FIG. 7 illustrates a flow diagram of mapping service group categories to user groups that have been given access to a given service group, in accordance with the principles of the present invention.
[0071] Reference is now made to FIGS. 8 and 9 that illustrate the Cloud administration process its hierarchy respectively, utilizing the tenant cloud instance manager as well as the manager of manager and the ability of uCloud platform to logically restrict and widen scope of Cloud Administration as well as monitoring;
[0072] It should be noted that reference throughout the specification to “tenants” includes both enterprises and service providers as “super-tenants”. Each Software Defined Cloud (SDC) has a management plane, as well as a Data Plane and Control Plane. The Management plane provisions, configures, and operates the cloud instances. The Control plane creates and manages the static topology configuration across network and security domains. The Data plane is part of the network that carries user networking traffic. Together, these three planes govern the SDC's abilities and define the logical boundaries of a given SDC. The Manager of Manager 604 in uCLoud Platform 100 which is accessible only to the uCloud Platform administrator 102 A, manages the tenant cloud instance manager 706 ( FIG. 10 ) in every tenant private cloud. The hierarchy of this management is shown in FIG. 9 .
[0073] Referring now to FIGS. 10 , 11 and 12 , the tenant cloud instance manager 706 is responsible for overseeing the management planes of various SDC's as well as any other virtual Applications that the tenant is running in its compute Nodes, network components and storage devices, respectively. The uCloud Platform 100 generates commands related to the management of Compute Nodes 120 a - n based on tenant cloud instance manager 706 and extended platform orchestrator. The extended platform orchestrator is responsible for intelligently dispersing commands to create, manage, delete, or modify components of a tenant's uCloud platform 100 , or the extended platform based on predetermined logic. These commands are communicated indirectly to the Controller Node 121 of a specific Enterprise environment. The controller node 121 then accesses the compute Nodes 120 a - n and executes the commands. The launched cloud instance (SDC) management planes are depicted as 708 a - n in FIG. 10 . The ability of the tenant cloud instance manager 706 to modify and delete SDC management plane characteristics (compute, network, storage, Users, and business processes is provided over the internet 111 . Tenants (depicted in FIG. 3 as 302 , 304 and 306 ) each have a Tenant cloud instance manager 706 viewable to through the web interface 104 depicted in FIG. 1 .
[0074] Again with reference to FIG. 8 , the monitoring platform 602 is not limited to one controller but rather, its scope is all controllers within the platform. The monitoring done by the controller 512 ( FIG. 5 ) is performed in a limited capacity, periodically gathering management plane information data in the extended platform for memory, CPU, network, storage utilizations. This information is gathered and then sent to the tenant cloud instance manager 706 .
[0075] Centralized management view of all management planes across the tenants is provided to uCloud Platform administrator 102 A through the uCloud web interface 104 depicted in FIG. 1 .
[0076] Reference is now made to FIG. 11 illustrating the logical flow of information from the uCloud Platform 100 to the Controller Node in a given Enterprise. The uCloud Platform 100 generates commands related to the management of Network components 122 and 123 based on tenant cloud instance manager and extended platform orchestrator element. The extended platform orchestrator is responsible for intelligently dispersing commands to create, manage, delete, or modify components of 100 , or the extended platform based on predetermined logic. These commands are communicated indirectly to the Controller Node ( 121 in FIG. 1 ) of a specific Enterprise environment 101 . The controller node then accesses the pertinent router nodes, and within them, the pertinent vAppliances, and executes the commands.
[0077] Reference is now made to FIG. 12 illustrating the logical flow of information from the uCloud Platform to the Controller Node in a given Enterprise. The uCloud Platform 100 generates commands related to the management of Storage components tenant cloud instance manager and extended platform orchestrator. The extended platform orchestrator is responsible for intelligently dispersing commands to create, manage, delete, or modify components of 100 , or the extended platform based on predetermined logic. These commands are communicated indirectly to the Controller Node 121 of a specific Enterprise environment. The controller node then accesses the pertinent storage devices and executes the commands.
[0078] Reference is now made to FIG. 13 illustrating the application-monitoring component of the uCloud Platform 100 in accordance with the principles of the present invention. The platform indirectly communicates with the Controller Node which monitors the application health. This entails passively monitoring a) the state of Enterprise SDC's ( 400 , 402 , 404 in FIG. 4 ), and b) the capacity of the Enterprise infrastructure. The Controller Node also actively monitors the state of the processes initiated by the uCloud Platform and executed by the Controller Node. The Controller Node relays the status of the above components to the uCloud Platform monitoring component 1000 .
[0079] Reference is now made to FIG. 14 illustrating the application-orchestration component of the uCloud Platform in accordance with the principles of the present invention. The app orchestrator performs the process of tracking service offerings that are logically connected to SDC's. It takes the requests from the service catalog and deterministically retrieves information on what compute Nodes and vAppliances are part of a given SDC. It launches service catalog applications within the compute nodes that are connected to a targeted SDC.
[0080] The process is as follows:
[0000] 1. receive request for launch of a virtual application from service catalog 508 .
2. retrieve information on destination of the request (which SDC in which tenant environment)
3. Retrieve information of what devices compute Nodes and vAppliances are involved in the SDC
4. once it determines the above, the app orchestrator sends a configuration to launch these virtual applications to the controller Node.
[0081] Additionally, the app orchestrator will be used in conjunction with the app monitor in the uCloud platform 100 as well as the monitoring controller present in the controller node in the extended platform to a) receive requests from controller node and b) access the relevant tenant extended platform, determines the impacted SDC, and c) perform appropriate corrective action.
[0082] Reference is now made to FIG. 15 illustrating the integration of the application-orchestration and application-monitoring components of the uCloud Platform in accordance with the principles of the present invention. FIG. 15 illustrates part of the Monitoring functionality of the uCLoud platform 100 . Through use of the monitoring controller, the app monitor collects health information of the extended platform (as detailed herein above). In addition, a tenant can define a “disruptive event”. In the event of a disruptive event the monitoring controller will alert the app orchestrator to perform corrective action. The monitoring controller performs corrective action by rebuilding relevant portions of extended platform control plane.
[0083] Reference is now made to FIG. 16 illustrating the big data component of the uCloud Platform 100 and the relationship to the monitoring component of the platform. Based on the data collected by the Controller Node 121 that is relayed to the Platform and stored in a Database, an analysis can be made of, a) SDC and compute nodes usage, and b) disruptive events reported. Heuristics of cloud usage is tracked by the Controller Node. Heuristic algorithmic analysis is used in 100 to understand aspects of tenant cloud usage.
[0084] SDC instance information is collected from the SDC management plane by the tenant cloud instance manager. (achieved by a) tenant cloud instance manager sending a command to the controller node via the message bus, b) controller node uses the command to retrieve collected information from the correct SDC management plane, c) information is relayed to tenant cloud instance manager, d) information is stored in a database)
[0085] SDC instance Information refers to Data about services usage, services types, SDC networking, compute, storage consumption data. This Data is collected continuously (via process outlined above) and archived to an external Big Data database ( 1303 , contained in 100 ).
[0086] Big data analytics engine processes the gathered information and performs heuristic big data analysis to determine cloud tenant services usage, services types, SDC networking, compute, storage consumption data, and then suggests optimal cloud deployment for tenant (through web interface in 100 ).
[0087] This analysis can contain a determination of high priority events, and report it to the relevant administrators 102 A, and 102 B. Additional analysis can be made using business metrics and return on investment computations.
[0088] Reference is now made to FIG. 17 illustrates the process of deploying uCloud within an Enterprise environment. Using gathered information on compute nodes 120 a - n , uCloud Platform 100 creates a customized package that contains a Controller Node 121 , designed for the Enterprise 101 . Administrator 102 B then downloads and installs Controller Node 121 into the Enterprise environment 101 . The uCloud Platform then orchestrates the infrastructure within the Enterprise environment, via the Controller Node. This includes configuration of router nodes 122 , firewall node 123 , compute Nodes 120 a - n , as well as any storage infrastructure.
[0089] FIG. 17 represents a holistic view of the cloud management platform capabilities of uCloud Platform. The platform is separated into the hosted platform 100 and the management platform.
[0090] The uCloud Platform 100 can support many tenants recalling that a tenant is defined as an enterprise or a service provider. The multi tenant concept can be seen in FIG. 2 , as well as in FIG. 3 . The tenant environment prior to deployment of uCloud is a collection of Compute Nodes. Post uCloud deployment, the environment, now called a private cloud, comprises an extended platform and compute nodes. The extended platform comprises of a limited number of Nodes dedicated for the logical creation of clouds (SDC's). The compute Nodes are used as Enterprise resources, and can be part of a single or multiple SDC's, or software defined clouds. The SDC concept is seen in FIG. 4 . This is referred to as the “logical view” of the private cloud. The division of the extended platform and the compute nodes is seen in FIG. 1 . This will be referred to as the “hardware view” of the private cloud. The combination of the logical and hardware views is seen in ( FIG. 18 ). As mentioned, the extended platform consists of several Nodes (servers). Each Node will run specific types of virtual Appliances, or vAppliances, that regulate and create logical boundaries for an SDC. Every SDC will contain a specific set of vAppliances. The shaded regions of (FLOW 1 ) represent exclusive use of a set of vAppliances by a specific SDC. The Compute Nodes of a private cloud, seen in FIG. 1 and in FLOW as C-N, are a resource that can be shared between multiple SDC's. This sharing concept is seen in FIG. 18 .
[0091] The uCLoud Platform manages SDC's by providing several features that will assist a tenant in operating the private cloud. These features include, but are not restricted to, a) service catalog of virtual applications to be run on a given SDC, b) monitoring of SDC's, c) Big Data analytics of SDC usage and functionality, and d) hierarchical logic dictating access to SDC's/virtual applications/health information/or other sensitive information. The process of performing each feature has been shown in FIGS. 5-14 .
[0092] The uCloud Platform configuration process is summarized as follows: Using gathered information on compute nodes 120 a - n , uCloud Platform 100 creates a customized package that contains a Controller Node 121 , designed for the Enterprise 101 . 102 B then downloads and installs 121 into the Enterprise environment 101 . The uCloud Platform then orchestrates the infrastructure within the Enterprise environment, via the Controller Node. This includes configuration of router nodes 122 , firewall node 123 , compute Nodes 120 a - n , as well as any storage infrastructure. The combination of all uCLoud Platform components in the hosted and extended platforms allows for the operation of a multi-tenant, multi-User, scalable Private cloud.
[0093] FIGS. 22-24 illustrate a system and process for a predictable cloud cloud infrastructure assurance model. FIG. 22 illustrates an overview of an embodiment of the invention. The embodiment includes an assurance manager 2310 , which is part of the uCloud platform. It performs two primary processes.
[0094] FIG. 23 illustrates the first process of collection of the data for cloud infrastructure assurance. At step 2330 , the assurance receives events reported by the infrastructure monitor 2320 . At step 2340 , the assurance manager categories the received events into faults and informational events. Faults are classified as events that require corrective action, while informational events do not require action under this invention. At step 2350 , the faults are further classified into critical, major, or minor faults. The assurance manager associates the faults with tenants, software defined clouds, hardware, or other computing resources 2360 . The resulting fault information and associated computing resources are stored in the fault database 2380 for later processing 2370 .
[0095] FIG. 24 illustrates the second process of evaluation. The assurance manager 2310 periodically polls the fault database 2380 in order to evaluate critical, major, and minor faults 2410 . The assurance manager groups related computing resources such as SDCs and the corresponding SDC hardware and tabulates the number of faults within a time interval. Where there is an abnormally high number of faults in the group, it is identified as a “hot spot” 2420 . The assurance manager 2310 classifies types of critical and major faults into types such as network, storage, input/output, hardware, or custom fault types. 2430 . The assurance manager performs heuristic analysis 2440 for the most frequent fault types for adjustments and outputs a time assurance report for the SDC 2450 .
[0096] FIGS. 25 and 26 illustrate a system and process for a correlation of large network compute fault event streams. FIG. 25 illustrates an overview of major system components of an embodiment of the invention, while FIG. 26 illustrates a combination of system components and processes applied to that embodiment of the invention.
[0097] The assurance manager 2610 , a virtual component of the uCloud platform of FIG. 1 , identifies the faults that can be correlated to connectivity, timeout, and congestion problems. The assurance manager 2610 extracts the connectivity faults from the cloud network fault event stream 2620 . The assurance manager 2610 then correlates the faults to the tenant, SDC, network subnet, router, and/or vAppliance instances 2630 . In other words, for each tenant, the cloud network fault events will be correlated per SDC, and within each SDC, per network subnet. The same applies to all related SDC router vAppliances and the other elements. For each tenant/SDC/network subnet/Router vAppliance, the assurance manager 2610 tracks the time occurrence of each fault. It also identifies fault types, such as internet facing connectivity faults, faults relating to the internal subnet within the SDC, and enterprise facing issues, internet facing connectivity issues relate to SDC's that are public facing (public or public routed SDC's), internal subnet issues relate to SDC internal traffic issues, enterprise facing issues that could correspond to enterprise facing issues (routed or public routed SDC's) 2640 . The assurance manager 2610 generates an assurance report for tenant admin for root cause analysis identifying SDC network fault behavior by time for congestion and connectivity fault types 2650 . This report is saved in the assurance database 2660 .
[0098] FIGS. 27 and 28 illustrate a system and process for correlation of large cloud load balance fault event streams. FIG. 27 illustrates an overview of major system components of an embodiment of the invention, while FIG. 28 illustrates a combination of system components and processes applied to that embodiment of the invention.
[0099] A tenant administrator specifies nodes to be used for load balancing server farms during initial onboarding. The load balancing server farm is used to provide a single internet service from multiple nodes of uCloud. Assurance manager 2610 extracts faults associated with virtual machine applications marked as nodes for load balancing server farms by tenant/SDC 2820 . The assurance manager 2610 also extracts virtual internet protocol connectivity failure faults for applications. The assurance 2610 manager extracts compute assurance faults 2840 . The assurance manager 2610 correlates the two types of faults to isolate compute hardware failure affecting load-balancing capability 2830 . The assurance manager 2610 generates an assurance report for load balancing virtual internet protocol issues by tenant/SDC/load balancing appliance/compute nodes 2850 . The generated report is saved in the assurance database 2660 .
[0100] While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure, as defined by the following claims. | Method and Apparatus for rapid scalable unified infrastructure system management platform are disclosed by discovery of compute nodes, network components across data centers, both public and private for a user; assessment of type, capability, VLAN, security, virtualization configuration of the discovered unified infrastructure nodes and components; configuration of nodes and components covering add, delete, modify, scale; and rapid roll out of nodes and components across data centers both public and private. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to data storage libraries housing multiple tapes or other data storage cartridges. More particularly, the invention concerns a data storage library that utilizes library-local features to regulate access to shared read/write drives among multiple hosts, thereby avoiding arbitrating host software.
2. Description of the Related Art
A small computer system interface (“SCSI”) medium changer is a data storage device including storage slots, drives, and input/output (I/O) slots. SCSI medium changers also include robotic mechanisms that move data cartridges among other SCSI medium changer components. One example of a SCSI medium changer device is an IBM model 3575 tape library.
In many applications, it is desirable to share some or all components of a SCSI medium changer among multiple host applications. Sharing is especially desirable for tape libraries, since they are often used for the limited purpose of backing up data, and otherwise lie dormant during long periods when the tape library could be working for other hosts. Thus, especially for large tape libraries, it is desirable to have several host applications take turns using the library and its tape drives.
One problem with achieving this level of sharing is the need to arbitrate access among the different hosts. Namely, the sharing host applications must have some mechanism to ensure that one host does not access, or worse yet, update the contents of another host's cartridges. One popular solution is to install intervening software between the library and its hosts to arbitrate access to the library cartridges and tape drives. This software is known as “middleware,” and numerous examples are commercially available. Nonetheless, there are certain drawbacks. For instance, additional expense is required to purchase and maintain the middleware programs. Installation of the middleware requires the user to sacrifice processing capability of existing host hardware, or invest in additional processing hardware to run the middleware.
In contrast with middleware, a different approach is to logically partition storage slots and tape drives into distinct logical SCSI medium changer devices. This approach is implemented in the IBM model 3575 tape library, for example. The partitioning approach establishes “logical” partitions, each including an assortment of slots and one or more tape drives. Each partition is exclusively associated with one host. Thus, this approach shares the library resources by exclusively associating specific library resources to particular hosts.
Although this approach has certain advantages, engineers at International Business Machines Corp. (“IBM”) are continually seeking to improve the performance and efficiency of such systems. In this respect, one area of continual focus concerns the possibility of greater efficiency and device utilization through more efficient sharing schemes. In this respect, the present inventors have recognized that the partition approach still does not sufficiently share the read/write drives, one of the most expensive components in a tape library. Namely, one drive may be extremely busy processing requests of its corresponding host application, while other drives are inactive. Nonetheless, the other drives cannot be recruited to satisfy the busy host's requests due to the lines of partition.
Consequently, from the standpoint of efficiency, known library sharing schemes may not be completely adequate for some applications due to certain unsolved problems.
SUMMARY OF THE INVENTION
Broadly, the present invention concerns a data storage library that utilizes library-local features to regulate access to shared read/write drives among multiple hosts, thereby avoiding arbitrating host software. The library includes multiple data storage media, multiple data storage media slots, multiple read/write drives, and a library controller. The storage slots are originally partitioned into multiple “logical libraries,” with one or more hosts having access rights to the slots of each logical library. The controller will prevent a requesting host from removing a cartridge from a source storage slot unless the requesting host has access rights to the logical library of the source storage slot. In contrast to the partitioned storage slots, empty read/write drives are normally shared among all hosts. However, the controller will prevent a requesting host from unloading a cartridge from a read/write drive unless the requesting host has access rights to the “originating” logical library containing the storage slot from where the cartridge was loaded into the drive.
Accordingly, one embodiment of this invention concerns a method to regulate access to shared read/write drives among multiple hosts, thereby avoiding arbitrating host software. In another embodiment, the invention may be implemented to provide an apparatus, such as a data storage library, including structure to regulate access to shared read/write drives among multiple hosts, and thus avoid arbitrating host software. In still another embodiment, the invention may be implemented to provide a signal-bearing medium tangibly embodying a program of machine-readable instructions executable by a digital data processing apparatus to perform operations as described herein. Another embodiment concerns logic circuitry having multiple interconnected electrically conductive elements configured to perform such operations.
The invention affords its users with a number of distinct advantages. Importantly, the present invention efficiently utilizes expensive library hardware resources by sharing empty read/write drives among multiple hosts. Accordingly, the present invention treats read/write drives as serially reusable resources, rather than exclusively assigning each drive to one or more hosts. Since this sharing scheme is implemented by the library controller, the invention advantageously utilizes library-local components to arbitrate host access to shared read/write drives. Thus, the invention avoids the need for expensive middleware programs to arbitrate host access to shared read/write drives. Similarly, the invention avoids sacrificing processing capability of existing host hardware that would be caused by running host-based arbitrating software. The invention also provides a number of other advantages and benefits, which should be apparent from the following description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the hardware components and interconnections of a data storage system according to the invention.
FIG. 2 is a block diagram of a digital data processing machine according to the invention.
FIG. 3 shows an exemplary signal-bearing medium according to the invention.
FIG. 4 is a flowchart of an operational sequence for library-local arbitration of host access commands according to the invention.
DETAILED DESCRIPTION
The nature, objectives, and advantages of the invention will become more apparent to those skilled in the art after considering the following detailed description in connection with the accompanying drawings.
HARDWARE COMPONENTS & INTERCONNECTIONS
Introduction
One aspect of the invention concerns a data storage system, which may be embodied by various hardware components and interconnections as described in FIG. 1 . FIG. 1 shows a data storage library 100 coupled to a number of hierarchically superior hosts 102 . The library 100 includes many portable data storage media, such as magnetic tape cartridges, optical cartridges, writeable CDs, etc. For ease of reference, the portable data storage media of the library 100 are referred to as “cartridges.”
Host(s)
Among other possible functions, the hosts 102 supply data to the library 100 for storage, and send requests to the library 100 to retrieve data. Multiple hosts 102 are shown, since one beneficial feature of the data storage library 100 its sharing of read/write drives among multiple hosts. As illustrated, the hosts 102 include hosts 102 a - 102 d.
The host role may be satisfied by various types of hardware, such as a digital data processing computer, logic circuit, construction of discrete circuit components, interface to a human operator, etc. As an example, one or more hosts 102 may comprise IBM RS/ 6000 machines employing an operating system such as AIX. The hosts 102 may also be coupled to respective interfaces (not shown), enabling the hosts 102 to exchange information with a human operator. Each such interface may comprise a control panel, video monitor, computer keyboard/mouse, or another appropriate human/machine interface.
The hosts 102 manage data in the library 100 using “location-centric” commands, and may utilize the SCSI medium changer protocol as one example. With location-centric commands, the hosts 102 request cartridge movement by specifying source and destination locations in the library 100 . Using the SCSI medium changer protocol to further illustrate one example, the hosts 102 may specify locations such as locations of medium transport elements, storage elements, import/export elements, data transfer elements, and the like.
Library
The library 100 is coupled to the hosts 102 by an interface 109 , which may be embodied in various forms. Some examples include wires/cables, one or more busses, fiber optic lines, wireless transmission, intelligent communications channel, etc. The library 100 carries out host requests to move cartridges, access cartridges, etc.
In one embodiment, the library 100 comprises a SCSI removable media library, such as a tape library. Along with other alternatives, the library 100 may utilize other connectivity options, such as a fibre channel-to-SCSI bridge product, SCSI-to-SCSI multiplexer, etc.
Drive
The library 100 includes multiple drives 106 to conduct read/write operations with cartridges in the library 100 . In the present example, two drives 106 a - 106 b are shown. Advantageously, the controller 108 oversees sharing of the drives 106 among the hosts 102 , avoiding the need for any additional, library-external hardware or “middleware” software package. Since the drives 106 are shared without preference for one or another, the drives 106 a - 106 b may be called a “drive pool”.
Each drive 106 comprises suitable hardware to access the format of data storage cartridge in the library 100 . For example, in the case of magnetic tape cartridges, the drive 106 may comprise IBM model 3590 tape drives. Cartridges are directed to/from the drives 106 by robotics 110 , described below.
Cartridge Storage & Management
The library 100 includes equipment to physically move and store the cartridges. For instance, storage slots 114 house dormant cartridges. The storage slots 114 comprise shelves or other data storage library compartments. I/O slots 112 are provided to transfer cartridges to/from the library 100 without disrupting the operation of the robotics 110 or drives 106 . Using the I/O slots 112 , an operator can introduce cartridges into the library 100 (“insert” operation), or the library 100 can expel cartridges (“eject” operation). For example, the I/O slots 112 may comprise “pass-through” slots, a carriage, conveyor, etc.
The storage slots 114 are logically divided into multiple “partitions,” also called “logical libraries.” In the present example, four partitions 114 a - 114 d are illustrated. The partitions 114 a - 114 d may be selected to achieve any desired relationship with the physical storage slots. For example, a partition may include one slot, a row of slots, a panel of slots, a selection of individual slots, or any other arrangement.
According to the present invention, the partitions are used to implement one technique for sharing the storage slots 114 among the multiple hosts 102 . As explained below, the library controller 108 acts as a gateway that prevents a host from accessing the slots of each partition 114 a - 114 d unless that host has “access rights” to that partition. Access rights occur according to a user selected host-partition mapping that is established at system configuration, or another appropriate time. As an example, the host-partition mapping may specify that the host 102 a has exclusive access to the partition 114 a , the host 102 b has access to the partition 114 b , and so on. Under host-partition mapping, one or more hosts have access rights to each partition.
To move cartridges between the drives 106 , I/O slots 112 , and storage slots 114 , the library 100 includes robotics 110 . The robotics 110 access these components by respective paths 110 a , 110 b , 110 c , and 110 d . The robotics 110 may be implemented by any suitable cartridge movement machinery, such as robotic arms, integrated cartridge loading equipment, conveyors, grippers movable on an x-y coordinate system, etc. The robotics 110 may include a single device that is shared among the hosts 102 , or multiple devices that are partitioned or shared, depending upon the needs of the application. Likewise, the I/O slots 112 may be partitioned or shared, depending upon the requirements of the application.
Controller
The library 100 operates under supervision of the controller 108 , which receives commands from the hosts 102 requesting the controller 108 to move cartridges between storage slots 114 , I/O slots 112 , and the drives 106 . The controller 108 communicates with the hosts 102 via the interface 109 . In addition to the interface 109 , which constitutes a “control” path, the library 100 also includes a “data” path (not shown) that carries data between the hosts 102 and the read/write drives 106 .
The controller 108 comprises a digital data processing machine, logic circuit, construction of discrete circuit components, or other automated mechanism, and operates according to suitable programming, physical configuration, etc. To provide a specific example, the controller 108 may comprise an IBM POWER-PC processor.
The hosts 102 send location-centric movement requests for controller 108 to move cartridges. Each movement request includes a movement command along with various parameters, such as source and destination addresses corresponding to desired locations among the storage slots 114 , I/O slots 112 , and drives 106 . The controller 108 maintains a drive map 116 and partition map 118 . The drive map 116 maintains information that is used by the controller 108 in arbitrating use of the drives 106 among the hosts 102 , as explained below. TABLE 1 shows an example of the drive map 116 . Each row represents one drive, and lists the following related information:
1. The identity of the drive 106 a - 106 b represented by this row.
2. Whether the drive contains a cartridge (“full”) or not (“empty”).
3. If the drive contains a cartridge, the identity of the “originating” partition 114 a - 114 d where the cartridge came from.
TABLE 1
DRIVE MAP
DRIVE
FULL/EMPTY
ORIGINATING PARTITION
DRIVE 106a
FULL
PARTITION 114d
DRIVE 106b
EMPTY
N/A
The partition map 118 contains the host-partition mapping to aid the controller 108 in properly limiting each host's access to the host's designated partition. Each partition is only accessible by hosts with access rights to that partition. TABLE 2 shows an example of the partition map 118 . Each row represents one storage slot 114 , and lists the following related information:
1. The storage slot's physical address.
2. The identity of the partition containing this slot.
3. The identities of all hosts with access rights to the partition containing this slot.
TABLE 2
PARTITION MAP
PHYSICAL ADDRESS
HOST(S) WITH
OF STORAGE SLOT
PARTITION
ACCESS RIGHTS
000001
114a
102a
000002
114a
102a
000003
114a
102a
000004
114a
102a
. . .
. . .
. . .
000234
114b
102b, 102c
000235
114b
102b, 102c
000236
114b
102b, 102c
. . .
. . .
. . .
000301
114c
102c, 102d
000302
114c
102c, 102d
. . .
. . .
. . .
001024
114d
102d
001025
114d
102d
001026
114d
102d
001027
114d
102d
001028
114d
102d
001029
114d
102d
. . .
. . .
. . .
002056
114d
102d
Exemplary Digital Data Processing Apparatus
The controller 108 may be implemented in various forms, including a digital data processing apparatus as one example. This apparatus may be embodied by various hardware components and interconnections; one example is the digital data processing apparatus 200 of FIG. 2 . The apparatus 200 includes a processor 202 , such as a microprocessor or other processing machine, coupled to a storage 204 . In the present example, the storage 204 includes a fast-access storage 206 , as well as nonvolatile storage 208 . The fast-access storage 206 may comprise random access memory (“RAM”), and may be used to store the programming instructions executed by the processor 202 . The nonvolatile storage 208 may comprise, for example, one or more magnetic data storage disks such as a “hard drive,” a tape drive, or any other suitable storage device. The apparatus 200 also includes an input/output 210 , such as a line, bus, cable, electromagnetic link, or other means for the processor 202 to exchange data with other hardware external to the apparatus 200 .
Despite the specific foregoing description, ordinarily skilled artisans (having the benefit of this disclosure) will recognize that the apparatus discussed above may be implemented in a machine of different construction, without departing from the scope of the invention. As a specific example, one of the components 206 , 208 may be eliminated; furthermore, the storage 204 may be provided on-board the processor 202 , or even provided externally to the apparatus 200 .
Logic Circuitry
In contrast to the digital data storage apparatus discussed previously, a different embodiment of the invention uses logic circuitry instead of computer-executed instructions to implement the controller 108 . Depending upon the particular requirements of the application in the areas of speed, expense, tooling costs, and the like, this logic may be implemented by constructing an application-specific integrated circuit (“ASIC”) having thousands of tiny integrated transistors. Such an ASIC may be implemented with CMOS, TTL, VLSI, or another suitable construction. Other alternatives include a digital signal processing chip (“DSP”), discrete circuitry (such as resistors, capacitors, diodes, inductors, and transistors), field programmable gate array (“FPGA”), programmable logic array (“PLA”), and the like.
OPERATION
In addition to the various hardware embodiments described above, a different aspect of the invention concerns a method for performing library-local arbitration of host access commands in a partitioned data storage library.
Signal-Bearing Media
In the context of FIGS. 1-2, such a method may be implemented, for example, by operating the controller 108 , as embodied by a digital data processing apparatus 200 , to execute a sequence of machine-readable instructions. These instructions may reside in various types of signal-bearing media. In this respect, one aspect of the present invention concerns a programmed product, comprising signal-bearing media tangibly embodying a program of machine-readable instructions executable by a digital data processor to perform a method for performing library-local arbitration of host access commands in a partitioned data storage library.
This signal-bearing media may comprise, for example, RAM (not shown) contained within the controller 108 , as represented by the fast-access storage 206 . Alternatively, the instructions may be contained in another signal-bearing media, such as a magnetic data storage diskette 300 (FIG. 3 ), directly or indirectly accessible by the processor 200 . Whether contained in the storage 206 , diskette 300 , or elsewhere, the instructions may be stored on a variety of machine-readable data storage media, such as direct access storage (e.g., a conventional “hard drive,” redundant array of inexpensive disks (“RAID”), or another DASD), magnetic tape, electronic read-only memory (e.g., ROM, EPROM, or EEPROM), optical storage (e.g., CD-ROM, WORM, DVD, digital optical tape), paper “punch” cards, or other suitable signal-bearing media including transmission media such as digital and analog and communication links and wireless. In an illustrative embodiment of the invention, the machine-readable instructions may comprise software object code, compiled from a language such as “C,” etc.
Logic Circuitry
In contrast to the signal-bearing medium discussed above, the method aspect of the invention may be implemented using logic circuitry, without using a processor to execute instructions. In this embodiment, the logic circuitry is implemented in the controller 108 , and is configured to perform operations to implement the method of the invention. The logic circuitry may be implemented using many different types of circuitry, as discussed above.
Operating Sequence
FIG. 4 shows one example of a sequence 400 to performing library-local arbitration of host access commands in a partitioned data storage library. For ease of explanation, but without any intended limitation, the example of FIG. 4 is described in the context of the hardware components and interconnections shown in FIG. 1, described above.
The steps 400 are initiated in step 402 . After step 402 , the library 100 is configured in step 404 , 406 . As an example, these steps may be performed when the library 100 is initially installed, subsequently reconfigured, or otherwise setup. In step 404 , the storage slots 114 are logically allocated into partitions (also called “logical libraries”). As an example, step 404 may be achieved by an operator transmitting input data to the controller 108 via a keyboard or library control panel (not shown). This input data specifies the extent of each partition, and as an example, may identify:
1. The number of partitions.
2. The storage slots 114 contained in each partition.
3. Any “unshared” I/O slots 112 , and the partition containing each unshared I/O slot.
4. Any unshared drives 106 , and the partition containing each unshared drive. For clarity of explanation, the present illustration does not depict any unshared drives, to focus on the drive sharing aspect of the invention.
After step 404 , step 406 conducts host-partition matching. This may be performed, for example, by the operator transmitting further input data to the controller 108 . This input data associates one or more hosts with each partition; each host associated with a partition is said to have “access rights” to the facilities of that partition. If desired, a host may have access rights to than one partition; this may be avoided, however, by redefining these multiple partitions as a single partition. Also in step 406 , the controller 108 stores the host-partition mapping in the partition map 118 .
When step 406 is complete, the initial configuration of the library is finished. Next, the controller 108 determines whether it has received any host cartridge movement requests (step 408 ). If not, step 408 repeats. When the controller 108 receives a cartridge movement request from one of the hosts 102 , the routine 400 branches according to whether the host requested an “unload” operation or a “load” operation. An unload operation involves transferring a cartridge from a drive to an I/O slot 112 or storage slot 114 , whereas a load operation involves the opposite action.
If the controller 108 received a cartridge load request, step 408 advances to step 410 . In step 410 , the controller 108 examines the load request, which includes a load command and various load parameters, including (1) identification of a “source” storage or I/O slot containing the desired cartridge, and (2) optionally, specification of a “destination” read/write drive for the load operation. The controller 108 proceeds to access the partition map 118 to determine whether the host has access rights to the partition containing the identified source storage slot (if a destination drive has been specified and this drive is allocated to a partition). If not, then this host does not have permission to access the source slot and/or destination drive according to the host-partition mapping that was established in step 406 . In this event, the controller 108 denies the host request in step 412 by returning an error message to the host, not responding, etc. Step 412 then leads back to step 408 , to wait for the next host movement request.
In contrast, if the host has permission to access the cartridge in the source slot (and destination drive, if specified), then step 410 proceeds to step 414 . In step 414 , the controller 108 directs the robotics 110 to load the cartridge from the specified storage slot into the identified destination drive (if one was specified), or alternatively into any available drive if none was specified. Since the drives 106 a - 106 b are shared among all hosts 102 , the controller 108 may select any available drive if none was specified. If a specified destination drive is unavailable, of if all drives are unavailable and none were specified, the controller 108 may transfer the desired cartridge into a preloading shelf or loader, enter the cartridge's name in a load-pending memory queue for subsequent physical loading, etc. Assuming drive availability, in step 414 controller 108 also updates the drive map 116 , which was described above in TABLE 2. Namely, step 414 updates the drive map to show the following data, cross-referenced against the chosen drive: (1) the partition where the loaded cartridge came from, and (2) the “full” status of the drive. After step 414 , the load operation is complete, and control returns to step 408 to await the next cartridge movement request.
In contrast to the foregoing sequence, if the controller 108 received a cartridge unload request in step 408 , then the routine 400 advances to step 416 instead of step 410 . In step 416 , the controller 108 examines the unload request, which includes an unload command and various parameters including (1) identification of the source drive 106 containing the cartridge to be unloaded, and (2) identification of a destination storage slot or 110 slot. Also in step 416 , the controller 108 accesses the drive map 116 and partition map 1128 as follows. Namely, the drive map 116 indicates the originating partition, where the cartridge in the drive came from; the partition map 118 identifies the host(s) with access rights to the source partition. If the requesting host has access rights to the originating partition according to the partition map 118 , then the controller 108 moves the cartridge from the drive to the destination slow pursuant to the host's request (step 420 ). Otherwise, if the requesting host does not have access rights to the originating partition, then the controller 108 denies the host request in step 418 by returning an error message to the host, not responding at all, etc. In an alternative embodiment, the requesting host is required to have access rights to both the originating partition and destination location. In this embodiment, if the requesting host has access rights to the originating partition and destination location according to the partition map 118 , then the controller 108 moves the cartridge from the drive to the destination slot pursuant to host's request (step 420 ). Otherwise, if the requesting host does not have access rights to both partitions (i.e., originating and destination slot), then the controller 108 denies the host request in step 418 by returning an error message to the host, not responding at all, etc. After steps 418 or 420 , the controller returns to step 408 to wait for the next host movement command.
OTHER EMBODIMENTS
While the foregoing disclosure shows a number of illustrative embodiments of the invention, it will be apparent to those skilled in the art that various changes and modifications can be made herein without departing from the scope of the invention as defined by the appended claims. Furthermore, although elements of the invention may be described or claimed in the singular, the plural is contemplated unless limitation to the singular is explicitly stated. | A data storage library utilizes library-local features to regulate access to shared read/write drives among multiple hosts, and thereby avoid the need for arbitrating host software. The library includes multiple data storage media, multiple data storage media slots, multiple read/write drives, and a library controller. The slots are originally partitioned into multiple logical libraries. Normally, the library shares the read/write drives among all hosts. However, when a host submits a request to unload a cartridge from a read/write drive, the library only honors that request if the host has access rights to the logical library from where the cartridge was originally loaded. Similarly, for each slot, the controller prevents a requesting host from loading a cartridge from that storage slot unless the requesting host has access rights to the logical library that includes that storage slot. | 6 |
RELATED APPLICATIONS
This application claims priority to the provisional application having Ser. No. 60/624,736, which was filed on Nov. 3, 2004. The provisional application having Ser. No. 60/624,736 is herein incorporated by reference in its entirety.
The application is also related to the subject matter disclosed in U.S. application Ser. No. 10/228,385, filed 26 Aug. 2002, the subject matter of which is herein incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to apparatus and methods for monitoring fatigue, structural response and operational limits in structural components. More particularly the present invention relates to apparatus and methods for installation of monitoring systems on marine and land structural members.
DESCRIPTION OF THE RELATED ART
All structures respond in some way to loading, either in compression, tension, or combinations of various loading modes. While most structures and systems are designed to accommodate planned loading, it is well known that loads exceeding design limits or continued cyclical loading may induce fatigue in the structure. While some structures may be readily monitored for signs of fatigue, others are not easily monitored. Examples include subsea structures, such as pipelines, risers, wellheads, etc.
In most instances, monitoring systems are installed when the structure is installed or constructed. However, there exists a system of subsea risers, pipelines and other structures that have already been installed without the benefit of monitoring systems. These subsea components are subject not only to normal planned current or wave loading, but met ocean events, such as hurricanes, or sustained cyclical loading from vortex induced vibration (VIV) loading.
A major concern in all offshore operations is the operational life of subsea components. A fatigue-induced failure can result in a substantial economic loss as well as an environmental disaster should produced hydrocarbons be released into the sea. When a subsea production structure is nearing the end of its serviceable life or has suffered substantial fatigue, producing companies are likely to shut-in production rather than run the risk of a catastrophic failure. This can result in substantial financial losses to the producing company.
Currently, most subsea structures, such as risers and pipelines, including steel catenary risers, are not monitored. Structural integrity of such bodies is modeled, based on known loading factors, sea state data, and boundary conditions. Because there is no direct measurement of strain or fatigue in these structures, high safety factors, on the order of 10 to 20, are factored into these models. It will be appreciated that as the models indicate that a structure is nearing the end of its serviceable life or has undergone unacceptable fatigue, the choice for the production company is to repair or replace the structure or to shut-in production. In some instances, the structural integrity is far better than the models may predict. This means that the producing companies may be incurring substantial expense in repairing or replacing the structures or losses from shutting in production. The alternative, a loss of containment of produced hydrocarbons, would, however, subject any producing company to far greater liability costs when compared to repair, replacement or shut-in.
Recently efforts have been made to develop monitoring systems for subsea structures. U.S. Patent Publication 2004/0035216, published 26 Feb. 2004, U.S. application Ser. No. 10/228,385, entitled Apparatuses and Methods for Monitoring Stress in Steel Catenary Risers, which is herein incorporated by reference in its entirety, describes an apparatus and method for monitoring subsea structures utilizing a series of fiber optic Bragg grating (FBG) sensors to measure strain in several directions on a subsea structure. The design and use of FBG sensors is discussed within the '385 application. Multiple fiber optic strands from a centralized fiber bundle have a Bragg grating applied to them and are attached to the subsea structure. Small gratings are etched on the fibers where attached to the structure. As a light is applied to the fiber a return signal is received. As a strain is applied to the structure, the grating is likewise strained and the returned signal undergoes a frequency shift that is proportional to the strain. The aforementioned application discloses the performance of the FBG sensors and a means for attaching them to the structure. It will be appreciated that by obtaining actual strain data, the models used to determine serviceable life are more accurate and the safety factors can be reduced to manageable levels. As, such, producing companies are more likely to reduce repair/replacement costs or shut-in losses without substantially increasing environmental risk.
Thus, there exists a need for an improved method and apparatus to permit retrofit of an FBG or other sensor monitoring system that can be adapted to structures already in place.
SUMMARY OF THE PRESENT INVENTION
The present invention is directed to a means of retrofitting sensors to installed marine elements. More particularly, the present invention utilizes a set of collars that may be remotely installed on subsea structures. One or more fiber optic sensors and umbilicals leading to a system are affixed to the structure by means of multipart collars. The collars may be hingeable for ease of installation or may be assembled as separate items. The umbilical acts as a protective sleeve for the fiber optic sensor and its fiber optic communication line. The sensors may be bonded internal to the the umbilical. Moreover, the fiber optic sensors may be of the FBG type previously disclosed, or may be of the Fabry Perot (FP) interferometer type. The nature of FP sensors is well known to those of ordinary skill in the art. In a Fabry Perot sensor, light is reflected between two partially silvered surfaces. As the light is reflected, part of the light is transmitted each time it reaches the surface, resulting in multiple offset beams that set up an interference. The performance of FP sensors is similar in that relative movement between the two silvered surfaces will result in a change of wavelength of the light.
The present invention contemplates that the fiber optic sensors and their umbilicals are secured to the collars or other support structures. The support structure is then deployed subsea and installed on an existing subsea structure. The umbilicals may be removably attached to the support structure. This permits subsequent replacement of a sensor/umbilical in the event of failure. Alternatively, it permits installation of the sensor/umbilical following attachment of the support structure to the structure. In the present invention, multiple sensor/umbilical pairs may be attached to a single support structure. When the support structure is attached to the subsea structure, the sensors are fixed in position relative to the subsea structure. It will be appreciated that multiple support structures/umbilical/sensor assemblies may be attached to the subsea structure, thereby permitting strain monitoring along the length of the subsea structure. The flexibility of support structure design and attachment scheme of the sensor/umbilical pairs permits the user to design a custom monitoring system for the subsea structure.
In one application, the present invention may provide a large and dense array of sensors over a relatively small portion of the structure. In the case of a subsea pipeline or a riser, this type of deployment could be used to determine not only strain from physical forces (physical loading and current forces) but may be used to detect large volumes of denser production (slugs) as they pass through the monitored section. As the slugs pass through a pipeline, the internal pressure within the pipe increases, resulting in detectable strain in the pipe internal and external walls. This strain may be detected by the sensors arrayed to measure hoop strain and may be recorded by the monitoring system. As the slug passes down a pipeline, it will be detected by subsequent sensors. The design of a sensor array and its placement along a pipeline section may be used to characterize the slug velocity and size.
In another application, the present invention may provide for multiple support structures over long spans of the structure. In the case of SCRs, it would permit monitoring strain across the touch down zone. This type of application would also permit monitoring of the effects of temperatures on a subsea element. It will be appreciated that high temperature/high pressure well production may have hydrocarbon production temperatures in the range of 200° to 350° F. This production may be rapidly cooled as it passes through subsea flow lines to production risers. The effect of this rapid temperature change on subsea equipment is poorly documented. It will be appreciated that the failure of a piece of subsea equipment due to temperature failure would have a disastrous effect on the environment.
While the foregoing and following discussion focuses on the use of fiber optic FBG and FP sensors, it will be appreciated that the sensors described herein may include hybrid sensors, i.e., fiber optic sensors in combination with other types of transducers including a means for converting the transducer signal for transmission through a fiber optic medium.
The foregoing summary has outlined rather broadly the features and technical advantages of the present invention so that the detailed description of the preferred embodiment that follows may be better understood. Additional features and advantages of the invention will be described hereinafter, which form the subject of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiments disclosed might be readily used as a basis for modifying or designing other apparatuses and methods for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth and claimed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments and applications of the present invention, and, together with the detailed description, serve to explain the invention. In the drawings:
FIGS. 1A and 1B are side and top views, respectively, of a cutaway section of a tubular showing one embodiment of the present invention;
FIGS. 2A and 2B are side and top views, respectively, of a cutaway section of a tubular showing another embodiment of the present invention;
FIG. 3 is a perspective view of an application of the present invention showing spaced collars having multiple sensors on each fiber optic cable on an SCR;
FIG. 4 is a side view of another application of the present invention is which the sensor umbilical is wound helically between the collars so as to sense vortex induced vibration;
FIGS. 5A and 5B are side and top views of another embodiment of the present invention utilizing two locking collars;
FIGS. 6A and 6B are side and top views of another two collar embodiment of the present invention;
FIGS. 7A and 7B are top and side views of another embodiment of the present invention utilizing a bladder contact system;
FIGS. 8A-8C are detailed views of the bladder and sensor contact system of FIGS. 7A and 7B ;
FIGS. 9A-9C are top, cross-sectional and detailed views of another embodiment of the present invention;
FIGS. 10A and 10B are side and cross-sectional views of another embodiment of the present invention; and
FIGS. 11A and 11B are cross-sectional and detailed views of another embodiment of the present invention as applied to concrete or cement coated structures; and
FIGS. 12A and 12B are side and cross-sectional views of the present invention as applied to a tubular connection.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In one embodiment the structure to which the monitoring system is attached is discussed in terms of a tubular subsea element. However, it will be appreciated that the structure need not be tubular. The specific geometry of the support structure and the means of securing it about the structure may be readily varied to the geometry of the structure. Moreover, the structure need not be limited to a subsea element, as the same principles would operate with a horizontal or vertical structure, subsea or on the land.
In FIGS. 1A and 1B , a cutaway of a subsea element 10 is shown with one embodiment of the monitoring system of the present invention mounted thereon. A collar 20 is shown comprised of two collar sections 22 A and 22 B. The collar sections 22 A and 22 B each have a hinge portion built therein and are pinned together by pin 24 , thus allowing the collar sections 22 A and 22 B to open and close tightly about the vertical element 10 . It will be appreciated that a deformable material such as rubber or plastic may be placed on the internal surfaces of collar sections 22 A and 22 B. The material is deformed against the outer surface of the subsea element 10 when the collar 20 is closed thereabout, thereby further securing the collar 20 against movement relative to the subsea element 10 . The pin 24 may be secured by any number of means known to those skilled in the art, including, but not limited to cotter pins, snap rings, etc. In FIG. 1B , a collar latch 26 is depicted as holding collar sections 22 A and 22 B in a closed position about the vertical element 10 . The collar latch 26 may be readily selected by those skilled in the art from any number of latch designs that are capable of being operated underwater, either manually or by remotely operated vehicle (ROV). Collar sections 22 A and 22 B are provided with at least one groove or notch section 28 , which will serve to provide a placement point for the fiber optic umbilical, to be discussed below. It will be appreciated that the collar sections 22 A, 22 B, the pin 24 and latch 26 may be readily fabricated from metal, fiberglass, thermoplastic or other material suitable for the marine environment. Moreover, the collars may be coated with copper or other anti-fouling coating to prevent marine growth on the collars.
Multiple fiber optic umbilicals 40 are shown as being installed in collar 20 . The fiber optic umbilical 40 provides an appropriate shield for the one or more fiber optic fibers 42 within each umbilical 40 . The umbilical 40 may be constructed from an appropriate material, such as thermoplastic or other material. Each of the fibers 42 has at least one sensor 44 integrated therein and secured to the inner wall of the umbilical 40 by epoxy or some other suitable means. As noted above, the sensor 44 may be of the FBG or FP type. While fiber optic fibers 42 of FIG. 1A are shown with a single sensor 44 , multiple sensors may be placed on a single fiber. This may be achieved by designing the FBG or FP sensor 44 to have an initial different wavelength response to the same light source as other FBG or FP sensors 44 . Accordingly, any measurement of strain from the multiple sensors could be distinguished one from the other. The sensor umbilicals 40 are depicted as being within grooves 28 within the collar sections 22 A and 22 B. The umbilicals 40 are secured within the grooves 28 and to the collar sections 22 A and 22 B by means of umbilical latches 50 . The latch 50 may be readily selected by those skilled in the art from any number of latch designs that are capable of being operated underwater, either manually or by ROV. It will be appreciated that the number of umbilicals 40 that may be deployed on collar 20 and may be a simple matter of engineering design. The sensor umbilicals 40 are then connected to a system (not shown) designed to monitor and record strains on the element 10 . Moreover, the umbilical 40 may be used to shield multiple fibers 42 , each having multiple sensors 44 thereon.
The collar 20 with umbilicals 40 already installed thereon may be lowered on a heave-resistant line from an appropriate work vessel. At the selected depth, the collar 20 and umbilicals 40 may be maneuvered into position about structure 10 . The collars 20 may then be opened and closed about the structure 10 by means of divers or ROVs, depending upon the depth of installation. Further, installation of the collar or other support structure may be achieved utilizing an ROV together with a special installation system designed to permit the installation of multiple support structures in a single trip. U.S. Pat. No. 6,659,539, incorporated herein by reference in its entirety, describes a method and apparatus for installing multiple clamshell devices, such as collar 20 , using Shell's RIVET™ system, commercially available from one or more Shell Companies. Utilizing the RIVET™, the collars 20 and umbilicals 40 would be loaded into the RIVET™, lowered to the desired position next to the structure 10 and RIVET™ arms would be activated to close the collar 20 sections about the marine element 10 . An ROV can be used to activate the RIVET™ structure or it may be remotely activated. The ROV may also be used to close the collar latch 26 , if required. Alternatively, a self-closing latch 26 may be used on collar sections 22 A and 22 B.
The monitoring system may be located on a structure or vessel above the water line. However, in many instances, the sensors may not be readily adjacent to a surface structure, making it impractical to have umbilicals 40 lead back to the surface structure for connection to the monitoring system. It is contemplated with respect to the present invention that the monitoring system may further include a subsea-based system. The subsea system would analyze and record the strain information much like a surface system. The information could be stored for periodic transmission from the subsea system to a surface based system or retrieval of data from the subsea system. This may be accomplished by means of short range electromagnetic transmission, acoustic transmission via transponders and receivers or simple data retrieval utilizing an ROV system. Alternatively, the monitoring and recording system could be based in a surface buoy tethered to the marine element. The surface buoy could be battery and/or solar powered to provide power for the monitoring system. Further, the surface buoy system could transmit information to a remote station. Thus, it would be possible to support a remote monitoring system away from a structure. It will be appreciated that the remote monitoring system disclosed therein could be utilized with any of the embodiments discussed herein.
FIGS. 2A and 2B depict side and vertical cutaways of another embodiment of the present invention. A collar 20 , comprised of collar sections 22 A and 22 B, each having a mating hinge section incorporated therein are secured about marine element 10 by means of hinge pin 24 and latch 26 . In the embodiment depicted in FIGS. 2A and 2B , a single groove 28 is incorporated into collar 20 . An umbilical 40 is shown as being placed in groove 28 and secured within the collar 20 by means of a suitable latch 50 . Whereas the umbilical 40 of FIGS. 1A and 1B had but a single fiber therein, the embodiment shown in FIGS. 2A and 2B depict multiple fiber optic fibers 42 therein, each having a sensor 44 bonded to the inside wall of the umbilical 40 . The embodiment shown in FIGS. 2A and 2B depict each of the sensors 44 at approximately the same axial position within the umbilical 40 . It will be appreciated that each fiber optic fiber 42 need not have its sensor bonded to the inside of the umbilical 40 wall in the same axial position. Moreover, more than one sensor 44 may be placed on a single fiber optic cable 42 , as discussed above. The sensors 44 may be spaced azimuthally inside umbilical 40 . Motion by marine element 10 in a specific direction will affect each sensor FIG. 3 . is a perspective view of a marine element 60 , in this case an SCR, on which a plurality of collars 20 and umbilicals 40 have been mounted in the touch down zone (TDZ), i.e., that portion of the riser where it comes into contact with the seabed 70 . The implementation depicted in FIG. 3 utilizes multiple sensors 44 on a single fiber optic fiber 42 within umbilical 40 . It will be appreciated, however, that the ability to detect a frequency shift created by FBGs, and therefore the strain seen by a particular sensor 44 , will decrease as the number of sensors on a single fiber optic fiber increases. As a result, it may be desirable as the number of collars 20 installed on a structure increases, to have separate umbilicals 40 and/or fibers 42 on the collars 20 .
FIG. 4 depicts a series of collars 20 placed on a vertical element 10 . Unlike the alignment in shown in FIG. 1A , the umbilicals 40 are shown as being deployed in a helical manner by indexing each umbilical 40 over to the adjacent groove 28 in collar sections 22 A and 22 B. As noted previously, the umbilicals 40 are secured to the collar 20 by means of an umbilical latch 50 . The umbilicals 40 may then be installed on collars 20 in a helical manner as shown in FIG. 4 using ROVs to place the umbilical 40 and close latch 50 to secure them to the collar 20 . It is well known to those skilled in art that the installation of helical bodies about a larger body will have the result of suppressing VIV. At the same time, it will be appreciated that a single umbilical 40 /sensor 44 combination that has failed during its operational life may be replaced by sending down an ROV to open the appropriate latch 50 on each collar to remove the defective umbilical 40 /sensor 44 and replace it with an operational one.
Another embodiment of the present invention is depicted in FIGS. 5A and 5B , in which a dual collar system utilizing spacer members placed between the collars. A marine element 70 is shown having two collars 101 placed at two different locations along the longitudinal axis of the tubular 70 . Each of the collars 101 are comprised of collar halves 100 A and 100 B and are free to rotate about pin 102 . Each collar 101 is also equipped with a latch 104 to secure the collar halves 100 A and 100 B together. Strips of spacers 109 are show as being affixed to and connecting collars 101 . The spacers 109 depicted in FIGS. 5A and 5B are shown as rectangular strips in compression between the collars 101 . The spacers may also have other geometric configurations and may made from ABS plastic, PVC plastic, or other thermo plastics, soft metals, fiberglass or other materials that would permit the spacers 109 to flex sufficiently to place them in compression between collars 101 . A fiber optic umbilical 110 attached to a surface monitoring system (not shown) is shown as being connected to fiber optic junction 112 . Junction 112 may be affixed to one of the collars 100 A or 100 B or may be affixed to the spacer 109 . The junction 112 shown in FIG. 5A is shown as being “daisy-chained” through fiber optic umbilical 113 to other similar junctions 112 mounted on the spacers 109 . Each junction 112 further has a fiber optic sensor lead 114 leading away from the junction 112 and terminating in a FBG or FP sensor 116 . FIG. 5A shows the sensor 116 as being mounted on the inside of spacer 109 to protect it from current borne objects. The sensor 116 may further be protected by means of epoxy, plastic or other suitable marine resistant coating. With the spacers 109 being under compression, any strain seen by marine element 70 will result in a change in the compression of the spacers 109 . These changes may be detected by the sensors 116 and transmitted to the monitoring system. While FIG. 5A shows multiple junctions 112 , it will be appreciated that a single fiber optic junction having multiple fiber optic sensor leads 114 may be used to place multiple sensors 116 on the spacers 109 .
A variation of this spacer system for monitoring is shown in FIGS. 6A and 6B . Instead of flexible spacers 109 as used in FIGS. 5A and 5B , multiple spacer bars 120 are used as spacers between collars 100 A and 100 B secured about marine element 70 . The spacer bars 120 may be placed in tension, compression or an unloaded condition between collars 100 A and 100 B. A fiber optic umbilical 110 , attached to a surface monitoring system (not shown) is shown as being connected to a single fiber optic junction 112 . Multiple fiber optic sensor leads 114 lead away from junction 112 and terminate in FBG or FP sensors 116 placed on the inside of spacer bars 120 . Alternatively, multiple junctions 112 may be used similar to those depicted in FIGS. 5A and 5B . Strain seen by the marine element 70 will be transmitted via collars 100 A and 100 B to the spacer bars 120 . The strain may be detected by the sensors 116 , transmitted through junction 112 , and fiber optic cable 110 to the surface system or another system, where it may be recorded. It will be appreciated that implementations depicted in FIGS. 5A , 5 B and 6 A, 6 B may be installed utilizing the aforementioned RIVET™ system.
An alternative to mounting sensors on intermediate objects attached to a marine element is to mount the sensor directly on the marine element. However, retrofitting sensors directly to an installed marine element is generally difficult in assuring (a) placement and (b) contact between the sensor and marine element. FIGS. 7A and 7B depict the design of a collar system that permits a sensor to be directly in contact with an installed marine element. A single collar 200 is comprised of collar halves 202 A and 202 B pivoting about pin 206 . The collar halves 202 A and 202 B are secured about the marine element utilizing a latch 204 , for example a self-locking latch. Each collar half 202 A and 202 B may have at least one recess 212 therein for the mounting of an inflatable bladder 210 A and 210 B which is placed between the inside of the collar halves 202 A and 202 B and the marine element 70 . Each of the collar halves 202 A and 202 B is provided with an injection port 208 A and 208 B which are depicted in greater detail in FIGS. 9A-9C .
Collar 202 B is shown in section and detail in FIGS. 8A-8C . It will be appreciated that collar 202 A has similar detail but is not shown for the sake of brevity. Collar 202 B has an annular chamber 212 machined azimuthally about the interior of the collar 202 B. Inflatable bladder 210 B is mounted in the recess 212 and is in fluid communication with port 208 B. It will be appreciated that a check valve (not shown) may be placed in the fluid passage between bladder 210 B and port 208 B. A fiber optic umbilical 214 is depicted passing through access port 216 in collar 202 B. The access port 216 may be sealed to the marine environment by means of epoxy, potting compound or other suitable substance. Chamber 212 B further includes a flexible, non-corrosive carrier plate 220 B bearing fiber optic strand 215 B which terminates in a FBG or FP sensor 222 B. As depicted in FIGS. 8A-8C , the carrier plate 220 B is retained within the chamber by placing part of the plate within relief grooves 218 formed in the chamber 212 . Other methods for retaining the carrier plate 220 B may used such as leaf springs or other suitable retaining systems. A vent port 224 B is further drilled in collar 202 B and may further be provided with a check valve (not shown) to permit the flow of water from chamber 212 B to the marine environment but prevent water from the marine environment from flowing back into the chamber 212 B.
In operation, the collar 200 may be installed about a marine element 70 by a diver, ROV or ROV and RIVET™ system. As noted above, the latch 204 is designed to be self-locking to tightly fit collar 200 about the marine element 70 . Following securing the collar 200 about the marine element 70 , a diver or ROV may be sent down to the collar 200 . An epoxy may be pumped into port 208 B, which is in fluid communication with the bladder 210 B. As can be seen in FIG. 8B , as the epoxy 240 enters the bladder 210 B, the bladder 210 B expands and starts to deflect towards the marine element 70 , pulling the carrier plate 220 B out of grooves 218 B. Alternatively, the carrier plate 220 B may be scored adjacent to where it is affixed to chamber, rendering it frangible across the scoring allowing it to part and move toward the marine element 70 as the bladder 210 B is inflated by pumping in the epoxy 240 . In FIG. 8C , the bladder 210 B is shown as fully inflated with the sensor 220 B in contact with the marine element 70 . It will be appreciated that as bladder 210 B is inflated, that it will displace water originally in annulus between chamber 212 B and marine element 70 . Accordingly vent port 224 B is provided to permit the displacement of the water and the addition of a check valve can prevent the return of water back into the annulus through port 224 . The pump is disconnected from port 208 B and the epoxy 240 is allowed to cure. With fiber optic cable 214 in communication with a surface monitoring system, this embodiment provides for a direct contact between the marine element 70 and the sensor 222 B. It will be appreciated that multiple carrier plates 220 and sensors 222 may be installed in the chamber 212 B, either utilizing multiple cables 214 or a single cable and a fiber optic junction that leads to multiple sensors. While FIGS. 7A , 7 B and 8 A- 8 C depict two azimuthal bladders 210 A and 210 B, it will be appreciated that small individual bladders may be used for one or more sensors. This type of arrangement would require additional pumping ports or a flow system that permits selection and inflation of the individual bladders without over-pressurizing other bladders that could result in damage to the sensor. Other systems may be readily designed to advance the sensor 222 into contact with the marine element upon injection of epoxy or some other bonding fluid. For example, sensor 222 may be mounted on a rod recessed in a sleeve in port 208 . Upon injection of epoxy through port 208 , the rod bearing the sensor is advanced into contact with the marine element as epoxy continues to fill cavity 212 displacing any water through port 224 . It will be appreciated that the embodiments depicted in FIGS. 1 , 2 and 7 - 8 are designed to be secured around an existing marine element in a hinged or clamshell fashion that may use the RIVET™ tool for installation.
In other instances, a marine element may be horizontal or lying at or along the ocean bottom or partially embedded in the ocean bottom. It will be appreciated that it would be difficult, if not impossible, to install a fully encircling collar of the types disclosed above. Accordingly, there exists yet another embodiment to permit retro-fitting to horizontal and/or partially embedded marine elements. An embodiment for monitoring a partially embedded marine element 70 is depicted in FIGS. 9A-9C . FIG. 9A is a top view of the marine element having a shroud 300 disposed over the top of the marine element 70 . The shroud 300 may be fabricated from fiberglass, thermoplastic, metal or other materials suitable for a marine environment. The shroud 300 may be lowered onto the marine element 70 from a surface vessel with the assistance of a diver or an ROV. The shroud 300 is secured to the marine element 70 by at least one spring-loaded (springs not shown), locking balls 302 installed in the interior of the shroud. As the shroud 300 lowered over the marine element 70 , the spring loaded balls 302 are pushed back into shroud 300 . As the shroud 300 is further lowered, the locking balls 302 pass the diameter of the marine element 70 and are then biased outwardly by the springs, thereby affixing the shroud 300 to the marine element 70 . It will be appreciated that other retaining methods may be used to secure the shroud 300 to the marine element, including screws passing through shroud 300 that may be tightened about the marine element by a diver or an ROV. Alternatively, spring-loaded or screw-activated locking dogs may be used to secure the shroud 300 to the marine element 70 . A sensor assembly 304 , including fiber optic umbilical 310 , is mounted atop the shroud 300 . The fiber optic umbilical 310 is connected to an instrumentation system (either surface or subsurface) that is used to monitor and record the data.
The sensor assembly is shown in greater detail in FIG. 9C , which is a cross sectional view of the sensor assembly 304 and marine element 70 . The shroud 300 is provided with a slotted hole 320 , having slot portion 322 therein. A slotted sensor module 308 is designed to fit within threaded slotted hole 320 . The module 308 has a key 306 manufactured therein and cooperates with slot 322 to align and limit the module 308 movement toward the marine element 70 . The module 308 may be comprised of a potted epoxy thermoplastic, metal or other marine resistant material. The fiber optic umbilical 310 may be potted as part of the module and terminates in a FBG or FP sensor 312 mounted at the end of the module. Alternatively, a hole in the sensor module 308 or shroud 300 may be provided for passing the fiber optic cable 310 to the end of the sensor module. The sensor assembly 304 may further be provided with a grommet 324 or protective other means to protect sensor 312 . The sensor module 308 is secured in slotted hole 320 by a lock down screw or bolt 314 that mates with the threads in slotted hole 320 . The module 308 and grommet 324 may be designed to bring the grommet 324 into contact with the marine element 70 and thus permit the sensor 312 to directly monitor strain. Alternatively, if the sensor 312 is not in direct contact with the marine element 70 , it will still be capable of monitoring the marine element 70 as large mechanical strains placed on the marine element will be passed to the sensor 312 through shroud 300 . The illustrated embodiment thereby provides for a means for monitoring strains in elements that are horizontally situated or partially embedded.
In other instances, it may be desirable to monitor the strain placed on a tubular or other connection. A system for carrying out monitoring is depicted in FIGS. 10A and 10B , which are side and cross-sectional views of such a system. Two tubular elements 70 are joined in a pin and box connection 400 in which the male threaded end of one of the tubulars is screwed into sealing engagement with the box end of the other tubular. In this embodiment collar halves 402 A and 402 B rotate about pin 404 . In this instance, the assembly is made up of two collar sets, each disposed on one side of the connection 400 . The respective collars may be secured by latches, bolts, machine screws 406 or other suitable retaining mechanism. A sensor support connection 408 is attached to each of the collars 402 by epoxy or other suitable means. The connections 408 are aligned to permit the attachment of a sensor support 410 prior to deployment. A fiber optic umbilical (not shown) is introduced such that a sensor 420 may be disposed in between the sensor support 410 and pin and box connection 400 . This permits sensor 420 to directly monitor strain incurred by pin and box connection 400 . While a single sensor is depicted in FIGS. 10A and 10B , it will be appreciated that multiple sensor supports 410 and sensors may be deployed using junction boxes and shown in FIGS. 5A and 5B .
In some instances, a marine element 70 , such as a pipeline, is coated with concrete to add extra weight and to prevent the pipeline from moving in response to near bottom currents. The present invention contemplates yet another embodiment to permit monitoring of concrete coated marine elements. In cross-sectional view FIG. 11A , a marine element 70 having a concrete coating 72 thereabout is shown in a horizontal position partially embedded in the surface. A sensor assembly 340 is depicted in FIG. 11A and shown in greater detail in FIG. 11B . A hole 342 is drilled and/or milled through the concrete coating 72 . This may be accomplished by a diver or by using a work ROV equipped with a drill. It will be appreciated that a masonry drill and/or mill that is less capable of cutting into the steel of the marine element 70 may be used to prevent damaging marine element 70 . Upon completion of drilling, a threaded, slotted sensor housing 344 may be inserted in the hole 342 . The slotted sensor housing 344 is designed to receive a sensor module 346 having keyed portion 350 designed to mate with the slotted sensor housing 344 to align and position the sensor module 344 . As with the embodiment of FIGS. 10A and 10B , the module 346 may be made of any suitable marine resistant material. The module 346 provides a pass-through or potted fiber optic cable 348 that terminates in a FBG or FP sensor 352 on the bottom of module 346 . The module 346 is retained in the housing 344 utilizing a set screw 354 or other suitable means. The module 346 itself is retained within the concrete coating 72 by a quick setting epoxy 356 that is pumped into the annulus between the housing 344 and hole 342 . Alternatively, a tapered sleeve or other friction retaining means may be used to retain the housing 344 within the hole 342 . As will be noted in FIG. 11B , as illustrated, the sensor 352 is not in direct contact with the marine body 70 . Rather, any strains will be transmitted through the cement coating 72 , to the housing 344 and to the sensor module 346 and sensor 352 .
FIGS. 12A and 12B are cross-sectional and detailed views, respectively, of another single collar embodiment of the present invention. Two collar halves 80 and 82 pivot about pin 83 . The collar halves 80 and 82 may be made of metal, thermoplastic or other materials suited to long term marine exposure. They are positioned about marine element 70 closed and secured by a suitable latch 84 . A sensor base 86 is affixed to one of the collar ( 80 or 82 ) halves. The base 86 may be attached utilizing adhesives, resins, or may be welded to the selected collar half. One or more fiber optic cable grooves 92 are formed or machined in the sensor base 86 . A locking latch arm 90 pivots about pin 86 , which is in turn connected to sensor base 86 . The locking latch arm 90 is drilled and threaded to receive contact pin 94 . The contact pin 94 is used to insure that the fiber umbilical optic 94 having fiber optic cable 95 and FBG or FP sensor (not shown) remain in contact with the sensor base 86 . In this instance, the collar may be installed on the tubular 70 prior to being installed in its location. The fiber optic umbilical 94 may be installed after the marine element 70 has been installed.
The present application has disclosed a number of different support structures that may be used to retrofit existing, in place marine structures with fiber optic monitoring equipment. As noted above, the fiber optic sensors may be used for the purpose of strain measurement, slug detection and temperature measurement. Various modifications in the apparatus and techniques described herein may be made without departing from the scope of the present invention. It should be understood that the embodiments and techniques described in the foregoing are illustrative and are not intended to operate as a limitation on the scope of the invention. | Sensors, including fiber optic sensors and their umbilicals, are mounted on support structures designed to be retro-fitted to in-place structures, including subsea structures. The sensor support structures are designed to monitor structure conditions, including strain, temperature, and in the instance of pipelines, the existence of production slugs. Moreover the support structures are designed for installation in harsh environments, such as deep water conditions using remotely operated vehicles. | 4 |
This application is a continuation-in-part of Application Ser. No. 193,142, filed on Oct. 2, 1980, which previous application is now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to an improved method for manufacturing power switching devices, such as gate turnoff thyristors (GTO), SCRs, light activated SCRs and power transistors.
Generally, thyristors have PNPN structures including a P-type anode layer, an N-type base layer, a P-type base layer and a N-type cathode layer.
For such thyristors, it is desired that minority carrier lifetimes in their P-type base layers are sufficiently high and those in their N-type base layers are sufficiently low, to allow anode currents of the thyristors to increase with an increase in the carrier lifetimes in the P-type base layers, and to allow the switching characteristics to improve with a decrease in the carrier lifetimes in the N-type base layers. Thereby, preferable thyristors characteristics are obtained.
A method for manufacturing such a desirable thyristor is disclosed in Japanese Journal of Applied Physics, Vol. 17, Supp. 17-1, pp. 275-281, 1978, "High Power Gate Turn-Off Thyristors." According to this method, a PNP structure is made at first by diffusing P-type impurities into an N-type substrate from both its surfaces. Next, a film containing phosphorus as an N-type impurity is deposited on one side-surface of the diffused PNP wafer. Thereafter, a PNPN structure is formed by a drive-in process.
In the above method, the film containing phosphorus should be essentially removed before the phosphorus drive-in, although this is not shown apparently in the publication.
The reason is that if the film containing phosphorus exists on the wafer surface, the phosphorus content in the N-type cathode layer will be extremely difficult to control during the phosphorus drive-in.
At this step, if too much phosphorus is diffused into the P-type base layer in error, breakdown voltage of the P-base and N-emitter junction decreases due to an increase in the impurity gradient.
According to the above publication, after the step of the phosphorus drive-in, gold is diffused as carrier life-time killer atoms into the wafer, specifically into the N-type base layer. Through the gold diffusion, minority carrier lifetime of the N-type base decreases. This process contributes to improvement of the switching characteristics of the thyristor.
It is also possible to expect that the phosphorus film formation on the substrate will improve minority carrier lifetime of the P-type base. The reason being that a phosphorus glass has a gettering effect on metal contaminations, such as gold and copper in silicon, as is disclosed in the Journal of the Electrochemical Society, June, 1963, pp. 533-537, "Gettering of Metallic Impurities from Planar Silicon Diodes" and in the Solid-State Electronics Pergamon Press, Vol. 11, pp. 1055-1061, 1968, "The Gettering of Gold and Copper from Silicon."
Especially, in the latter publication, hole lifetime values after phosphorus gettering are shown.
But unexpectedly, according to the actually manufactured thyristors obtained from the above method, carrier lifetimes in the P-type bases are mostly unchanged and low.
As a result, thyristors having high current, high surge current, low on-state voltage and high off-state voltage thus far have not been obtained.
SUMMARY OF THE INVENTION
Accordingly, an object of the invention is to provide a method for manufacturing power switching devices of which minority carrier lifetimes are properly controlled.
Another object of the invention is to provide a method for manufacturing power switching devices having high current and high surge current.
A further object of the invention is to provide a method for manufacturing power switching devices having low on-state voltage and high off-state voltage.
These and other objects have been attained by the method for manufacturing power switching devices which comprises generally the steps of: forming impurity diffused layers of both conductivity types in a semiconductor substrate; thereafter forming a film containing phosphorus on the substrate; and diffusing atoms into the substrate in order to control carrier time.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 11 are cross-sectional views of a semiconductor substrate illustrating various steps of one embodiment of the invention;
FIGS. 12 and 13 show cross-sectional views taken along line A--A and B--B in FIG. 11, respectively;
FIG. 14 illustrates a comparison of carrier lifeime variations in an N-type base layer made according to the embodiment of the invention as given from FIGS. 1 to 11 and according to a conventional method;
FIG. 15 illustrates a comparison of forward off-state current-voltage characteristics of a thyristor made according to the invention shown in FIGS. 1 to 11 and according to a conventional method;
FIG. 16 illustrates a comparison of forward on-state current-voltage characteristics of a thyristor made according to the invention shown in FIGS. 1 to 11 and according to a conventional method; and
FIGS. 17 and 27 are cross-sectional views of a semiconductor substrate illustrating various steps of another embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The inventors have studied the reasons why carrier lifetimes in P-type base layers of thyristors or power transistors according to a conventional method are still low in spite of the use of film formation including P-type or N-type impurities having a gettering effect, such as phosphorus, boron, and gallium.
As a result, it has been concluded that part of the heavy metallic impurities is caught into the gettering film, but most is collected only into the surface region of the semiconductor substrate while the gettering film is deposited on the P-type base layer.
Accordingly, while the P-type or N-type impurities are driven into the semiconductor substrate under a high temperature condition after the removal of the gettering film, the heavy metallic impurities collected in the surface region of the substrate are diffused again into the P-type base layer. Thus, carrier lifetime in the P-type base layer can not essentially increase.
According to the invention, a film including phosphorus is newly formed after the drive-in of the P-type and N-type impurities into the semiconductor substrate and before the diffusion of lifetime killer atoms. By introducing this new process, the heavy metallic impurities, which have been diffused at the drive-in step under a high temperature, are caught or collected in the surface region of the semiconductor substrate once again. In this way, the invention can provide power switching devices which have high current, high surge current, low on-state voltage and high off-state voltage.
EXAMPLE 1
One embodiment of the invention, which is applied to a gate turn-off thyristor (GTO), will be described in detail with reference to FIGS. 1 to 11.
In FIG. 1, an N-type silicon substrate 1 containing phosphorus of a 40 mm diameter, of a 500 μm thickness and of a 110 Ω.cm resistivity is cleaned in a conventional manner. Next, in FIG. 2, gallium is diffused from both surfaces of substrate 1 into the substrate at a temperature of 1250° C. for approximately 30 hours, using gallium as a diffusion source. P-type layers 2 and 3 of the surface impurity concentration of 2×10 18 cm -3 and of the diffusion depth of 50 μm are formed. In this step, boron can be also used as a diffusion source instead of gallium. The P-type layer 2 constitutes a P-type base layer. The P-type layer 3 constitutes a P-type anode layer. The N-type layer 4 placed between these P-type layers 2 and 3 constitutes an N-type base layer.
Thereafter, in FIG. 3, thermal oxidation films 5 and 6 of silicon dioxide are grown on the respective surfaces of the substrate 1 in a mixture gas of steam and oxygen at a temperature of 1000° C. for approximately 2 hours. The thickness of the thermal oxidation films 5 and 6 is approximately 5000 A each.
Film 5 is then removed, and phosphorsilicate glass films 7 and 8 are deposited respectively on both sides of the substrate 1. This phosphorsilicate glass deposition is performed at a temperature of 1100° C. for approximately 2 hours, using phosphorus oxychloride (POCl 3 ) as a source. Any film containing such an element as antimony or arsenic instead of phosphorsilicate glass films 7 and 8, can be deposited. The formation of these films 7 and 8, which serve as diffusion sources, can be performed by various known methods other than the method described. When the deposition has finished, an N-type layer 10 having high impurity concentration and a 3 μm thickness is formed in the surface region of the P-type base layer 2, and the carrier lifetime of layer 2 is increased (FIG. 4).
Next, the phosphorsilicate glass films 7 and 8 and thermal oxidation film 6 are removed. Thereafter, N-type impurities, that is to say phosphorus atoms, are driven into the P-type base layer 2 at a temperature of 1200° C. for approximately 8 hours, and an N-type layer 10 comes to be 10 μm in thickness (FIG. 5). At this time, the carrier lifetime of the P-type base layer 2 becomes much lower.
A resistive film is next formed on the N-type layer 10, and it is selectively exposed and is developed to form a resistor pattern 11. Thereafter, using this resistor pattern 11 as a mask, the N-type layer 10 and the surface region of the P-type layer 2 is mesa-etched by a conventional dry or wet etching method, and recesses 12 and N-type cathode layers 13 are formed (FIG. 6).
After this, both surfaces of substrate 1 are thermally oxidized in a mixture gas of steam and oxygen at a temperature of 1000° C. for approximately 2 hours, and thermal oxidation films of 5000 A in thickness are formed. The thermal oxidation film on the anode layer 3 side is removed, and the thermal oxidation film 14 on the cathode layers 13 side is left (FIG. 7).
Next, phosphorsilicate glass films 15 and 16 are deposited on the both surfaces of the substrate 1, using phosphorus oxychloride (POCl 3 ) as a source, at a temperature 1000° C. for approximately 1 hour. These phosphorsilicate glass films 15 and 16 can contain such impurities as gallium. The formation of these films 15 and 16 can be performed by various known methods other than the method described. On formation of the films 15 and 16, an N-type layer 17 having high impurity concentration and about 1 μm thickness is formed in the surface region of the anode layer 3 (FIG. 8). Heavy metallic contaminations such as copper, iron and gold are caught into the phosphorsilicate glass film 16 or collected into the surface region of the substrate 1. As a result, carrier lifetime of the P-type base layer 2 is increased.
Next, the phosphorsilicate glass films 15 and 16, and N-type layer 17 are removed, and thereafter a gold film 19 is evaporated as a material for stimulating carrier recombination, that is to say, lifetime killer atoms, on the surface of the anode layer 3. At a temperature of 800° C. for approximately 1 hour, gold diffusion is performed, so that the carrier lifetime of the N-type base layer 4 is controlled (FIG. 9). Instead of gold, platinum can be used to control the carrier lifetime. Carrier lifetime killer can be introduced by irradiating the semiconductor substrate 1 by electron radiation, for example, under the condition of 3 MeV electron energy and 10 14 electrons/cm 2 dosage.
After the gold film 19 is removed, oxidation film 14 is selectively removed by a photoengraving process and contact holes 20 for cathode electrodes and contact holes 21 for gate electrodes are formed. Thereafter, substrate 1 is fixed to a tungsten disk 23 after some pressure with a thin aluminum film 22 between them. Then the entire assembly is heat-treated at a temperature of 700° C. for approximately 2 hours, and the silicon, aluminum and tungsten are alloyed (FIG. 10).
Next, an aluminum film is evaporated on the overall surface of the cathode side of the substrate 1, and is selectively etched-off to form cathode electrodes 24 and gate electrodes 25. The substrate 1 is then heat-treated at a temperature of 500° C. for approximately 15 minutes to obtain respective electrode ohmic-contact. Thereafter, as shown in FIG. 11, the periphery of the substrate 1 is beveled, and it is also encapsulated by a silicone rubber 26 for passivation of the beveled surface. Gate lead wires 27 of aluminum are next connected to gate electrodes 25 by bonding, and a molybdenum cathode disk 28 is contacted with the cathode electrodes 24 under some pressure. Thereby a gate turn-off thyristor is completed.
FIG. 12 shows the cross-sectional view of the substrate 1 taken along line A--A of FIG. 11. FIG. 13 shows the cross-sectional view of the substrate 1 taken along line B--B of FIG. 11. The cross-sectional view taken along line C--C of FIG. 12 corresponds to FIG. 11.
In FIG. 14, arrows 94 of solid lines show the process sequence of the method mentioned above according to the invention, and the round marks represent the values of minority carrier lifetimes of the N-type base layers 4 at the respective steps. On the other hand, in FIG. 14, arrows 95 of dotted lines show the process sequence of a conventional method, and the triangle marks represent the values of minority carrier lifetimes of the N-type base layers at the respective steps. In FIG. 14, step 2 is the time when the gallium diffusion has finished (FIG. 2). Step 4 is the time when the deposition of phosphorsilicate glass film has finished (FIG. 4). Step 5 is the time when the phosphorus diffusion under a high temperature has finished (FIG. 5). Step 8 is the time when the phosphorsilicate glass film has been deposited in accordance with the subject invention (FIG. 8). Step 9 corresponds to the time when the gold diffusion is finished.
According to this invention, carrier lifetime of the N-type base layer at Step 9 is 1.1˜1.3 μsec, which is controlled within a small deviation, compared with 0.6˜1.1 μsec values obtained from a conventional method. These carrier lifetimes have been measured by a well-known diode voltage decay method. In this case, minority carrier lifetime of the P-type base layer can be calculated from the minority carrier lifetime of the N-type base layer or can be estimated from electrical characteristics of the thyristor made. An explanation of the former follows.
If X is the depth of the P-type base layer, t PB (X) is the carrier lifetime of the P-type base layer expressed as a function of X, t NB is the carrier lifetime of the N-type base layer, C NB is the impurity concentration of the N-type base layer, and C PB (X) is the impurity concentration of the P-type base layer which is a function of X, then: ##EQU1## An average lifetime of the P-type base layer t PB is approximately expressed by the following formula, if C PB is the average impurity concentration of the P-type base layer: ##EQU2##
In the above fabrication, C NB =4×10 13 cm -3 , C PB =4×10 17 cm -3 . So, the following formula is approximately given:
t.sub.PB ≈t.sub.NB /100
However, the carrier lifetime t PB after the gold diffusion cannot be obtained by using the above formula since the carrier lifetime of the N-type base layer after gold diffusion becomes lower than that before gold diffusion. On the other hand, the carrier lifetime of the P-type base layer is scarcely influenced by the gold diffusion and, therefore, is retained as before the gold diffusion. Accordingly, the minority carrier lifetime of the P-type base layer becomes very high. Actually, the minority carrier lifetime of the P-type base layer according to the invention was approximately 40 times higher than that of a conventional method.
Another method for decreasing the carrier lifetime of the N-type base layer 4 (i.e., introducing carrier lifetime killer) is to generate crystal defects and vacancies in silicon crystal by electron irradiation. The crystal defects profile has not been measured exactly, but is substantially the same carrier lifetime distribution in the n- and p-base regions as that of gold diffusion. Carrier lifetime in the N-type base obtained after electron irradiation under the conditions of 3 MeV electron energy and 10 14 electron/cm 2 electron dosage corresponds to that of gold diffusion under the condition of 800° C. temperature and a one-hour diffusion time. The electron irradiation process is completed by annealing at a temperature below 350° C., 30 minutes after irradiation.
FIG. 15 shows the forward off-state current-voltage characteristics for the gate turn-off thyristor manufactured by the above-mentioned embodiment of the invention (CURVE 96), and that manufactured by a conventional method (CURVE 97). The characteristics were measured under the condition that each junction temperature was 115° C., and each shunt resistance RGC between cathode and gate was 20Ω. As is obvious from FIG. 15, a forward off-state voltage according to the embodiment of the invention is approximately twice as high as that according to the conventional method.
FIG. 16 shows forward on-state current-voltage characteristics for the gate turn-off thyristor manufactured by the above-mentioned embodiment of the invention (CURVE 98) and that manufactured by a conventional method (CURVE 99). In this case, the characteristics were measured under the condition that each total cathode area was 3.02 cm 2 , and each current-voltage value was obtained for a 50 Hz sinusoidal one-cycle peak waveform.
As is obvious from FIG. 16, the forward on-state voltage at the anode current of 1000 A according to the embodiment of the invention is only half as much as that according to the conventional method. As a result, the invention makes it possible to decrease the on-state power loss. In addition to these merits, the embodiment of the invention, compared with the conventional method, improves surge current capability from 300 A to 5000 A, and the latching current from 10 A to 2 A.
EXAMPLE 2
Another embodiment of the invention, which is applied to a thyristor, will be described in detail with reference to FIGS. 17 to 27. In FIG. 17, an N-type silicon substrate 31 containing phosphorus, of a 40 mm diameter, and 500 μm thickness, and of a 110 Ωcm resistivity is provided with conventional cleaning in preparation for further processing.
Next, gallium is diffused from both surfaces of the substrate 31 at a temperature of 1250° C. for approximately 30 hours, using gallium as a diffusion source, to form P-type layers 32, 33, with a surface impurity concentration of 2×10 18 cm -3 and a diffusion depth of 50 μm (FIG. 18). In this step, boron can be also used as a diffusion source instead of gallium. The P-type layer 32 constitutes a P-type base layer. The P-type layer 33 constitutes a P-type anode layer, and the N-type layer 34 placed between these P-type layers 32 and 33 constitutes an N-type base layer.
Thermal oxidation films 35 and 36 of silicon dioxide are then grown on the respective surfaces of the substrate 31 in a mixture gas of steam and oxygen, at a temperature of 1000° C., for approximately 2 hours (FIG. 19). The thickness of the thermal oxidation films 35 and 36 is around 5000 A each. Film 35 is then selectively removed by a known photo engraving process. After this, phosphorsilicate glass films 37 and 38 are deposited, respectively, one on each side of substrate 31.
This phosphorsilicate glass deposition is performed at a temperature of 1100° C. for approximately 2 hours, using phosphorus oxychloride (POCl 3 ) as a source. When the deposition is finished, an N-type layer 40 having high impurity concentration and a 3 μm thickness is formed in the surface region of the P-type base layer 32, and the carrier lifetime of the layer 32 is increased (FIG. 20).
Next, phosphorsilicate glass films 37 and 38 and thermal oxidation films 35 and 36 are removed. Thereafter, N-type impurities, that is to say phosphorus atoms, are driven into the P-type base layer 32 at the temperature of 1200° C. for approximately 8 hours, and N-type layer 40 comes to be 10 μm in thickness (FIG. 21). At this time, the carrier lifetime of the P-type base layer 32 becomes much lower. Afterwards, both surfaces of the substrate 31 are thermally oxidized in a mixture gas of steam and oxygen at a temperature of 1000° C. for approximately 2 hours, and thermal oxidation films of 5000 A in thickness are formed. The thermal oxidation film on the anode side is removed, and the thermal oxidation film 44 on the cathode side is left (FIG. 22).
Phosphorsilicate glass films 45 and 46 are then deposited on both surfaces of the substrate 31, using phosphorus oxychloride (POCl 3 ) as a source, at a temperature of 1000° C., for approximately 1 hour. At the same time, an N-type layer 47 of high impurity concentration and of approximately 1 μm thickness is formed in the surface region of the anode layer 33 (FIG. 23). After this process, the carrier lifetime of the P-type base layer 32 is increased.
Next, the phosphorsilicate glass films 45 and 46 and the N-type layer 47 are removed. Thereafter, a gold film 49 is evaporated on the surface of the anode layer 33 as a material for stimulating carrier recombination, that is to say lifetime killer atoms. Gold diffusion is performed at a temperature of 800° C. for approximately 1 hour so that carrier lifetime of the N-type base layer 34 is controlled (FIG. 24).
After the gold film 49 is removed, oxidation film 44 is selectively removed by a photoengraving process and contact holes 50 for cathode electrodes and contact holes 51 for gate electrodes are formed (FIG. 25). After this, the substrate 31 is fixed to a tungsten disk 53 under some pressure with a thin aluminum film 52 between them. The assembly is then heat-treated at a temperature of 700° C. for approximately 2 hours, and the silicon, aluminum and tungsten are alloyed (FIG. 26).
Next, an aluminum film is evaporated on the overall surface of the cathode side of the substrate 31. The film is selectively etched off to form cathode electrodes 54 and gate electrodes 55. Substrate 31 is then heat-treated at a temperature of 500° C. for approximately 15 minutes, and the thyristor is completed (FIG. 27).
In this thyristor, as compared with a thyristor made by a conventional method, minority carrier lifetime of the P-type base layer is also improved, and high-current characteristics are achieved.
By the way, the temperature to form the phosphorsilicate glass films 15 and 75 mentioned above is desired to be from 700° C. to 1100° C. The reason for this follows from a study of the temperature dependency upon the diffusion coefficient of copper, iron and gold, which are metallic contaminations in semiconductor substrates.
The diffusion coefficient of copper or iron is 6×10 -9 cm 2 /sec at the temperature of 500° C., but is much increased to become more than 10 -6 cm 2 /sec at the temperature of more than 900° C. The diffusion coefficient of gold is 10-9 cm 2 /sec at the temperature of 500° C., but is much increased to become more than 10 -7 cm 2 /sec at a temperature of more than 900° C.
Accordingly, at the temperature of more than 900° C., diffusion of the heavy metallic contaminations is stimulated and the heavy metallic atoms in a semiconductor substrate is absorbed into a phosphorsilicate glass film sufficiently. If the temperature to form the film is above 1100° C., phosphorus in the phosphorsilicate glass film will be diffused into the semiconductor substrate, so that the impurity concentration distribution in the substrate will be unfavorably changed.
Accordingly, the temperature to form phosphorsilicate glass films is desired to range from 700° C. to 1100° C. Within such a temperature, crystal defects in a semiconductor substrate is decreased by the anneal effect. For example, the number of crystal defects in the substrate is decreased to become approximately 1/100 of that at the time before the substrate is heated.
Further, in the above-mentioned methods, the thermal oxidation films 14, and 44 for preventing phosphorus diffusion are formed under the phosphorsilicate glass films 15, 45, and 75, respectively. However, without formation of the thermal oxidation films, the steps of forming a phosphorsilicate glass film, removing it, and thereafter etching-off a surface region of the substrate where phosphorus is diffused can be adopted
In addition, the P-type layers 2, 3, 32, and 33 can be formed on the formation of the N-type layers 10 and 40, using what is called simultaneous diffusion technique. | A method for manufacturing power switching devices such as thyristors and power transistors comprising the steps of forming impurity diffused layers of one conductivity type and of the opposite conductivity type in a semiconductor substrate of one conductivity type; forming a film containing phosphorus on the substrate; diffusing lifetime killer atoms into the substrate; and forming electrodes on the substrate. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to a method and apparatus for compensating for optical impairments electrically and a system incorporating the same.
BACKGROUND TO THE INVENTION
[0002] Optical communications systems typically comprise of a transmitter which converts electrical signals into optical signals, an optical link over which the optical signals are transported and a receiver which converts the optical signal into an electrical signal, the electrical signal recovered at the receiver ideally being identical to the electrical signal originating at the transmitter. The optical link generally consists of optical transmission fibre to convey the signal and optical amplifiers to compensate for the loss that the fibre introduces. The optical amplifiers are generally interspersed at regular intervals along the link (e.g. every 40-200 km).
[0003] One impairment the optical fibre may exhibit is chromatic dispersion. This is where different optical frequencies of the light propagate at different speeds in the fibre. This results in the optical signal being distorted. Eventually after propagating over some distance of fibre, the signal will not be recoverable unless some compensation of this effect is afforded. For example, if a data rate of 10 GBit/s is used in an intensity modulation format at 1550 nm in standard fibre, then the signal will be irrecoverable after around 200 km without some form of compensation. Commercially deployed telecommunications systems use optical dispersion compensation devices to overcome this limitation. There are a number of optical dispersion compensation devices which fulfil this role, the preferred type being dispersion compensating fibre modules. These modules consist of optical fibre of a different type to the transmission fibre, known as dispersion compensating fibre. This fibre has dispersion which is of the opposite sign to the transmission fibre, such that when the dispersion compensating fibre is coupled to the transmission fibre, the overall net dispersion is within the limit of an uncompensated system. Typically the fibre has a higher magnitude of dispersion to the transmission fibre, to reduce the length required. The fibre is generally coiled and placed in modules. A number of modules may be used, distributed at the amplifier sites and terminal sites, or even lumped at one or a few sites.
[0004] However, there are a number of drawbacks to using dispersion compensating fibre modules for compensating for the optical dispersion. The most obvious disadvantage is that they tend to be very costly. However, they are also relatively large and have high optical loss. This latter feature results in more optical amplification being required which in turn increases cost and can have degrading effect on performance. A further disadvantage is that dispersion compensating fibre modules tend to be more sensitive to nonlinear distortion, thus also reducing performance. It is therefore desirable to reduce in number or eliminate completely the dispersion compensating devices to reduce the system cost and simultaneously increase the system performance.
[0005] One method for removing the optical dispersion compensation devices is disclosed in U.S. patent application Ser. No. 10/262,944, filed on Oct. 3, 2002 and published as US 2004/0067064 A1 on Apr. 8 2004. In this application, instead of compensating for the optical dispersion using an optical dispersion compensating device, the dispersion is compensated by electrical means. Such a method is illustrated in FIG. 1 . In this example the electrical signal applied to the optical transmitter is first pre-distorted by applying a digital filter. The pre-distortion function is such that after the signal has passed through the system, it can be recovered at the optical receiver. One feature of this prior art is that to adequately compensate for the dispersion of the system it is necessary to have a pre-distorted signal which modulates both the amplitude and phase of the optical signal. That is the signal applied to the modulator is a complex signal, such that it contains both amplitude and phase information in a polar coordinate system or In-phase and Quadrature components in a Cartesian coordinate system. Accordingly, it is necessary to use an optical modulator which takes a complex signal as its input, a complex modulator. Such a modulator is considerably more expensive to fabricate than a conventional modulator, as the structure is larger and there are more processing steps involved in its fabrication. Additionally a significant expense is the amplifier used to provide sufficient voltage swing to drive the amplifier. Since two such amplifiers are required, this expense is increased. A disadvantage of using a complex modulator is that its optical loss is generally significantly higher than a conventional one. A further disadvantage is that the fabrication steps involved are very different from that of a semiconductor laser, such that it has not been possible to monolithically integrate a complex modulator with a semiconductor laser on the same substrate.
OBJECT TO THE INVENTION
[0006] The invention seeks to provide an improved method and apparatus for compensating optical impairments electrically using an optical modulator which does not require a complex input. The invention also seeks to provide an improved method and apparatus for compensating optical impairments electrically using an optical modulator of a design which may be monolithically integrated with a semiconductor laser.
SUMMARY OF THE INVENTION
[0007] According to a first aspect of the invention, there is provided a pre-distortion unit for compensating optical transmission impairments of a communications signal conveyed through an optical communications system comprising: at least one electrical filter for modifying an electrical input signal using a pre-distortion function to generate a pre-distorted electrical signal which mitigates the impairments in an optical system; and at least one upconverter for modulating the pre-distorted electrical signal onto an electrical carrier signal for modulation of an optical signal to generate a corresponding pre-distorted optical signal. This unit may be used to compensate for optical transmission impairments electrically, with the advantage that the pre-distorted signal has a single electrical output which may be applied to an optical modulator; the optical modulator not needing to be a complex optical modulator. It has the further advantage that it may be used with a low cost optical modulator such as an electrosborption modulator or a monolithically integrated laser electroabsorption modulator. It has the further advantage that it may be used with a directly modulated laser.
[0008] According to a second aspect of the invention, there is provided a system for compensating for optical transmission impairments on an optical signal conveyed through an optical communications system, the system comprising: at least one electrical filter for modifying an electrical input signal using a pre-distortion function to generate a pre-distorted electrical signal which mitigates the impairments in an optical system; and at least one upconverter for modulating the pre-distorted electrical signal onto an electrical carrier signal; and an optical transmitter for generating an optical signal and modulating said optical signal, using the upconverted pre-distorted electrical signal; and an optical receiver for converting the optical signal into an electrical signal. This unit is particularly advantageous as it may be used to compensate for optical transmission impairments electrically and does not need a complex optical modulator. It has the further advantage that it enables a low cost optical modulator such as an electrosborption modulator or an monolithically integrated laser electroabsorption modulator to be used. It has the further advantage that it enables a directly modulated laser to be used.
[0009] According to a third aspect of the invention, there is provided a method of compensating optical impairments of an optical signal conveyed through an optical communications system, the method comprising the steps of: filtering an electrical input signal using a pre-distortion function to generate a pre-distorted electrical signal which mitigates the impairments in an optical system; and modulating an RF carrier with a pre-disorted electrical signal to generate an upconverted pre-distorted electrical signal modulating an optical source using the upconverted pre-distorted electrical signal to generate a corresponding pre-distorted optical signal for transmission through the optical communications system. This method has the advantage that it may be used to compensate for optical transmission impairments electrically and does not need a complex optical modulator. It has the further advantage that it enables a low cost optical modulator such as an electrosborption modulator or a monolithically integrated laser electroabsorption modulator to be used. It has the further advantage that it enables a directly modulated laser to be used.
[0010] According to a fourth aspect of the invention, there is provided a pre-distorted optical signal suitable for being conveyed through a communications system, which has been filtered by a pre-distortion function which mitigates impairments in an optical system; and upconverted to an RF frequency; and upconverted to an optical frequency. This signal has the advantage that its generation does not need a complex optical modulator. It has the further advantage that it enables a low cost optical modulator such as an electrosborption modulator or an monolithically integrated laser electroabsorption modulator to be used. It has the further advantage that it enables a directly modulated laser to be used.
[0011] According to a fifth aspect of the invention, there is provided a pre-distortion unit in which the electrical filter is a digital filter, with the advantages that a more complicated pre-distortion function may be used and higher signal integrity may be maintained.
[0012] According to a sixth aspect of the invention there is provided a pre-distortion unit in which there are a plurality of electrical filters and a plurality of upconverters, each with different carrier frequencies and combined to form a composite signal. This arrangement has the advantage that multiple channels may be transmitted using a single modulator and thus the number of components and hence cost may be reduced.
[0013] According to a seventh aspect of the invention, there is provided a method in which the impairment is dispersion, with the advantage that dispersion compensating modules are not required and that the cost is reduced.
[0014] According to an eight aspect of the invention, there is provided a method in which the impairment is fibre-nonlinearity, with the advantage that the performance will be improved and as a result longer transmission distances will be possible.
[0015] According to a ninth aspect of the invention, there is provided a method in which the impairment is modulator chirp in addition to dispersion or fibre nonlinearity, with the advantage that a less ideal modulator may be used. If an electroabsorption modulator is used, a greater tolerance to chirp will mean that the wavelength window of operation will be increased.
[0016] According to a tenth aspect of the invention, there is provided a system in which the receiver comprises a local oscillator optical source for coherently interfering with the received signal. This has the advantage that the filtering of the unwanted signal components may be performed electrically, rather than optically.
[0017] According to an eleventh aspect of the invention, there us provided a system wherein the receiver has an interferometer for decoding a differential phase modulation format. This has the advantage that the performance will be improved and as a result longer transmission distances will be possible.
[0018] The invention is also directed to a method by which the described apparatus operates and including method steps for carrying out every function of the apparatus.
[0019] The invention also provides for a system for the purposes of communications which comprises one or more instances of apparatus embodying the present invention, together with other additional apparatus.
[0020] The invention also provides for computer software in a machine-readable form and arranged, in operation, to carry out every function of the apparatus and/or methods.
[0021] The preferred features may be combined as appropriate, as would be apparent to a skilled person, and may be combined with any of the aspects of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] In order to show how the invention may be carried into effect, embodiments of the invention are now described below by way of example only and with reference to the accompanying figures in which:
[0023] FIG. 1 shows a prior art system for compensating for optical impairments using an electrical pre-distortion of the original signal.
[0024] FIG. 2 shows a block diagram schematically illustrating the principle components and operations of a device for compensating for optical impairments electrically in accordance with a first embodiment of the present invention.
[0025] FIG. 3 shows a block diagram schematically illustrating the principle components and operations of a system for compensating for optical impairments electrically in accordance with a first embodiment of the present invention.
[0026] FIG. 4 shows example spectra at various points in the system of FIG. 3 in accordance with a first embodiment of the present invention.
[0027] FIG. 5 shows a block diagram schematically illustrating the principle components and operations of a modified device for compensating for optical impairments electrically in accordance with a second embodiment of the present invention.
[0028] FIG. 6 shows a block diagram schematically illustrating the principle components and operations of a system for compensating for optical impairments electrically in accordance with a third embodiment of the present invention.
[0029] FIG. 7 shows example spectra at various points in the system of FIG. 6 in accordance with a third embodiment of the present invention.
[0030] FIG. 8 shows a block diagram schematically illustrating the principle components and operations of a system for compensating for optical impairments electrically in accordance with a fourth embodiment of the present invention.
[0031] FIG. 9 shows example spectra at various points in the system of FIG. 8 in accordance with a fourth embodiment of the present invention.
[0032] FIG. 10 shows a block diagram schematically illustrating the principle components and operations of a system for compensating for optical impairments electrically in accordance with a fifth embodiment of the present invention.
DETAILED DESCRIPTION OF INVENTION
[0033] Any range or device value given herein may be extended or altered without losing the effect sought, as will be apparent to the skilled person for an understanding of the teachings herein.
[0034] Referring firstly to FIG. 1 there is shown a prior art transmitter for compensating for the chromatic dispersion of a telecommunications system by using an electrical pre-distortion of the original signal. There is an optical transmitter 105 comprising an optical source 106 coupled to a complex optical modulator 107 , which is capable of modulating the amplitude and phase of the optical signal in a Cartesian format by way of applying in-phase (I) 104 a and quadrature (Q) 104 b signal components. The information to be transmitted is coupled to an electrical pre-distortion unit 100 , comprising two paths to generate the I component 104 a and the Q component 104 b of the pre-distorted signal. Each respective path comprises an electrical filter 101 a and 101 b , a serial to parallel converter 102 a and 102 b , and a digital-to analogue converter 103 a and 103 b . The electrical filters 101 a and 101 b respectively take as inputs the I and Q components of the required pre-distortion transfer function, generated by a processor 108 adapted to determine the correct coefficients for mitigation of the impairments
[0035] FIG. 2 shows a schematic block diagram in accordance with the first embodiment of the present invention. Here there is an optical transmitter 215 comprising an optical source 216 (which may be a semiconductor laser and may be wavelength tunable) and an optical modulator 206 . The optical modulator 206 is different from the complex optical modulator 217 in that it only takes a single input 206 and can therefore not modulate the amplitude and phase of an optical signal independently. This modulator 206 may be an electroabsorption modulator with a single electrical input. The modulator 206 may be monolithically integrated on the same substrate as the optical source. The information to be transmitted is coupled to a different electrical pre-distortion unit 210 comprising two paths to generate the I 214 a and Q 214 b signal components of the pre-distorted signal. The two paths each comprise an electrical filter 211 a and 211 b , which may be digital filters, a serial to parallel converter 212 a and 212 b and a digital to analogue converter 213 a and 213 b . The electrical filters 211 a and 211 b respectively take as inputs the I and Q components of the required pre-distortion transfer function. The I and Q signals 214 a and 214 b , are coupled to an upconverter unit 200 . The upconverter 200 takes the I signal 214 a and an RF signal 204 to produce a signal 205 a which is the composite modulated signal of 214 a on the RF carrier 204 . This signal 205 a is similar to 214 a , but shifted in frequency by RF carrier 204 . Such an element can be achieved by a multiplying function or by some other nonlinear element such as a mixer. Similarly, the Q signal 214 b is upconverted to signal 205 b using upconverter 201 b . However, the RF signal input to 201 b is the RF signal 204 modified in phase by 202 , such that the phase of the RF signal applied to 201 b is approximately 90 degrees out of phase compared to the RF signal applied to 201 a . The two signals 205 a and 205 b are combined using a conventional combiner 203 to produce a single output 206 .
[0036] FIG. 3 shows the first embodiment of the present invention in an optical system with an optical receiver. There is an optical pre-distortion unit 210 coupled to an optical transmitter 215 including optical modulator 205 . The optical system is coupled to the optical link 300 which may comprise of optical fibre, optical amplifiers and other optical components. The optical link in coupled to a coherent receiver 301 . The coherent receiver 301 comprises an optical source 302 which may be wavelength tunable and may be shared with another unit such as an optical transmitter for the opposite direction. The signal from the optical source 302 is combined with the signal from the link 300 with an optical coupler 303 . The optical coupler 303 combines its input signals in a polarisation diverse form such that it generates two output signals with a different polarisation relationship between the input signals. The difference in this polarisation relationship between the output ports is approximately orthogonal, such that there is always a combined beat signal at one or other of the ports. Such a coupler can be implemented with a conventional coupler followed by a polarisation beam splitter, with the polarisation angle of the optical source 302 aligned such that there is approximately equal source power from 302 delivered to each arm of the beam splitter. The two outputs from the optical coupler 303 are detected independently with an optical detector 304 a and 304 b , an electrical filter 305 a and 305 b an electrical envelope detector 306 a and 306 b and subsequently combined with 305 and threshold detected into an digital signal with 308 . The coherent optical receiver is similar to a conventional coherent optical receiver except that the filtering means 305 a and 305 b has a different characteristic as will be later apparent. The envelope detector may be implemented as a squaring function, which itself may be realised as a mixer with the two inputs matched in phase and amplitude response and commoned together.
[0037] FIG. 4 shows example spectra at various points in the system for the first embodiment. FIG. 4 a shows the spectra of the electrical signal 206 from the pre-distortion unit 210 . This assumes a bit rate of 10 Gbit/s, an RF signal 204 of 10 GHz and an electrical bandwidth for the optical modulator 205 of 10 GHz. Here it can be seen that the modulated data has been upconverted onto a 10 GHz carrier. The electrical spectrum is shown in the conventional way with both positive and negative frequencies, though negative frequencies are not observable.
[0038] FIG. 4 b shows the optical signal emerging from the optical transmitter 215 . Here it may be seen that there is a central carrier and the frequency scale is now relative to this carrier (so both positive and negative frequencies on this scale are observable). In addition to the carrier, there are two optical sidebands 401 and 402 each containing the data spectrum. In general only one of these sidebands will have the correct pre-distortion signal for the optical system and the other will be the complex conjugate. Which is which depends on whether there is phase lead or phase lag introduced by 202 .
[0039] FIG. 4 c shows the electrical spectrum emerging from the optical detectors 304 a and 304 b assuming they have a 20 GHz bandwidth (again only positive frequencies are observable). Now both sidebands 401 and 402 lie at positive frequencies and so are observable. However, due to the frequency roll-off of the optical detectors 304 a and 304 b , the higher frequency sideband 402 is attenuated relative to the lower frequency sideband 401 . Superimposed onto FIG. 4 c is an example filter characteristic for filtering means 305 a and 305 b . In a conventional coherent receiver the filtering means 305 a and 305 b would only have the function of high pass filtering the signal to remove the unwanted components below 10 GHz which are direct detected (i.e. present even in the absence of any signal from 302 ). In the present invention, the filtering means 305 a and 305 b has the additional function of suppressing the unwanted sideband. In this example, the phase of 202 has been selected such that the lower sideband 401 contains the correct pre-distorted signal. The filtering means 305 a and 305 b therefore has a characteristic such as to substantially remove the upper sideband 402 . In this example the filter function has been designed such that it only selects the upper portion of sideband 401 . This has the advantage that the RF frequency from 204 can be of lower frequency as only one half of sideband 402 is required to recover the original signal.
[0040] FIG. 4 d shows the signal after it has been envelope detected with 306 a and 306 b . This signal is now ideally nominally the same as the original signal, although any nonideality in the performance of the components may cause this to deviate.
[0041] FIG. 5 shows a second embodiment of the present invention in which there is an optical transmitter 215 and an optical pre-distortion unit 210 . Here there are two paths and two electrical filters 211 a and 211 b , taking additional inputs from the I and Q components of the pre-distortion transfer function respectively. In this embodiment, these digital signals are directly fed into the upconverter unit 200 , which is now implemented in a digital form. The output from the upconverter unit is then a single digital signal which is coupled to a serial to parallel converter 212 and a digital to analogue converter 213 . This configuration has the advantage that more of the processing is performed digitally for greater fidelity and only a single digital to analogue converter is required. However this digital to analogue converter must have a wider bandwidth.
[0042] FIG. 6 shows a third embodiment in which a direct detection receiver is used instead of a coherent receiver. Here there is also an optical transmitter 215 , a pre-distortion unit 210 an optical link 300 and a receiver 301 . However in this instance instead of removing the unwanted sideband 401 by an electrical filtering means, an optical filtering means is used 500 . This filter may positioned anywhere within the optical part of the system, e.g. before, after or within the optical link 300 . The optical filtering means may be positioned within the optical transmitter 215 and may also be combined within an optical element used for establishing the wavelength of the optical source. Typically a laser package would incorporate an optical filter on the rear facet for monitoring its wavelength. By moving this element to the front facet, the element would perform the dual functions of wavelength monitoring and unwanted sideband removal. The optical filter 500 may instead be incorporated within the receiver. The advantage of placing this element at the receiver is that it has the desirable effect of reducing optical noise occurring from the optical amplifiers. The receiver itself comprises an optical detector 304 , optionally a squaring element 501 and a threshold detector 308 .
[0043] FIG. 7 shoes example spectra at various points in the system for the third embodiment. FIG. 7 a shows the electrical spectra applied to the optical transmitter 215 . FIG. 7 b shows the optical spectra emerging from the optical transmitter 215 . Also shown in FIG. 7 b is the characteristic of the filtering means 500 , used to select the wanted sideband 401 and attenuate the unwanted sideband 402 . In this example, a low-cost filter with a relatively broad cut-off has been used, such that a significant proportion of the carrier 403 will also pass through. FIG. 7 c shows the electrical spectrum after the optical detector 304 . Because a reasonable proportion of the carrier signal 403 is present, there is a beating of this carrier with the wanted sideband 401 , which results in the baseband signal being upconverted to the frequency offset of the carrier (10 GHz in this example). As a result an envelope detection element 501 is used to downconvert this signal to the baseband. The final demodulated signal is shown in FIG. 7 d.
[0044] FIG. 8 shows a fourth embodiment in which a sharper roll-off filtering means 500 is used. Here there is an optical transmitter 215 , a pre-disortion unit 210 , an optical link 300 and a receiver 301 . Here the roll-off of the filtering means is sharp enough so that both the optical carrier 403 and the unwanted sideband are substantially eliminated, such that the squaring element may be omitted.
[0045] FIG. 9 shows example spectra at various points in the system for the fourth embodiment. FIG. 9 a is the electrical spectra from the pre-distortion unit 210 . FIG. 9 b is the optical sprectra emerging from the optical transmitter 215 . Superimposed on FIG. 9 a is the characteristic of filtering means 500 . Here the roll-off is sharp to substantially reduce the carrier 403 in addition to the unwanted sideband 402 . FIG. 9 c shows the electrical signal after the optical detector 304 . This signal has been demodulated to baseband.
[0046] FIG. 10 shows a fifth embodiment in which a differential phase shift keyed (DPSK) modulation format is used. There is an encoding unit 1007 for differentially encoding the data to be transmitted, a pre-distortion unit 210 , an optical transmitter 215 a filtering means 500 an optical link 300 and a DPSK receiver 301 . The DPSK receiver 301 comprises a DPSK demodulator 1000 , an optical detector 1004 , a threshold detector 1005 and a decoding unit 1006 . The DPSK demodulator 1000 comprises a Mach-Zehnder interferometer (MZI) formed between two optical 1002 and 1003 . The MZI is constructed such that there is a path difference between the arms 1001 of approximate equivalent length to the bit perioid in the data. The optical detector 1004 may comprise of a balanced receiver, or a pair of receivers or a single receiver. The DPSK receiver has the advantage of increased sensitivity and therefore increased performance compared to a direct detection receiver. At least part of the filtering means may be performed in the MZI. In particular, by appropriate phase adjustment between the arms it is possible to substantially null the carrier component, thereby reducing the amount of filtering required by other components. It is also possible to integrate the filter and the MZI together, which may be in the form of an integrated planar circuit. The DPSK receiver may also be implemented using a local oscillator laser, an electrical MZI and an electrical filtering means.
[0047] There are many variations of modular known to those skilled in the art that may be used within the optical transmitter. These include, but are not limited to Mach-Zehnder modulators, directional coupler modulators and electroabsorption modulators. Additionally, it is possible to modulate the optical source itself directly. In the case of a semiconductor laser this achieved by modulating the current drive to the laser, and is known as a directly modulated laser.
[0048] There are many variations of receiver known to those skilled in the art that may also include a filtering means for removing the unwanted sideband 402 . These include but are not limited to direct detection receivers, heterodyne receivers, homodyne receivers, intradyne receivers and may use a variety of modulation formats including but not limited to amplitude modulation, phase modulation, multisymbol coding schemes such as QPSK and QAM.
[0049] In addition to dispersion, there are many other impairments which may be compensated, including but not limited to fibre nonlinearity (e.g. self phase modulation) and modulator chirp. Chirp is where the modulator may have the characteristic of modulating both amplitude and phase simultaneously but not independently. In such circumstances chirp can have the effect of causing a distortion to the transmitted waveform.
[0050] As well as compensating for a single channel, it is possible to transmit multiple channels by having a number of digital filters and upconverters within the pre-distortion unit, each having different carrier frequencies. These signals can then all be combined together to form a single electrical signal comprising many carriers. This electrical signal can then be applied to an optical modulator to allow multiple channels to be transmitted using a single modulator. | Optical impairments such as dispersion and fibre nonlinearity are compensated by generating a pre-distorted electrical signal at the transmitter. This signal is modulated onto a carrier signal, so that it is upconverted in frequency. This up converted signal is then used to modulate an optical source. Generally the optical signal will have two sidebands, one of which has the correctly pre-distorted information and the other which is unwanted. Information in the unwanted optical sideband is either filtered optically or electrically. In the preferred embodiments, the transmitter uses a tunable semiconductor laser with an integrated electroabsorption modulator to modulate the light. The preferred receiver is a coherent receiver with a tunable local oscillator laser. The receiver uses an electrical filter to remove the information in the unwanted sideband. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This nonprovisional application claims the benefit of, and priority from U.S. provisional application 61/584,512 filed Jan. 9, 2012. The contents of such prior provisional application and all other documents referenced in this application are hereby incorporated by reference in their entirety as if fully set forth herein.
TECHNICAL FIELD
[0002] The present disclosure relates generally to strap connectors, and more specifically to a G-Hook adapted to accept a threaded strap and to interface with stitched-in webbing loops in a load support system in a claw-like manner to establish an operative connection between the strap and the webbing loops.
BACKGROUND
[0003] In many modern backpack systems loads are distributed by use of strap connections running between the pack and a vest or other torso covering structure worn by the user. By cinching the strap connections between the pack and the user's torso, such systems facilitate a more even distribution of load by moving a portion of the load from the user's shoulders and onto the torso and waist. Such load distribution reduces fatigue during prolonged use by allowing a broader group of muscle groups to carry the load. In practice, the straps may be operatively connected to the torso by hooking into loops on so called MOLLE (Modular Light Weight Load Carrying Equipment) webbing. Such MOLLE webbing typically includes a series of open loops formed by stitching the webbing to a vest panel or other support structure at positions along the length of the webbing. The straps from the pack may be attached to hook connectors which engage the loops to establish a reversible connection.
[0004] In the past, the hook connectors have been made predominantly from metal to provide adequate strength. However, such metal components may be subject to damage and corrosion, and are more visible when using night vision. Some plastic hook connectors have been used but such structures have been relatively large and bulky in order to provide the desired strength. Moreover, prior plastic parts have been difficult to attach to the connecting strap in a secure manner.
BRIEF SUMMARY
[0005] The present disclosure provides advantages and alternatives over the prior art by providing a loop engaging G-hook with a metal interior having a polymer covering. The metal interior remains uncovered in selected regions which engage the connection strap and loops during use. One uncovered region may be a wave-form crossbar in a threading eyelet engaging the strap. Another uncovered portion may define an inwardly projecting ridge disposed along the inboard edge of the hooking arm adapted to extend through the loops. The selective combination of bare and covered metal provides a high level of strength in a low profile structure while securely engaging the strap and loops.
[0006] In accordance with one exemplary aspect, the present disclosure provides a G-Hook of multi-layer construction adapted to operatively connect an elongated connection strap to a webbing loop projecting away from an underlying support surface. The G-Hook includes a base portion of substantially planar geometry having an interior eyelet extending through the base portion. The eyelet is adapted to receive the connection strap in pass through relation across the base portion. The G-Hook further includes a hooking arm of generally “J” shaped configuration partially surrounding a loop engagement slot disposed adjacent to the base portion. The hooking arm has a first lateral segment extending away from the base portion, a crossing segment disposed transverse to the first lateral segment and a second lateral segment extending away from the crossing segment in the direction of the base portion. The second lateral segment has a free end spaced apart from the base portion with a space between the free end and the base portion defining a perimeter passage into the loop engagement slot opening. A metal crossbar extends between lateral sides of the eyelet. A metal ridge is disposed along an inboard side of the crossing segment and projects into the loop engagement slot towards the base portion. The crossbar and metal ridge are uncovered portions of a metal insert disposed in embedded, sandwiched relation between a pair of opposing polymeric covering layers.
[0007] Other features and advantages of the disclosure will become apparent to those of skill in the art upon review of the following detailed description, claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a schematic perspective view of one embodiment for an exemplary G-hook in accordance with the present disclosure;
[0009] FIG. 2 is another schematic perspective view illustrating the reverse side of the exemplary G-hook in FIG. 1 ;
[0010] FIG. 3 is a schematic assembly view illustrating the components of an exemplary G-hook consistent with FIGS. 1 and 2 ;
[0011] FIG. 4 is a schematic perspective view illustrating an exemplary metal insert used in the assembly practice illustrated in FIG. 3 .
[0012] FIGS. 5-7 are a series of schematic views illustrating threading a strap around a metal wave-form crossbar in a threading eyelet of an exemplary G-hook consistent with FIGS. 1 and 2 ;
[0013] FIG. 8 is a schematic view of an exemplary vest incorporating a MOLLE webbing system suitable for engagement by an exemplary G-hook consistent with FIGS. 1 and 2 ;
[0014] FIGS. 9 and 10 are a set of schematic views illustrating the establishment of a claw-like engagement between the hooking arm of an exemplary G-hook consistent with FIGS. 1 and 2 and a MOLLE loop to provide a secure connection between the MOLLE loop and a threaded strap;
[0015] FIG. 11 is a view illustrating left side and right side connections using exemplary G-hooks in accordance with the present disclosure;
[0016] FIG. 12 is a schematic perspective view illustrating another embodiment for an exemplary G-hook in accordance with the present disclosure;
[0017] FIG. 13 is a plan view of the exemplary G-hook of FIG. 12 .
[0018] FIG. 14 is a view taken generally along line 14 - 14 in FIG. 13 ; and
[0019] FIG. 15 is a view taken generally along line 15 - 15 in FIG. 13 .
[0020] Before exemplary embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is in no way limited in its application or construction to the details and the arrangements of the components set forth in the following description or illustrated in the drawings. Rather, the disclosure is capable of other embodiments and being practiced or being carried out in various ways.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0021] Reference will now be made to figures wherein to the extent possible, like reference numerals are used to designate like elements in the various views. Turning to FIGS. 1 and 2 , an exemplary G-hook 10 is shown. As illustrated, the exemplary G-hook 10 includes a base portion 12 of generally rectangular annular construction with rounded corners having an eyelet 14 adapted to receive a strap threaded in a manner as will be described further hereinafter. As shown, the base portion 12 may substantially surround the eyelet 14 such that the eyelet is enclosed on all sides. A crossbar 16 of substantially sine wave construction extends across the eyelet 14 . In the exemplary embodiment, the crossbar is uncovered metal and acts to engage the threaded strap in the final connected arrangement. In the illustrated exemplary embodiment, the crossbar 16 defines substantially one complete wave with a maxima peak and a minima peak projecting away from opposite faces of the G-Hook 10 . However, other configurations may likewise be used.
[0022] In the illustrated exemplary construction, the amplitude of the wave formed by the crossbar 16 is such that both peaks of the wave may extend past the plane defined by the surrounding base portion 12 . As will be appreciated, such a configuration with peaks extending beyond the surrounding base portion may facilitate threading a strap between the crossbar 16 and the surrounding base portion 12 in a manner as will be described hereinafter. However it is also contemplated that the total amplitude of the wave may be equal to or less than the thickness dimension of the eyelet 14 and that no portion of the crossbar 16 projects past the plane of the surrounding base portion 12 if desired.
[0023] As shown, the exemplary G-Hook 10 further includes a hooking arm denoted generally by reference numeral 20 of generally claw-like, “J” shaped construction extending away from one lateral side of the base portion 12 to define a loop engagement slot 22 below the base portion 12 . In the illustrated exemplary construction, the hooking arm 20 may include a first lateral leg 24 connected to a lateral side of the base portion 12 with a crossing segment 26 extending transverse to the first lateral leg 24 and a second lateral leg 28 projecting upwardly from the crossing segment 26 towards the base portion 12 . As illustrated, the second lateral leg 28 has a free distal end and does not intersect with the base portion 12 . Accordingly, the gap between the base portion 12 and the second lateral leg 28 defines a lateral passageway into the loop engagement slot 22 .
[0024] In the illustrated exemplary construction, an uncovered metal ridge 30 projects away from the inboard side of the crossing segment 26 and into the loop engagement slot 22 towards the base portion 12 . As will be described further hereinafter, the metal ridge 30 may engage the interior of a MOLLE loop during hooking engagement between the G-Hook and the MOLLE loop during use to promote a secure connection.
[0025] As can be best seen through reference to FIGS. 3 and 4 , in accordance with the illustrated exemplary construction both the crossbar 16 and the metal ridge 30 are portions of a metal insert 40 of steel or other suitable material. By way of example only, and not limitation, the metal insert 40 may be a one-piece structure formed from relatively light gauge spring steal or the like sandwiched between a first covering layer 42 of one piece construction and a second covering layer 44 of one piece construction. The first covering layer 42 and the second covering layer 44 each may be formed of non-fragmenting polymer configured to substantially cover portions of the metal insert other than the crossbar 16 and the metal ridge 30 . In the event of impact, the polymer and metal will not fragment into multiple pieces, but will simply deform or be pierced.
[0026] As shown, the first covering layer 42 and the second covering layer 44 may have matching perimeter geometries which each substantially correspond to the desired final perimeter geometry for the assembled G-Hook 10 . In the illustrated exemplary construction, the portions the first covering layer 42 and the second covering layer 44 cooperatively forming the second lateral leg 28 may be slightly raised relative to the portions forming the crossing segment 26 so as to define a raised step 46 between the crossing segment 26 and the second lateral leg 28 on one or both faces of the assembled G-Hook ( FIG. 2 ). As will be described, during use, the raised steps 46 may aid in blocking against unintended withdrawal of the G-Hook 10 following loop engagement.
[0027] As shown, the first covering layer 42 and the second covering layer 44 may each include a pattern of surface indentations 47 which facilitate gripping by a user without unduly reducing strength. In this regard, the first covering layer 42 and the second covering layer 44 may have either similar or dissimilar surface topography features across their respective faces. Regardless of the surface topography features for the first covering layer 42 and the second covering layer 44 , each of these layers includes an enclosed window opening 48 adapted to overlay and receive portions of the crossbar 16 with surrounding space to define the open eyelet 14 with spacing on either side of the crossbar 16 as seen in FIGS. 1 and 2 .
[0028] As best seen through joint reference to FIGS. 3 and 4 , the first covering layer 42 may include a recess 50 having a perimeter geometry substantially matching the outer perimeter of the metal insert 40 such that the metal insert may be received in nesting relation to be at least partially sunken within the recess 50 during assembly or over molding. In accordance with one exemplary practice, to aid in proper positioning and to reduce the possibility of lateral shifting after assembly, the surface of the recess may be provided with a pattern of raised detents 52 positioned for acceptance within aligned openings 54 in the metal insert 40 . If desired, a minor image recess (not shown) may likewise be provided at the interior surface of the second covering layer 44 . Regardless of whether the recess is provided at the first covering layer 42 , the second covering layer 44 or both, in the final construction the metal insert 40 will be in sufficient sunken relation to permit the outer perimeter ridges of the first covering layer 42 and the second covering layer 44 to be welded or otherwise sealed along a perimeter seam line without interference from the metal insert or over molded plastic over the metal insert. Thus, the metal insert 40 will be in embedded sandwiched relation between the covering layers.
[0029] As illustrated, an inboard surface of the metal insert 40 disposed generally parallel to the crossbar 16 forms the uncovered metal ridge 30 in the final construction. In the illustrated exemplary embodiment, the metal insert 40 includes a lower segment 56 positioned generally in embedded juxtaposed relation to segments of the first covering layer 42 and the second covering layer 44 forming the crossing segment 26 . However, the height dimension of this lower segment is slightly greater than the height dimension of the overlying portions of the first covering layer 42 and the second covering layer 44 . Thus, the uncovered metal ridge 30 projects beyond the boundary of the crossing segment covering layers and into the loop engagement slot 22 in the final construction.
[0030] Referring to FIGS. 5-7 , an exemplary threading arrangement is illustrated for a connection strap 60 . As indicated previously, the connection strap 60 may be connected at its other end to a backpack or other structure (not shown). As illustrated, in the exemplary threading practice the connection strap is threaded through one side of the open eyelet 14 and around the crossbar 16 and back out the other side of the open eyelet 14 to cinch the connection strap 60 in place. Once the cinch connection is made, the connection strap 60 may substantially cover the bare metal of the crossbar 16 ( FIG. 7 ). As will be appreciated, the wave construction of the crossbar 16 may facilitate threading by presenting spaces between the crossbar 16 and the surrounding surface of the base portion 12 . Moreover, with the peaks of the waveform crossbar extending beyond the plane of the base portion 12 on both faces, the connection strap 60 may be threaded without regard to the orientation of the G-hook 10 . That is, the hooking arm 20 may be either up or down as may be desired for the type of connection to be made by the G-Hook.
[0031] As noted previously, a G-Hook 10 in accordance with the present disclosure may be well suited to operatively engage loops on so called MOLLE (Modular Light Weight Load Carrying Equipment) webbing. By way of example only and not limitation, FIG. 8 is a schematic illustration of a torso covering garment such as a vest 66 or the like as may be worn by a user incorporating a multiplicity of MOLLE webbing loops. In the illustrated exemplary arrangement, the vest 66 includes one or more attached webbings 68 . Of course, the number and placement of the webbings 68 is subject to substantial discretion and may be varied as desired depending upon the intended use. As shown, the webbings 68 may include connection elements 70 in the form of connective stitching, mechanical attachments, adhesives or the like attaching the webbings 68 to the surface of the vest 66 . The connections may be disposed periodically along the length of the webbings to form a series of loops 72 between the connection elements 70 such that the loops 72 are adapted to matedly receive male elements in pass-through relation. By way of example only, and not limitation, the vest webbings 16 may be formed from segments of elastomeric or inelastic fabric, although other materials as may be desired may likewise be used.
[0032] Referring now to FIGS. 9 and 10 , the insertion of the hooking arm 20 into a webbing loop 72 is illustrated. As shown, this insertion is accomplished by extending the crossing segment 26 and the second lateral leg 28 of the hooking arm 20 into a loop 72 ( FIG. 9 ). Upon full insertion, the second lateral leg 28 extends through to the far side of the loop 72 and the loop 72 is captured within the loop engagement slot 22 . In this condition, the loop 72 rests on the hooking arm and substantially covers the metal ridge 30 . Thus, a low profile connection is established. As tension is applied to the connection strap 60 , the metal ridge 60 will be pulled towards the opposing connection element 70 and will advance into the naturally occurring crevice between the connection element and the underlying base material of the vest 66 and the raised step 46 is positioned outboard from the ridge of the loop 72 . In this final tensioned condition, the raised step 46 will block unintentional withdrawal of the hooking arm from the loop in the absence of intentional manipulation.
[0033] In the illustrated exemplary construction, G-Hook 10 also may include an extended finger pull tab 74 at the corner of the hooking arm forming the intersection between the first lateral leg portion 24 and the crossing segment 26 . This extended finger pull tab aids a user in grasping the G-hook 10 for tilting manipulation when disengagement is desired.
[0034] As noted previously, the exemplary construction may be used for both left side and right side engagement. This feature is illustrated in FIG. 11 wherein the connection straps have been removed for purposes of visibility. As will be appreciated, the ability to use a common design for both left and right side connections may provide a the user with substantial versatility. In particular, a user may use a single design G-hook 10 to attach straps from both sides of a backpack (not shown) to adjacent loops 72 on a torso covering garment to secure the pack in place in a buckle-like fashion and to distribute a portion of the load away from the user's shoulders.
[0035] FIGS. 12 and 13 provide an alternative embodiment for an exemplary G-Hook 110 consistent with the present disclosure, wherein like elements to those described previously are designated by like reference numerals increased by 100 . As will be understood, the embodiment of FIGS. 11 and 12 is substantially similar to those previously described with the exception that the second lateral leg 128 defining the free end of the hooking arm defines a generally wedge-shaped beak extending outboard beyond the edge of the base portion 112 .
[0036] As shown, in the embodiment of FIGS. 12 and 13 the second lateral leg includes a convex curved outboard surface with the second lateral leg 128 having a configuration corresponding generally to that of the bow of a ship with a narrowing width progressing outwardly and downwardly. As best seen through joint reference to FIGS. 13 and 14 , in the exemplary G-Hook 110 , the second lateral leg 128 has an upper surface 180 which both slopes and narrows to a distal point 182 at the outer edge of the second lateral leg 128 . In addition, the front and rear faces of the second lateral leg 128 converge progressively towards one another at the distal point 182 . Thus, the second lateral leg is thicker adjacent the crossing segment 126 than at the convex curved outboard surface.
[0037] As will be appreciated, the configuration illustrated in FIGS. 12-15 may be beneficial in providing a very low resistance force as the second lateral leg 128 is inserted into a loop as previously described. However, since the second lateral leg 128 is still raised at the intersection with crossing segment 126 to form a raised step 146 , a secure blocking arrangement is maintained to prevent unintentional withdrawal.
[0038] As will be appreciated, the present disclosure provides a number of advantages. By way of example only these advantages may include, the absence of twisting or reconfiguration to switch sides; improved strength from the metal insert; low profile, secure connection under tension; reduced possibility for fragmentation; and adaptability to fit onto any suitable webbing. Of course, variations and modifications of the foregoing are within the scope of the present disclosure. Thus, it is to be understood that the disclosure disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present disclosure. | A loop engaging G-hook with a metal interior having a polymer covering. The metal interior remains uncovered in selected regions which engage the connection strap and loops during use. One uncovered region may be a wave-form crossbar in a threading eyelet engaging the strap. Another uncovered portion may define an inwardly projecting ridge disposed along the inboard edge of the hooking arm adapted to extend through the loops. The selective combination of bare and covered metal provides a high level of strength in a low profile hook structure. | 8 |
BACKGROUND
[0001] Public networks such as the Internet are commonly used to allow businesses and consumers to access and share information from a variety of sources. However, security is often a concern when accessing the Internet because there is a threat of malicious software being downloaded from a website or received in an e-mail which may contain viruses, Trojan horses, or other malicious executable code (collectively referred to as “malware”) that may infect computers inside the business or home.
[0002] An increasingly common technique used by malware authors is to create new threads of execution inside existing legitimate (i.e., trusted) processes running on a computer system. Known as code or process injection, the technique enables the new threads to protect and defend the rest of the malware installation by interfering with or recovering from any changes made by anti-malware products or tools.
[0003] Unfortunately, it is difficult for existing anti-malware products to identify such threads of execution accurately because the malicious code could be anywhere in the memory address space of any running process and the memory is not uniquely linked to a specific thread. In addition, even if the malicious code is detected by the anti-malware product, the process cannot always be killed as a whole. For example, if the running process is a user application process, killing it will cause the user to lose unsaved data. If the running process is a critical system process, killing it would cause the operating system to immediately crash.
[0004] This Background is provided to introduce a brief context for the Summary and Detailed Description that follow. This Background is not intended to be an aid in determining the scope of the claimed subject matter nor be viewed as limiting the claimed subject matter to implementations that solve any or all of the disadvantages or problems presented above.
SUMMARY
[0005] An arrangement for scanning and patching injected malware code that is executing in otherwise legitimate processes running on a computer system is provided in which malware code is located in the memory of processes by extracting the start addresses of processes' threads and then searching near these addresses. Additional blocks of code in memory that are invoked by the code identified by each start address are also identified and the blocks are then matched against scanning signatures associated with known malware threads. If the entire signature can be matched against a subset of the blocks, then the thread is determined to be infected. The infected thread is suspended and in-memory modifications are performed to patch the injected code to render it harmless. Once modified, the thread can be resumed or terminated (as may be specified by the signature) to disable the protection mechanisms of the malware without causing any harm to the process in which the thread is injected.
[0006] In an illustrative example, when a malware detection module in an anti-malware product detects an instance of malware that is known to inject threads, it invokes a thread scan by a thread scanning module by which threads associated with one or more named processes are matched to a subset of known malware thread signatures. By limiting the number of scanning targets and malware thread signatures against which they are matched, very effective scanning and patching may be realized without significantly impacting overall computer system performance.
[0007] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 shows an illustrative computing environment in which consumer and corporate users share public network infrastructure such as the Internet, and access resources located on the public network;
[0009] FIG. 2 is a flowchart of an overview of an illustrative method performed by the present thread scanning and patching to detect and disable injected malware;
[0010] FIG. 3 shows an illustrative computer system that runs an anti-malware product which includes functionality supporting the present thread scanning and patching;
[0011] FIG. 4 shows components used in an illustrative thread scanning module; and
[0012] FIG. 5 is a flowchart of an illustrative method that is performed by a block detection component in the thread scanning module.
[0013] Like reference numerals indicate like elements in the drawings. Elements are not drawn to scale unless otherwise indicated.
DETAILED DESCRIPTION
[0014] FIG. 1 shows an illustrative computing environment 100 in which a number of consumer users 110 1, 2 . . . N and business users 116 1, 2 . . . N share common public network infrastructure 122 such as the Internet. Resources 126 like web servers, databases, FTP (file transfer protocol) sites, and other Internet-based or distributed computing-type applications or services, may typically be accessed by users 110 and 116 using personal computers (“PCs”), laptops, and other computing platforms, as representatively indicated by reference numerals 118 and 120 , respectively. In addition, file and data may be shared among users through such facilities as e-mail or peer-to-peer file sharing.
[0015] While the Internet has been invaluable in enabling positive and productive computing experiences for many users, it unfortunately has been a transport mechanism by which malware such as computer viruses, worms, Trojan horses, and rootkits may be distributed to infect computer systems around the world. The term malware as used here is a collective noun that refers to viruses, worms, Trojan horses, rootkits, and other code that is intentionally designed to perform malicious tasks on a computer system.
[0016] Once malware has reached a computer system over a transport mechanism, it will generally attempt to perform some malicious action, generally called a “payload.” Payloads can include, for example, providing backdoor (i.e., unauthorized) access to the computer system, corrupting or deleting data on the computer, stealing information, or halting network service through a denial of service (“DoS”) attack.
[0017] The business users 116 typically are located in a corporate network (“corpnet”) that sits behind a firewall 130 that often provides, alone or in combination with other security products (not shown), protection against malware and other threats. Consumer users 110 often utilize locally running anti-malware products such as anti-virus programs, and may also receive some protection against malware from their Internet service provider (“ISP”).
[0018] Unfortunately, many malware examples employ some kind of self-defense or protection mechanism to help reduce the likelihood of detection and/or removal by anti-malware products. For example, malware may use armor that attempts to foil an analysis of the malicious code. This may include detecting when a debugger is running and trying to prevent it from working correctly, or adding lots of meaningless code to make it difficult to determine the purpose of the malicious code. Malware may use a stealth technique to hide itself by intercepting requests for information and returning false data. Malware may also encrypt itself or its payload to prevent detection and data retrieval.
[0019] Another technique called “process injection” has become increasingly popular among malware authors to conceal their code from anti-malware products or frustrate attempts to remove the malware. This technique involves injecting the malicious code into legitimate processes that are running on the computer. For example, a remote access Trojan horse may inject malicious code into a process used by a web browser application to avoid detection by a firewall (e.g., firewall 130 ) or the anti-malware product running on a PC. Not only will the malicious code be provided with Internet access, but the security applications running on the firewall or PC, which are often rule-based, will often not detect the malware, but only see the trusted Web browser application and associated processes.
[0020] Malicious code can be injected, for example, by loading executable code such as a DLL (“Dynamically Linked Library”) into a running process's memory. Operating systems, such as the Microsoft Windows® operating system, commonly provide several different ways to call external functions in a DLL file. Another approach malware authors take is to use the Windows-provided API (application programming interface) for debugging. Typically, a new thread is created in the target process with the thread's start address in memory set to the address of the executable malicious code. It is noted that the term “thread” is used here in its conventional sense to mean a set of instructions in program code that performs operations within an address space. Threads typically can execute independently of each other.
[0021] Even in cases where the injected malicious code can be detected, it can be often very difficult to remove, particularly when a system process has been impacted. One example of a critical system process in the Windows operating system is Winlogon. Terminating this process can often cause the computer system to immediately crash. This characteristic makes this process a popular target for malware authors. The author may configure the malware to create a custom thread in Winlogon to constantly monitor and then replace any files containing the malware code which are detected and deleted by anti-malware products.
[0022] The present thread scanning and patching arrangement can disable injected malware code, including code that is injected into critical system processes. In an illustrative example, the thread scanning and patching is implemented using a software module in an anti-malware product. FIG. 2 shows a flowchart for an overview of the techniques used to detect and disable injected malware code using the Winlogon example above. At 201 , the anti-malware product with the thread scanning and patching module uses a conventional computer hard disk based scanning technique (or other known technique) to detect malware running on the Winlogon process, for example, by comparing files on the hard disk against signatures of known malware. At 202 , a thread scan is triggered on the Winlogon system process. At 203 , a thread of malicious code is detected. At 204 , the code is modified to disable the constant monitoring by the malware. At 205 , the malware files can be deleted. At 206 , rebooting the computer system clears the remaining traces of the patched malware thread from Winlogon.
[0023] Details of the thread scanning and patching technique are shown in FIGS. 3-5 and described in the accompanying text. Turning now to FIG. 3 , an illustrative computer system 300 is shown that supports an anti-malware product 305 that incorporates a malware detection and remediation module 312 , and a thread scanning module 320 . Computer system 300 is representative of a typical personal computer as used, for example, by a consumer user 110 or by a business user 116 as shown in FIG. 1 .
[0024] The malware detection and remediation module 312 , in this example, is arranged to apply any of a variety of known (i.e., “conventional”) techniques to detect malware on the computer system 300 , for example, by scanning files 326 on the computer system's hard disk drive 330 (or other storage medium such as a persistent or other non-volatile memory), and comparing data in the files 326 to signatures of known malware that are contained in a signature repository 335 . Other conventional malware detection techniques that may be utilized include, for example, solutions that monitor network traffic leaving the computer system 300 , or methodologies which employ memory-based scanning.
[0025] The signature repository 335 is used to hold signatures used for detecting malware with conventional disk-based techniques, as well as for holding signatures of known malware threads, termed “thread scanning signatures.” In alternative implementations, the signatures used to support the malware detection techniques can be held separately from the thread scanning signatures.
[0026] In most implementations of the present arrangement, signatures 335 will contain instructions to direct the malware detection and remediation module 312 to invoke a thread scan (using the thread scanning module 320 ) for only a subset of all known malware threads. Sometimes, therefore, only specific processes 341 identified by name will be subjected to thread scanning. By being selective with respect to both the thread scanning targets and the number of malware signatures being matched against, an effective solution to injected malware can be provided while maintaining the overall performance of the computer system 300 .
[0027] Accordingly, when malware is detected for which thread scanning is utilized, the malware detection and remediation module 305 makes a call to the thread scanning module and will pass the process name and Thread Signature ID as parameters to the thread scanning module 320 . The thread scanning module 320 will locate threads 346 associated with the named processes in memory 350 in order to begin the thread scanning and patching technique. The details of the techniques used and the functional components of the thread scanning module are shown in FIG. 4 and described in more detail below.
[0028] As shown in FIG. 4 , the thread scanning module 320 includes a thread enumeration component 410 , a block detection complement 420 , a block matching component 430 , and a thread remediation component 440 .
[0029] The thread enumeration component 320 takes the process name as an input and locates candidate threads for scanning based on the process name. The thread enumeration component 320 relies upon operating system functionality to generate a list of running processes on the computer system 300 . The running process list is filtered by eliminating any process whose process name does not match the name received from the malware detection and remediation module 312 .
[0030] Each process that remains after the filtering is identified by a Process ID. For each such process, the operating system is queried to generate a list of threads for that process where each thread is identified by a Thread ID. The thread enumeration component 320 then queries the operating system to obtain the start address of each thread's code in the process's memory.
[0031] The thread enumeration component 410 forwards the thread list (Thread ID, Process ID, Entry Point) to the block detection component 420 . It is noted that the trailing asterisk notation used in FIG. 4 , “(x)*” means “zero or more of (x)”. Thus, for example, the notation (Thread ID, Process ID, Entry Point)* means that the thread list produced by the thread enumeration component 410 includes zero or more entries, each entry containing all of Thread ID, Process ID, and Entry Point.
[0032] The block detection module 420 uses the thread list (Thread ID, Process ID, Entry Point), and Thread Signature ID as inputs to analyze the machine code stored at a start address, and attempts to determine locations in memory where more code exists and the thread executes. The block detection component 420 then generates a list of detected blocks which is forwarded to the block matching component 430 , (where each block in the list is identified by Block Address) to which blocks in a given signature can be matched against. The list is in the form (Thread ID, Process ID, Block Address*)* which means that there are zero or more entries in the block list where each entry contains a Thread ID, a Process ID, and zero or more Block addresses.
[0033] More specifically, for each thread, the block detection module 420 accesses the memory space of the process to which the thread belongs. As shown in FIG. 5 , at 501 , a queue of memory addresses is formed where the start point address thread is the initial entry. At 502 , the first address in the memory queue is removed. At 503 , if the address is inside a block on the block list, then the step at 501 is repeated.
[0034] At 504 , the machine code of the address in the memory address queue is examined. At 505 , if the machine code jumps to new addresses in the memory, then those new addresses are added to the memory address queue. At 506 , when the end of the block of code is found, then the block is added to the block list.
[0035] The steps 501 - 506 are iterated so long as there are entries in the memory address queue, as indicated at 507 , and the size of the block list is smaller than a predefined limit, as indicated at 508 . This limit will typically be selected to meet the needs of a particular implementation as more resources in the computer system 300 will typically be consumed as the size of the block list increases.
[0036] Returning again to FIG. 4 , block matching component 430 takes the detected block list (Thread ID, Process ID, Block Address*)* and Thread Signature ID as inputs. Each block is attempted to be matched against a set of blocks in a thread scanning signature in signatures 335 . If all the blocks in the given thread scanning signature are matched, then the thread is determined to be infected with malicious code.
[0037] More specifically, each thread signature in the signature repository 335 defines the partial contents of multiple blocks of memory. To declare a thread as infected, every partial block in the thread scanning signature must be matched against one of the blocks identified by the block detection component 420 . However, as only the thread scanning signatures explicitly identified by the Thread Signature ID (that is passed as a parameter to the thread scanning module 320 ) are used for the matching, resources in the computer system 300 can generally be used efficiently.
[0038] As indicated by arrow 435 , threads that match any thread scanning signatures are passed back, by Thread ID and Malware Name, to the malware detection and remediation module 312 or other system or sub-system running on the computer system 300 , for example, to be reported by the anti-malware product to an end-user, or system administrator. A list of matched blocks for any detected thread and malware name (Thread ID, Malware Name, Matched Blocks*)* is reported to the thread remediation component 440 . The matching thread scanning signatures from repository 335 are also passed as shown in FIG. 4 .
[0039] The thread remediation component 440 takes the identity of the malware thread and the list of matched blocks as inputs. Each thread reported to the remediation component 440 is suspended. The matching thread scanning signature, which is typically arranged to contain patch instructions, is then examined. The patch instructions reference specific locations within the blocks and provide new values for the memory in these locations. The new values are written to the specified locations so that the process memory associated with the infected thread is modified.
[0040] Once modified, the thread may either be resumed or terminated, depending on the instructions in the thread scanning signature. A report may then be forwarded by Thread ID, Malware Name and Result (e.g., resumed, terminated), as indicated by arrow 442 to the malware detection and remediation module 312 or other system or sub-system running on the computer system 300 .
[0041] Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims. | An arrangement for scanning and patching injected malware code that is executing in otherwise legitimate processes running on a computer system is provided in which malware code is located in the memory of processes by extracting the start addresses of processes' threads and then searching near these addresses. Additional blocks of code in memory that are invoked by the code identified by each start address are also identified and the blocks are then matched against scanning signatures associated with known malware threads. If the entire signature can be matched against a subset of the blocks, then the thread is determined to be infected. The infected thread is suspended and in-memory modifications are performed to patch the injected code to render it harmless. The thread can be resumed or terminated to disable the protection mechanisms of the malware without causing any harm to the process in which the thread is injected. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on and claims priority to U.S. provisional patent application Ser. No. US 60/739,036, which was filed on Nov. 22, 2005.
BACKGROUND OF THE INVENTION
[0002] The present invention is directed to coasters on which beverage containers and enclosures are placed so as to avoid damage of the surface underneath. In particular, this invention is directed to a self-absorbing and self-conforming coaster adapted for use in a beverage holder of a vehicle, such as an automobile, boat, bus, and the like. The subject invention is also directed to a method for providing targeted advertising indicia on beverage holder coasters.
[0003] The typical automobile, boat, bus, light truck, tractor-trailer, or van typically comes equipped with at least one integrated beverage holder. Usually, this beverage holder is molded into the material of the dashboard, center console, door, or the like. Repeated use of the beverage holder to hold a beverage leaves a variety of residues in the holder, including spilt beverage, condensation, and the like. Over time, the buildup of such residue may lead to mold development, as well as being a gathering point for lint, paper, or other debris common on moving vehicles. Some previous attempts to alleviate this problem have included removable mats inserted into the bottom of the beverage holder. These mats are generally manufactured of a rubber-like material, which prevent moisture, beverage, and the like, from accumulating on the unprotected bottom of the holder. However, such a mat merely contains the spilt beverage, condensation, or the like, and must be removed for cleaning. In the event of a spill, the beverage remains on the mat until removal or evaporation leaves a sticky residue on the mat, requiring cleaning.
[0004] Additionally, aftermarket supplies of such mats may be limited, as each motor vehicle generally includes unique holders, as an industry standard size is not presently enforced. When such mats are available, they are typically expensive, as most aftermarket manufacturer accessories are.
[0005] Further, cleaning such a mat or the beverage holder itself may be time consuming and is not convenient during a long trip.
[0006] Thus, there is a need to defray the expense of a coaster for a beverage holder in the motor vehicle industry.
[0007] A need also exists for a coaster adapted to fit a variety of beverage holder sizes.
[0008] There further exists a need for a beverage holder coaster that is not in need of cleaning, being disposable.
[0009] There also exists a need for a beverage holder coaster adapted for use as an advertising medium.
[0010] Further there exists a need for a method for providing targeted advertising indicia on beverage holder coasters.
SUMMARY OF THE INVENTION
[0011] In accordance with the present invention, there is provided a self-absorbent, self-conforming coaster.
[0012] Further, in accordance with the present invention, there is provided a self-absorbing coaster adapted to fit a variety of beverage holder sizes.
[0013] Still further, in accordance with the present invention, there is provided a disposable coaster adapted to fit a variety of beverage holders located in a variety of vehicles.
[0014] In accordance with one aspect of the present invention, there is provided a beverage holder coaster including a body. The body includes at least one layer of at least partially absorbent material. The body includes an interior surface and an exterior surface. The body is adapted for being removably inserted into at least one of a plurality of different sized associated beverage holders. The associated beverage holder includes an interior surface.
[0015] In a preferred embodiment, the interior surface of the body is adapted for use as an advertising medium. Preferably, the interior surface of the body depicts advertising indicia.
[0016] The body of the beverage holder coaster is adapted for conforming to an associated beverage holder such that a non-adhesive contact is enabled between at least a part of the exterior surface of the body and a respective part of an interior surface of an associated beverage holder. The body, preferably, includes a periphery, which is adapted for folding upward enabling the contact between the at least a part of the exterior surface of the body and a respective part of an interior surface of an associated beverage holder. The periphery, preferably, includes a plurality of tabs formed by a respective plurality of slots included in the periphery, wherein slots are oriented toward a center of the body and spaced apart at a predetermined distance, and wherein the slots are of a predetermined length.
[0017] In another preferred embodiment, the exterior surface of the body is coated with an impermeable material. The at least one layer of the at least partially absorbent material of the body of the beverage holder coaster is selected from the group consisting of: at least partially a paper material layer, and at least partially a cotton material layer. As will be appreciated by those skilled in the art, the body is, preferably, disposable.
[0018] In accordance with another aspect of the present invention, there is provided a method for providing targeted advertising indicia on beverage holder coasters. The method begins with receiving from an associated customer, data representative of customer identification data. Next, a request is received from an associated customer, which includes data representative of advertising indicia to be provided on beverage holder coasters. Received data representative of customer identification data and of the advertising indicia, included in the request, is stored. Those skilled in the art will recognize that the received data is, preferably, stored in electronic form.
[0019] When necessary, the received data is customized, and then advertising indicia corresponding to the request received from an associated customer, is displayed on beverage holder coasters.
[0020] As will be apparent to those skilled in the art, data representative of customer identification data and data representative of advertising indicia to be provided on beverage holder coasters is received via communications network selected from the group comprising at least one of Internet network, and non-Internet network.
[0021] Still other objects and aspects of the present invention will become readily apparent to those skilled in this art from the following description wherein there is shown and described a preferred embodiment of this invention, simply by way of illustration of one of the best modes suited for to carry out the invention. As it will be realized by those skilled in the art, the invention is capable of other different embodiments and its several details are capable of modifications in various obvious aspects all without departing from the scope of the present invention. Accordingly, the drawings and description will be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF DRAWINGS
[0022] The accompanying drawings incorporated in and forming a part of the specification, illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention. In the drawings:
[0023] FIG. 1 illustrates a typical center console beverage holder of a vehicle in accordance with the present invention;
[0024] FIG. 2 illustrates a portion of a typical center console beverage holder having used coasters in accordance with the present invention;
[0025] FIG. 3 illustrates removing of a beverage holder coaster in accordance with the present of a invention; and
[0026] FIG. 4 illustrates using the interior surface of the body of the beverage holder coaster as an advertising medium in accordance with the present invention;
[0027] FIG. 5 is an overall diagram of the system for providing targeted advertising indicia on beverage holder coasters according to one embodiment of the subject application;
[0028] FIG. 6 is a block diagram illustrating a user device for use in the system for providing targeted advertising indicia on beverage holder coasters according to one embodiment of the subject application;
[0029] FIG. 7 is a block diagram illustrating a server for use in the system for providing targeted advertising indicia on beverage holder coasters according to one embodiment of the subject application;
[0030] FIG. 8 is a flowchart illustrating a method for providing targeted advertising indicia on beverage holder coasters in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The present invention is directed to coasters on which beverage containers and enclosures are placed so as to avoid damage of the surface underneath. In particular, the present invention is directed to a self-absorbent, self-conforming coaster. More particularly, the present invention is directed to a self-absorbing and self-conforming coaster adapted for use in a beverage holder of a vehicle, such as an automobile, boat, bus, and the like.
[0032] Turning now to FIG. 1 , there is shown a typical center console beverage holder 100 of a vehicle. The console beverage holder 100 includes beverage holder coasters 102 , 104 , 106 , and 108 inserted into different sized associated beverage holders 110 , 112 , 114 , and 116 , respectively. The beverage holder coasters 102 , 104 , 106 , and 108 each include a body including at least one layer of at least partially absorbent material. The at least partially absorbent material is, preferably, pliable. Further, the at least partially absorbent material is adapted to absorb a plurality of liquid types of varying viscosity.
[0033] Those skilled in the art will recognize that the material of the at least one layer of the beverage holder coasters 102 , 104 , 106 , and 108 is capable of being at least partially a paper material layer. The material of the at least one layer of the beverage holder coasters 102 , 104 , 106 , and 108 is also capable of being at least partially a cotton material layer. It will be evident to a skilled artisan that other at least partially absorbent materials known in the art are capable of being used for employing the beverage holder coasters 102 , 104 , 106 , and 108 without departing from the scope of the current invention. Those skilled in the art will appreciate that the beverage holder coasters 102 , 104 , 106 , and 108 , preferably, have a generally circular shape.
[0034] As illustrated in FIG. 1 , the beverage holder coasters 102 , 104 , 106 , and 108 conform to the different sized associated beverage holders 110 , 112 , 114 , and 116 , respectively. It will be understood by those skilled in the art that beverage holders 110 , 112 , 114 , and 116 are capable of having a variety of sizes and styles, including, for example and without limitation, holders capable of receiving large beverage containers on a raised outer ring on the bottom of the holder and small beverage containers on a recessed inner circle on the bottom of the holder.
[0035] Further description will be made with respect to the beverage holder coaster 102 . However, as will be apparent to a skilled artisan, beverage holder coasters 104 , 106 , and 108 are analogous to the beverage holder coaster 102 . Hence, the description presented herein for the beverage holder coaster 102 equally applies to beverage holder coasters 104 , 106 , and 108 .
[0036] As illustrated in FIG. 1 , the body of the beverage holder coaster 102 includes an exterior surface 118 adapted for contacting at least partially with an interior surface 120 of the of an associated beverage holder 110 . In a preferred embodiment, the exterior surface 118 is advantageously coated with an impermeable material, so as to prevent liquids absorbed through the top surface from passing through the bottom surface to the associated beverage holder 110 (the bottom surface not shown in the drawing). The body further includes a periphery 122 adapted for folding upward. As will be appreciated by those skilled in the art, the latter enables a contact between at least a part of the exterior surface 118 of the body and a respective part of the interior surface 120 of an associated beverage holder 110 . The body is further adapted for enveloping at least partially an associated beverage enclosure 124 . The body includes an interior surface 126 adapted for forming a non-adhesive contact with at least a part of an exterior surface of an associated beverage enclosure 124 . The interior surface 126 of the body of the beverage holder coaster 102 is, preferably, coated with a semi-impermeable material (not shown in the drawing). The latter advantageously allows liquid to be absorbed by the beverage holder coaster 102 , but prevents the beverage enclosure 122 placed on the coaster 122 from sticking to it.
[0037] The beverage holder coasters beverage holder coasters 102 , 104 , 106 , and 108 will be described in greater detail below with reference to FIG. 2 .
[0038] Turning now to FIG. 2 , there is shown a portion of a typical center console beverage holder 200 having used coasters 202 and 204 in accordance with the present invention. Those skilled in the art will recognize that the bodies of coasters 202 , 204 are capable of being fabricated multilayered, as shown in FIG. 2 . The periphery 206 , 208 of the bodies of coasters 202 , 204 , respectively, advantageously includes a plurality of tabs 210 , 212 formed by a respective plurality of slots 214 , 216 included in the periphery 206 , 208 , respectively. As will be appreciated by a skilled artisan, the plurality of slots 214 , 216 is oriented toward a center of the body of a respective coaster 202 , 204 . The slots 214 , 216 are spaced apart at a predetermined distance and are of a predetermined length. The slotted periphery 206 , 208 allow the tabs 210 , 212 to fold upward, along the sides of respective beverage holders 218 , 220 . The skilled artisan will appreciate from the attached figures that the use of the slotted tabs 210 , 212 enables the respective coaster 202 , 204 to prevent liquid accumulation on the sides of respective beverage holders 218 , 220 .
[0039] Turning now to FIG. 3 , there is shown a portion of a typical center console beverage holder 300 . As will be apparent to those skilled in the art, FIG. 3 illustrates removal of a beverage holder coaster 302 from a respective beverage holder 304 . As shown in FIG. 3 , the beverage holder coaster 302 includes tabs 306 .
[0040] Turning now to FIG. 4 , there is shown a portion of a typical center console beverage holder 400 . As shown in FIG. 4 , an interior surface 402 of the body of the beverage holder coaster 404 is used as an advertising medium. Those skilled in the art will appreciate that the interior surface 402 of the body of the beverage holder coaster 402 depicts logo information 406 of a particular company.
[0041] Operation of the beverage holder coaster of the subject application will be explained with reference to FIG. 1 , FIG. 2 , and FIG. 3 . Referring now to FIG. 1 , beverage holder coasters 102 , 104 , 106 , and 108 are inserted into different sized associated beverage holders 110 , 112 , 114 , and 116 , respectively. The beverage holder coasters 102 , 104 , 106 , and 108 are inserted such that they rest on at least a portion of the bottom of a respective beverage holder 110 , 112 , 114 , and 116 .
[0042] Those skilled in the art will appreciate that the beverage holder coasters 102 , 104 , 106 , and 108 after being inserted, advantageously engage themselves to the sides and bottom of a respective beverage holder 110 , 112 , 114 , and 116 by means of the tabs 210 , 212 (shown in FIG. 2 ) and the materials used in the construction of the respective beverage holder coasters 102 , 104 , 106 , and 108 . A user is then able to place a beverage container, such as a cup, bottle, can, or the like, (illustrated in FIG. 1 as a beverage enclosure 122 ) in the beverage holder 110 on top of the coaster 102 . As bumps, spills, condensation, and the like, occur the beverage holder coaster 102 suitably absorbs the liquids, preventing such liquid from coming into contact with the bottom and sides of the beverage holder 110 .
[0043] Once the beverage has been consumed, or alternatively once the beverage holder coaster 102 has become saturated, such as illustrated in FIG. 2 by coasters 202 , 204 , the beverage holder coaster 102 is removed via any suitable means and replaced with a fresh coaster. FIG. 3 illustrates removal of the beverage holder coaster 302 from a respective beverage holder 304 . Preferably, a user is able to secure the beverage holder coaster 302 by grasping one of the extended tabs 306 in accordance with one embodiment of the present invention. As will be recognized by those skilled in the art, the beverage holder coaster 302 is, preferably disposed after being removed from the respective beverage holder 304 .
[0044] In a preferred embodiment of the subject application, as illustrated in FIG. 4 , the beverage holder coaster 404 is adapted to receive advertisement indicia on the interior surface 402 of the body of the beverage holder coaster 404 . Preferably, the advertisement indicia is a printed advertisement using ink absorbed directly onto the beverage holder coaster 404 via any means known in the art. Suitable examples of such techniques are shown on any printed paper or cotton napkins, towels, and the like. The skilled artisan will appreciate that other methods of affixing advertisement indicia on the interior surface 402 of the beverage holder coaster 404 are capable of being advantageously used, without departing from the scope of the present invention.
[0045] Referring now to FIG. 5 , there is shown an overall diagram of the system 500 for providing targeted advertising indicia on beverage holder coasters in accordance with one embodiment of the subject application. As shown in FIG. 5 , the system 500 is capable of implementation using a distributed computing environment, illustrated as a computer network 502 . It will be appreciated by those skilled in the art that the computer network 502 is any distributed communications system known in the art capable of enabling the exchange of data between two or more electronic devices. The skilled artisan will further appreciate that the computer network 502 includes, for example and without limitation, a virtual local area network, a wide area network, a personal area network, a local area network, the Internet, an intranet, or the any suitable combination thereof. In accordance with the preferred embodiment of the subject application, the computer network 502 is comprised of physical layers and transport layers, as illustrated by the myriad of conventional data transport mechanisms, such as, for example and without limitation, Token-Ring, 802.11(x), Ethernet, or other wireless or wire-based data communication mechanisms. The skilled artisan will appreciate that while a computer network 502 is shown in FIG. 5 , the subject application is equally capable of use in a stand-alone system, as will be known in the art.
[0046] The system 500 illustrated in FIG. 5 further depicts a user device 504 , in data communication with the computer network 502 via a communications link 506 . It will be appreciated by those skilled in the art that the user device 504 is shown in FIG. 1 as a personal computer for illustration purposes only. As will be understood by those skilled in the art, the user device 504 is representative of any computing device known in the art, including, for example and without limitation, a laptop computer, a workstation computer, a personal data assistant, a web-enabled cellular telephone, a smart phone, a proprietary network device, or other web-enabled electronic device. The communications link 506 is any suitable channel of data communications known in the art including, but not limited to wireless communications, for example and without limitation, Bluetooth, WiMax, 802.11a, 802.11b, 802.11g, 802.11(x), a proprietary communications network, infrared, optical, the public switched telephone network, or any suitable wireless data transmission system, or wired communications known in the art. Preferably, the user device 504 is suitably adapted to generate and transmit electronic documents, document processing instructions, user interface modifications, upgrades, updates, personalization data, or the like, via the computer network 502 . In accordance with one embodiment of the subject application, the user device 504 is suitably adapted to run a web browser application, enabling communication with various devices via the Internet 502 . The operation of the user device 504 will better be understood in conjunction with the block diagram illustrated in FIG. 6 , explained in greater detail below.
[0047] The system 500 further illustrates a network server 508 coupled to a data storage device 510 . Preferably, the network server 508 is representative of any network server known in the art capable of storing document data, image data, video data, sound data, multimedia data, or other suitable electronic data, hosting web pages, web sites, or the like, as will be known in the art. In accordance with one embodiment of the subject application, the data storage device 510 includes a plurality of electronic data, including image data, document data, customer identification data, advertising indicia, or the like. The network server 508 is communicatively coupled to the computer network 502 via a suitable communications link 512 . As will be understood by those skilled in the art, the communications link 512 includes, for example and without limitation a proprietary communications network, infrared, optical, Bluetooth, WiMax, 802.11a, 802.11b, 802.11g, 802.11(x), the public switched telephone network, or any suitable wireless data transmission system, or wired communications known in the art. The operation of the network server 508 will be better understood in conjunction with the block diagram illustrated in FIG. 7 , explained in greater detail below.
[0048] Turning now to FIG. 6 , illustrated is a hardware diagram of a suitable user device 600 , shown in FIG. 5 as the user device 504 , for use in connection with the subject system. A suitable user device includes a processor unit 602 which is advantageously placed in data communication with read only memory 604 , suitably non-volatile read only memory, volatile read only memory or a combination thereof, random access memory 606 , display interface 608 , storage interface 610 , and network interface 612 . In a preferred embodiment, interface to the foregoing modules is suitably accomplished via a bus 614 .
[0049] The read only memory 604 suitably includes firmware, such as static data or fixed instructions, such as BIOS, system functions, configuration data, and other routines used for operation of the user device 600 via CPU 602 .
[0050] The random access memory 406 provides a storage area for data and instructions associated with applications and data handling accomplished by the processor 602 .
[0051] The display interface 608 receives data or instructions from other components on the bus 614 , which data is specific to generating a display to facilitate a user interface. The display interface 608 suitably provides output to a display terminal 626 , suitably a video display device such as a monitor, LCD, plasma, or any other suitable visual output device as will be appreciated by one of ordinary skill in the art.
[0052] The storage interface 610 suitably provides a mechanism for non-volatile, bulk or long term storage of data or instructions in the user device 600 . The storage interface 610 suitably uses a storage mechanism, such as storage 618 , suitably comprised of a disk, tape, CD, DVD, or other relatively higher capacity addressable or serial storage medium.
[0053] The network interface 612 suitably communicates to at least one other network interface, shown as network interface 620 , such as a network interface card, and wireless network interface 630 , such as a WiFi wireless network card. It will be appreciated that by one of ordinary skill in the art that a suitable network interface is comprised of both physical and protocol layers and is suitably any wired system, such as Ethernet, token ring, or any other wide area or local area network communication system, or wireless system, such as WiFi, WiMax, or any other suitable wireless network system, as will be appreciated by on of ordinary skill in the art. In the illustration, the network interface 620 is interconnected for data interchange via a physical network 632 , suitably comprised of a local area network, wide area network, or a combination thereof.
[0054] An input/output interface 616 in data communication with the bus 614 is suitably connected with an input device 622 , such as a keyboard or the like. The input/output interface 616 also suitably provides data output to a peripheral interface 624 , such as a USB, universal serial bus output, SCSI, Firewire (IEEE 1394) output, or any other interface as may be appropriate for a selected application. Finally, the input/output interface 616 is suitably in data communication with a pointing device interface 628 for connection with devices, such as a mouse, light pen, touch screen, or the like.
[0055] Referring now to FIG. 7 , illustrated is a representative architecture of a suitable server 700 , shown in FIG. 5 as the network server 508 , on which operations of the subject system are completed. Included is a processor 702 , suitably comprised of a central processor unit. However, it will be appreciated that processor 702 may advantageously be composed of multiple processors working in concert with one another as will be appreciated by one of ordinary skill in the art. Also included is a non-volatile or read only memory 704 which is advantageously used for static or fixed data or instructions, such as BIOS functions, system functions, system configuration, and other routines or data used for operation of the server 700 .
[0056] Also included in the server 700 is random access memory 706 , suitably formed of dynamic random access memory, static random access memory, or any other suitable, addressable memory system. Random access memory provides a storage area for data instructions associated with applications and data handling accomplished by the processor 702 .
[0057] A storage interface 708 suitably provides a mechanism for volatile, bulk or long term storage of data associated with the server 700 . The storage interface 708 suitably uses bulk storage, such as any suitable addressable or serial storage, such as a disk, optical, tape drive and the like as shown as 716 , as well as any suitable storage medium as will be appreciated by one of ordinary skill in the art.
[0058] A network interface subsystem 710 suitably routes input and output from an associated network allowing the server 700 to communicate to other devices. The network interface subsystem 710 suitably interfaces with one or more connections with external devices to the server 700 . By way of example, illustrated is at least one network interface card 714 for data communication with fixed or wired networks, such as Ethernet, token ring, and the like, and a wireless interface 718 , suitably adapted for wireless communication via means such as WiFi, WiMax, wireless modem, cellular network, or any suitable wireless communication system. It is to be appreciated however, that the network interface subsystem suitably utilizes any physical or non-physical data transfer layer or protocol layer as will be appreciated by one of ordinary skill in the art. In the illustration, the network interface 714 is interconnected for data interchange via a physical network 720 , suitably comprised of a local area network, wide area network, or a combination thereof.
[0059] Data communication between the processor 702 , read only memory 704 , random access memory 706 , storage interface 708 and the network subsystem 710 is suitably accomplished via a bus data transfer mechanism, such as illustrated by bus 712 .
[0060] Suitable executable instructions on the server 700 facilitate communication with a plurality of external devices, such as workstations, document processing devices, other servers, or the like. While, in operation, a typical server operates autonomously, it is to be appreciated that direct control by a local user is sometimes desirable, and is suitably accomplished via an optional input/output interface 722 as will be appreciated by one of ordinary skill in the art.
[0061] In operation, a user associated with the user device 504 accesses the computer network 502 via a suitable browser application. Preferably, the server 508 hosts a web site accessible via the computer network 502 . In accordance with one embodiment of the subject application, the user device 504 displays the web site hosted by the server 508 , inclusive of a plurality of various coasters, suitably adapted for imprinting with user specified indicia. The user then navigates the web site, via the web browser operative on the user device 504 , to view the various coasters available.
[0062] The user is then prompted, via any suitable means, to select at least one coaster for purchasing. Once the desired coaster is selected by the user, the server 508 then prompts the user to select a standard coaster or to customize the selected coaster. When a standard coaster is selected, the user is then prompted to select a quantity. The quantity is then used to calculate a cost associated with the coaster. The user then selects a desired shipping method and costs associated therewith are added to the total. Once the coaster costs and shipping costs are calculate, taxes, if any, are added to the final costs. The user is then prompted to create an account on the server 508 . As will be appreciated byt hose skilled in the art, suitable account information includes, for example and without limitation, a username, password, user address, contact information, billing data, or the like. This account data is then stored in the data storage device 510 for future use, e.g., should the user desire to purchase additional coasters, modify an order, cancel an order, or the like.
[0063] The user is then prompted to select a payment method. Payment is capable of being made via credit card, pre-paid account, account billings, wire transfer, or the like. Once payment is received by the server 508 , a receipt is generated and forwarded to the user via the computer network 502 . Thereafter, the coasters are manufactured and shipped to the customer.
[0064] When the user desires to customize the coasters, the user is prompted to customization parameters. For example and without limitation, the user is capable of uploading a logo, a text phrase, or other indicia for incorporation into the coasters. The customization data is then stored in the storage device 510 , along with the identification data received from the customer. It will be appreciated by those skilled in the art that the type of customizing indicia will vary the costs associated with the coaster accordingly. For example, when a logo or other graphical indicia is selected by the user for incorporation into the coaster, the colors, complexity, size, and the like, will all have impacts on the costs associated with producing the coasters. The price is then calculated, as set forth above, in accordance with shipping and taxes, and the user is prompted to select a payment method. Once the payment has been received by the server 508 , a receipt is returned and the coasters are manufactured and shipped to the user.
[0065] The skilled artisan will appreciate that the subject system 100 and components described above with respect to FIG. 1 , FIG. 2 , FIG. 3 , FIG. 4 , FIG. 5 , FIG. 6 , and FIG. 7 will be better understood in conjunction with the methodologies described hereinafter with respect to FIG. 8 . Turning now to FIG. 8 , there is shown a flowchart 800 illustrating a method for providing targeted advertising indicia on beverage holder coasters in accordance with one embodiment of the subject application. Beginning at step 802 , the server 508 receives, from a user device 504 via the computer network 520 , selection data representative of at least one selected beverage holder coaster. Preferably, the use selects one of a plurality of beverage coasters that are displayed on a web browser of the user device 504 .
[0066] The user is then prompted, via the user interface of the user device 504 , at step 804 to upload customization indicia for incorporation onto the selected beverage coaster. Such customization indicia includes, for example and without limitation, a logo, trademark, graphical image, text, or the like. In accordance with one embodiment of the subject application, the customization indicia is representative of an advertisement desired by the user. At step 806 , the server 508 receives the customization indicia via the computer network 502 . The server 508 further receives user identification data at step 808 corresponding to account information associated with the user. It will be understood by those skilled in the art that suitable account information includes, for example and without limitation, a username/password, address information, contact information, billing information, and the like. In accordance with one embodiment of the subject application, the identification data is received in conjunction with the creation of a new user account on the server 508 . In accordance with another embodiment of the subject application, the identification data corresponds to login data used by the server 508 to retrieve user information previously stored.
[0067] The identification data and the associated customizing indicia are then stored in the associated data storage device 510 of the server 508 at step 810 . Preferably, the data stored on the storage device 510 further includes data representing the selected beverage coaster in association with the user information and the uploaded customization indicia. At step 812 , a graphical representation is generated representing the selected beverage coaster and the corresponding customization indicia. Preferably, this graphical representation is an image of the selected coaster incorporating the customization indicia displayed on the user interface associated with the user device 504 . User acceptance of the displayed image is then received via the computer network 502 by the server 508 at step 814 .
[0068] The server 508 then calculates the costs associated with the production of the selected coaster at step 816 . Thereafter, the user is prompted to select a payment method, e.g., pre-paid account, billing account, wire transfer, credit card or the like. Once the server 508 has received the payment data, a receipt is returned to the user. Thereafter, the user confirms the charges and the coasters are ready for production. It will be appreciated by those skilled in the art that the costs calculated are determined by the server 508 based upon the desired quantity, the size of the indicia, the color or colors associated with the indicia, the type of font contained in the indicia, and the like.
[0069] The skilled artisan will appreciate that the beverage holder coaster described above and illustrated in the examples of FIGS. 1-4 is capable of use in a variety of beverage holder settings. Preferably, the coaster is adapted for use in motorized vehicles, such as, for example and without limitation, airplanes, automobiles, light-trucks, vans, buses, tractor-trailers, motorboats, and the like, as well as used in non-motorized vehicles, including, for example and without limitation, sailboats and the like. While explained herein as emplaced in a beverage container located in a motor or non-motor vehicle, the skilled artisan will appreciate that the coaster is equally capable of use in home facilities, restaurants, airports, offices, and the like. As will be appreciated by those skilled in the art, the construction of the beverage holder coaster in accordance with the present invention, particularly when combined with the alternate embodiments of the semi-permeable weave and impermeable bottom, also is capable of preventing unwanted condensation from marring glass, wood, marble, or metal countertops, desks, tables, furniture, and the like.
[0070] As will be further apparent to those skilled in the art, the method for providing targeted advertising indicia on beverage holder coasters illustrated by FIG. 8 is capable of use in any suitable applications, including without limitation, motorized and non-motorized vehicles, home facilities, restaurants, airports, offices, and the like.
[0071] The method of the subject application extends to computer programs in the form of source code, object code, code intermediate sources and object code (such as in a partially compiled form), or in any other form suitable for use in the implementation of the invention. Computer programs are suitably standalone applications, software components, scripts or plug-ins to other applications. Computer programs embedding the invention are advantageously embodied on a carrier, being any entity or device capable of carrying the computer program: for example, a storage medium such as ROM or RAM, optical recording media such as CD-ROM or magnetic recording media such as floppy discs. The carrier is also any transmissible carrier such as an electrical or optical signal conveyed by electrical or optical cable, or by radio or other means. Computer programs are suitably downloaded across the Internet from a server. Computer programs are also capable of being embedded in an integrated circuit. Any and all such embodiments containing code that will cause a computer to perform substantially the invention principles as described, will fall within the scope of the invention.
[0072] The foregoing description of preferred embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to use the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. | A self-absorbent, self-conforming disposable coaster for different sized beverage holders and a method for providing targeted advertising indicia thereon, are presented. The coaster is inserted into a beverage holder prior to placing a beverage container therein. Once the beverage has been consumed, or when the coaster has reached a predetermined saturation point, the coaster is discarded and a new coaster is inserted. Thus the beverage container holder remains clean. The exterior surface of the coaster is, preferably, coated with an impermeable material, to prevent liquids absorbed through the top surface from passing through the coater to the beverage holder. The coaster further allows for the emplacement of an advertisement indicia on its surface. Data representative of advertising indicia to be provided on beverage holder coasters is received via suitable communications network. | 6 |
The present invention generally relates to a stimulation electrode system in combination with a heat transfer pack useful for both heating or cooling a body and providing electrical impulses to the body.
Transcutaneous electrical nerve stimulation is useful, for example, in post-operative and chronic pain control, while muscle stimulation is useful, for example, in maintenance and development of muscle tissue and has a particularly important function in sports medicine.
The treatment of localized injury or pain which may be caused by torn muscles and connective issues has been therapeutically treated by a heating or cooling of the sprained or strained muscle tissues. Hot and cold thermal packs are used to speed and enhance the healing process, and some treatment regimes may include the alternation of hot and cold applications to stimulate the healing process.
Holders, pouches, bags and the like have been utilized in combination with heating pads, hot water bottles, and other available hot/cold packs to serve as a barrier between the thermal pack and the user's skin.
Thus, the holder of the hot/cold packs provides a barrier which may be used to protect the user's skin from injury. Such a hot or cold body pack is described in U.S. Pat. No. 5,016,629.
Another important treatment for both pain control and muscle tone includes transcutaneous muscle stimulation as hereinabove noted.
Electrodes suitable for use in nerve and muscle stimulation preferably provide a uniform electrical coupling across the skin for electrical interface.
Prior art electrodes have utilized a number of conductive elements, such as carbon impregnated rubber and vinyl, as well as metallic foils.
However, a useful electrode must be flexible in order to accommodate relative movement of the patient's skin therebeneath.
In order to electrically couple the electrode to the skin, prior art devices have utilized many types of conductive electrolytes, both in the form of fluids and gels.
One type of electrode used for temporary application of muscle stimulation includes a flat, smooth contacting surface with a separate conductive cream or gel applied to the skin to electrically couple the electrode thereto. Experience with this system has shown that the cream or gel is messy to use and remove and the electrodes are not suitable for curved body parts. After use, the cream or gel must be cleaned or washed from the skin and electrode.
Another type of electrode most suitable for longer term application of electrical stimulation or monitoring includes a flexible conductive fabric or material.
Typically, this type of electrode includes a woven, knit or mesh material with a gel electrolyte impregnated therein in order to improve electrical conduction within the electrode.
In most instances, this conductive gel is adhesive in nature so that it may perform a dual function by both electrically coupling the electrode to the body and adhering the electrode to the body. A typical electrode of this kind is disclosed in U.S. Pat. No. 4,708,149 and U.S. Pat. No. 4,722,354. These electrodes include a conductive fabric with a flexible conductive adhesive disposed on one side of the conductive fabric for adhering the flexible transcutaneous electrical nerve and/or muscle stimulation electrode to the skin of a patient.
While this type of electrode is effective, a great number of electrodes may be required to provide long term treatment for certain injuries, such as those incurred in sports.
Since most of the known electrodes are disposable in nature and useful for only relatively short periods of time, due to removal for body hygiene, a considerable expense may be anticipated in the treatment of a patient.
The present invention is directed to an electrical stimulation heat/cold pack in which the electrical distribution portion of the electrode and heat/cold pack is reusable and, in fact, washable. Importantly, the heat/cold pack in accordance with the present invention is configured for both heating and cooling applications. In combination therewith and in accordance with the present invention, a separate adhesive electrically conductive pad is used to couple the "dry" heat/cold pack to the skin. Thus, only an expendable gel pad material need be disposable throughout the treatment of the patient. In addition, one embodiment of the present invention also enables the use of a plurality of electrodes, which may be of diverse size, in combination with a support member with spacing between electrodes selected and adjusted as may be preferred, depending on the use and application of the system.
SUMMARY OF THE INVENTION
An electrical stimulation body pack, in accordance with the present invention, generally includes a flexible pouch including means for containing a heat transfer medium and means for positioning and holding the flexible pouch against a body part.
A flexible, electrically conductive electrode, attached to the nonconductive pouch includes a lead wire for electrically connecting the patch to an electrical stimulator. More particularly, a plurality of flexible conductive electrodes may be attached to the pouch material, each being separately connected to electrical lead wires. The pouch and the flexible conductive electrodes may be formed from a washable material, thus enabling repeated reuse of this equipment in accordance with the present invention. In addition, the pouch may include a loop material and the electrodes may include hook means for enabling the electrodes to be disposed on either side of the pouch and at various positions.
The electrode of the present invention may include a separate conductive patch and an electrically conductive gel for releasably coupling the flexible conductive fabric patch to the body part with the electrically conductive gel being removable from the flexible conductive fabric patch. Thus, the conductive gel in accordance with the present invention is a separate and disposable item.
Since the conductive gel is not disposed within interstices of the fabric and bound to the fabric, a clean separation of the patch from the conductive gel is effected. In addition, because the gel has dimensional integrity, it cleanly separates from the body part. Hence, no separate cleaning or washing of the body part is necessary as is required by prior art devices.
In another embodiment of the present invention, the flexible conductive fabric patch, or patches, may be sewn to the pouch, and the lead wire includes a plurality of electrically conductive strands with the latter sewn to the flexible conductive fabric patch. This embodiment may be preferred when the pack is intended to be used solely for cooling applications only or solely for heating applications.
To facilitate coupling of the patches to an electrical stimulator a separate connector or snap may be used to join the lead wire to the output line or lines from the electrical stimulator.
Alternatively, the conductive fabric patch may be glued to the nonconductive fabric and the lead wire glued to the conductive fabric patch.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will be better understood by the following description when considered in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective view of an electrical stimulation heat/cool pack in accordance with the present invention;
FIG. 2 is a cross-sectional view of the electrical stimulation heat/cool pack shown in FIG. 1;
FIG. 3 is a perspective view of the embodiment shown in FIG. 1 as it may be disposed on a body part;
FIG. 4 is a cross-sectional representation of conductive patch shown in FIG. 1;
FIG. 5 is a perspective view, partially broken away, of a gel pad in accordance with the present invention; and
FIG. 6 is a figure showing release of the conductive fabric patch from the skin of the user.
DETAILED DESCRIPTION
Turning now to FIGS. 1-4, there is shown an electrical stimulation heat/cool pack 10 which generally includes a fabric pouch 12 formed from a nonconductive material and flexible conductive electrode patches 14 attached to the pouch 12. Straps 20, 22 provide a means for positioning and holding the nonconductive fabric 12 against a body part, such as a back 26, as shown in FIG. 3. Loops 26, 28 disposed on opposite sides 12a, 12b of the pouch 12 enable either side 12a, 12b to be compressed against a body part depending on whether a hot or cold application is desired as will be discussed hereinafter in greater detail.
The pouch 12 construction, as well as the straps 20, 22 may be made in accordance with the teachings of U.S. Pat. No. 5,016,629, which is incorporated herein by this specific reference thereto.
A heat transfer medium 29 may include a plurality of individual packets or one packet suitable for retaining heat or cold and be comprised of any suitable material as is well known in the art.
Both sides 12a, 12b of the pouch 12 are preferably formed from a velvet loop material. This enables the patches 14 to be positioned at any selected location on either side 12a, 12b of the pouch 12 by means of hooks 30, see FIG. 4.
When the patches 14 are disposed on one side 12a, the loops 26 are utilized with the straps 20, 22 to secure the heat/cold pack 10 against a body part. Alternatively, when the patches 14 are disposed on the other side 12b of the pouch 12, the loops 26 are utilized with the straps 20, 22 to secure the heat/cool pack 10 against a body part.
For use with a heat transfer medium 29, that has been cooled, a thin liner 32 is disposed under the velvet loop material on side 12a of the pouch 12. This thin layer 32 may be a plastic material in order to act as a moisture barrier for preventing condensation on the cooled heat transfer medium from passing through the velvet loop material and in the patches 14.
The opposite side 12b of the pouch 12 is utilized for heat application, ie when the heat transfer medium 29 is heated. In order to prevent skin burn, an insulated layer 34 is provided under the velvet loop material on side 12b of the pouch 12.
Thus the present invention is useable as both an ice pack stimulator as well as a heat pack stimulator with the repositioning of the patches 14 on sides 12a and 12b of the pouch 12.
While a plurality of conductive fabric patches are shown in FIGS. 1 and 2, a single patch may be utilized depending upon the circumstances of treatment. The array of patches shown in FIG. 1 is only representative in nature. However, it is important to note that the fixing of the conductive fabric patches 14 to the nonconductive fabric 12, via the velvet loop material and the hook 30, overcomes the problem associated with using multiple sets of electrodes. The use of loop material and hooks 30 enables easy position changes of the patches with respect to each other and the pouch 12.
When the pouch is to be used for the application of, for example, only a cooled medium or only a heated medium, it may be preferable that the patches 14 may be fixed to the pouch 12 by other suitable bonding methods, such as by adhesive or by sewing.
A spaced apart, fixed positioning of the electrode eliminates the cumbersome and unwieldy necessity of separate attachment of electrodes to a body. In addition, with single or smaller sets of electrodes, migration during prolonged stimulation may occur and thus cause difficulty in ensuring consistent placement of the electrodes with respect to one another.
More particularly, the nonconductive fabric pouch 12, in accordance with the present invention, may be formed from any suitable material which is preferably machine washable. The function of the nonconductive pouch 12 is to provide a support for the conductive patches 14 and prevent any unwanted electrical communication between the electrodes or contact with the electrodes when the patches are placed in contact with the body, and simultaneous transfer heat or cold to the body. Also important is the function of the pouch liner 32 in providing a moisture barrier and insulation 34 in preventing skin burn.
The liner, or moisture barrier layer 32, provided over the nonconductive fabric 12, prevents the entry of moisture as may be present in the environment of use as hereinabove discussed. Any suitable barrier such as polyurethane may be utilized.
The straps 20, 22, which are preferably formed of an elastic material, are preferably separate from the pouch 12 in order to facilitate the reversal of the pack 10, however they may be sewn to the pouch 12 in certain applications. As shown, the straps 20, 22 may be secured on a body by means o f a hook 36 and pile 38 arrangement, as is well known in the art. The purpose of the straps 20, 22 is to ensure contact of the patches 14 with the gel 16 over a long duration of time and insure good thermal transfer between the body and the heat transfer medium 29 in the pouch 12. Further, the straps 20, 22 provide additional pressure for insuring electrical contact between the conductive patches 14 and the body part through the gel 16.
In addition, the straps 20, 22 provide a means for compressing the body part as may be advantageous for use with sports injuries, for example. Also when properly sized, such compression straps 20, 22 may be useful for support of a body part, such as, for example, a low back support. (See FIG. 3)
In muscle stimulation applications, the electrodes have a tendency to migrate and hence prior art utilization of multiple separate electrodes requires constant monitoring in order to insure proper placement of the electrodes. The present invention overcomes this disadvantage by maintaining proper relative placement of multiple electrodes.
Turning to FIG. 4 and 5, the conductive fabric patches 14 may be formed from any suitable flexible, conductive fabric or material, but preferably are formed from a stretchable conductive material such as that described in U.S. Pat. Nos. 4,708,149 and 4,722,354, which are incorporated herewith in toto by specific reference thereto.
Conductivity of the fabric patches is provided by individual conductive fibers 40 (see FIG. 4). A particularly suitable fiber is one manufactured by Bekaert of West Germany. This fiber, a blend of 20% 316 stainless steel and 80% polyester, can be latch-needle, honeycomb knitted to a density of about 3.5 lbs. per sq. yd., producing a conductive, double-stretch knit. Naturally, other conductive fabrics may be utilized in the present invention.
Because the patches 14 are also machine washable, along with the pouch 12 and the straps 20, 22, the entire pouch 12 may be cleaned and reused, without disturbing the placement of the patches 14 on the pouch 12, which provides favorable cost benefits to the patient undergoing long term treatment as well as insuring proper electrode placement throughout the long term treatment.
As also shown in FIG. 4, a lead wire 42 comprises a plurality of connective strands 44 which may be of stainless steel. The strands may be sewn in place onto the conductive patches 14 and may be fanned if necessary to provide more intimate contact with the fibers 40. The compression, upon sewing of the strands 44, to the conductive patches 14 provides sufficient electrical contact therebetween to enable electrical impulses to be distributed over the entire area of patch 14. Each of the lead wires 42 are electrically connected to a remotely disposed electrical stimulator (not shown).
The sewing of the lead wire is facilitated by utilizing a large plurality of strands, such as for example, about 1000 to about 1200 strands of 8 micron stainless steel. Alternatively, the strands 44 may be adhered to the conductive patches with a suitable conductive glue thereby enabling the assembly of the electrode without any sewing steps. It should also be appreciated that any suitable electrical connection may be utilized in order to deliver an electrical charge to the individual electrode patches 14.
FIG. 5 shows a disposable gel pad 56 in accordance with the present invention, which should be formed in a sufficient size to cover the patches 14 but not overlap with adjacent fabric patches.
A suitable conductive gel adhesive 56 is manufactured by Valleylab, Inc. of Boulder, Color., under the name "Polyhesive®". The pads 56 may be formed by molding a liquid into a gel-like material.
In accordance with the present invention, the gel pad may have an overall thickness of between about 0.020 inches and about 0.100 inches.
A separate gel importantly enables the patches 14 and pouch 12 to be removed from the gel as shown in FIG. 6, thereby facilitating reuse of the patches 14 and pouch 12 without the necessity of scraping or removing gel therefrom. In addition, in prolonged use, as hereinabove mentioned, the patches 14 and support pouch 12 may be washed as necessary between use.
Although there has been hereinabove described a specific arrangement of an electrically stimulated heat/cool pack with moveable electrode patches in accordance with the present invention, for the purpose of illustrating the manner in which the invention may be used to advantage, it should be appreciated that the invention is not limited thereto. Accordingly, any and all modifications, variations, or equivalent arrangements which may occur to those skilled in the art, should be considered to be within the scope of the present invention as defined in the appended claims. | An electrical stimulation heat/cool pack includes a nonconductive pouch and straps for positioning and holding the nonconductive pouch against a body part. Flexible conductive fabric patches may be removeably attached, or permanently fixed, to the nonconductive pouch along with lead wires for electrically connecting the fabric patches to a remote pulse generator. An electrically conductive adhesive gel pad is provided for releasably coupling the flexible conductive fabric patch to the body part. | 0 |
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to a burner unit for the singeing of flat textile structures or the like, in particular a burner unit for singeing machines having a combustion chamber and one or more ramp stones forming one or more singe slits, the combustion chamber being fed by preferably two or more parallel burner slits from a gas mixture chamber.
A singeing machine provided with such a burner unit is known from EPO 140 181. It assures a particularly high uniformity of the singeing flame over the entire operating width of the burner unit. Measures of optimal gas mixing and of quieted feed into the region of the burner slit contribute to this, in addition to a cleaning of the burning gas. The ramp stones which, arranged in front of the slit, are also developed as to avoid disturbing influences on the desired stable flame. This is concretely established by a sequence of wide and narrow regions in front of the flame emergence place of the singe slit.
From Federal Republic of Germany Patent 22 13 631, it is furthermore known to provide the singe slit of a singeing machine with a course which differs from linear gas-feed/flame-formation; the singe slit is bent upward by about 30° with respect to the horizontal and continues upward into a convexly curved surface of the ramp stone. In this way, the singeing flame, supported by the suction stream of a suction bell is deflected upward. The flame formed in this way exerts a singeing action on the textile structure pulled over the edge of a table. This very gentle singeing is particularly suitable for the leveling of protruding fibers and for the repair of fabrics with broken filaments. The table can be displaced and locked horizontally and vertically with respect to the adjustment of the closeness of the singeing flame.
SUMMARY OF THE INVENTION
The object of the present invention is further to develop a burner unit of this type for singeing machines with respect to the forming and direction of the singeing flame in such a manner that the possibilities of individual adaptation to the most different circumstances which occur in practice are expanded by simple means.
In order to achieve this object, the invention provides that a ramp stone be adjustably movable in order to change the singe slit and/or the combustion chamber. In this way, the mouth of the singe slit can be shaped with respect to its "lips". This refers, with respect to displacement, not solely to the width of the slit but also to the cross-sectional shape of the combustion chamber which is determined primarily by the ramp stones. Thus, at the same time, the slit width of the narrow channels can accordingly be changed. This additional parameter considerably enriches the desired variation. Furthermore, the invention provides that the ramp stone to mounted on a ramp-stone support and that the ramp-stone support be movable for the displacement of the ramp stone. In this way, the well-proven replaceable connection between ramp stone and ramp-stone support can be retained; only the directly supporting region is displaceable towards the burner unit and lockable. Advantageously, one proceeds also here in the manner that the ramp stone is held by clamp on the ramp-stone support. Specifically, the displaceability is such that the ramp-stone support is pivotally mounted in front of the combustion chamber as seen in the direction of flow. The corresponding region is not only favorable for the arrangement of the means forming the pivot joint but also brings about an arrangement which is comparable to a sight leaf; the ramp stone moves in front of the burner slit or slits, constricting the singe slit to a greater or lesser extent. For optimizing, both ramp stones can be rotatably mounted in the manner described. With this type of burner unit of a singeing machine in which the gas mixing chamber is surrounded by a burner body which consists of two profiled parts of approximately U-shape in cross section, it is advantageous, with respect to the said pivot mounting, for one profiled part to have a pivot recess into which a pivot-joint projection of the ramp-stone support engages. The corresponding pivot-joint connection can extend practically over the entire operating width, so that the slit width of the singe slit is the same everywhere. Furthermore, it is the pivot-joint projection can be developed in the manner of a ledge. Such a ledge can be pushed overhead. With respect to the ledge which forms the pivot, it is furthermore proposed that it have a recess or flattening in the shape of a circular segment. This means that its head is cut back so that less "meat" is lost on the side of the profiled part. A sufficiently stable wall is retained towards the mixture distributing ledge. Accordingly, the pivot recess is adapted to the cross section of the ledge by a substantially straight bottom. Furthermore, the invention proposes that the singe slit be developed flush with the combustion chamber. Taking into account the path of the goods in front thereof, the singeing flame strikes at right angles against the goods which are conducted between two guide rolls. On the other hand, it may, however, be advantageous in certain cases for the singe slit to be developed at an angle to the combustion chamber. This opens up a more grazing direction of the singeing flame and thus a further possibility of very fine variation, also from the aspect of traveling in the direction of movement of the goods or opposite same. In order to obtain a so-called double-slit burner unit, it is therefore favorable for two ramp stones to be arranged opposite each other, forming the singe slit and the combustion chamber between each other, the front surface of the ramp stones facing the textile structure extending at an oblique angle to the linear direction of the combustion chamber. Furthermore, a development can be employed in which the ramp stones are developed protruding a different distance in the region of the singe slit. In this way, the alignment of the slit can be obtained with utilization of the protrusion of the one or other ramp stone. Finally, still another advantageous feature of the invention is that the second ramp stone in the direction of travel of the goods is developed extending backwards. Finally, there can also be used a development in which three ramp stones are present, a central ramp stone being stationary, they leaving the singe slits between them. With accordingly displaceability on both sides of the ramp stones, a shape of the singe slit which is independent from one another can be obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
With the above and other objects and other advantages in view, the present invention will become more clearly understood in connection with the detailed description of preferred embodiments, when considered with the accompanying drawings of which:
FIG. 1 shows the burner unit in a substantially diagrammatic side view, in accordance with the first embodiment;
FIG. 2 shows the same unit in approximately a half section;
FIG. 3 is an enlarged showing as compared with FIG. 2 of the region of the mixture distributing ledge and of the pivot mounting of the ramp-stone support;
FIG. 4 is a complete cross section through this burner unit further developed in the manner that both ramp-stone supports are rotatably mounted, as variant of the first embodiment;
FIG. 5 is a diagrammatic side view of the burner unit in accordance with the second embodiment;
FIG. 6 is a similar view in accordance with the third embodiment developed as double-slit burner unit, both singe slits being directed at an oblique angle in the same direction;
FIG. 7 is a burner unit in accordance with a fourth embodiment, the two singe slits being directed obliquely opposite each other;
FIG. 8 shows a burner unit in accordance with a fifth embodiment, also developed as double-slit burner unit, in which, however, the singe slits are so directed that they strike the passing web of goods at a right angle; and
FIG. 9 is a variant thereof, with a different silhouette of the combustion chamber.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The burner unit 1 of all embodiments shown including variants is a part of a singeing machine, which is not itself shown, such as known for instance from the not previously published German Utility Model Application 29 505 376.
The burner unit 1 can be displaced from a turned-off position into an operating position in the manner that its suction slit 2 is turned for singeing into the region close to a flat textile structure 3. The singeing flame 4 emerging from the singe slit 2 eliminates the fiber ends protruding from the center of the thread or flat textile structure 3.
The burner unit 1, as a general rule, has a width of several meters. At its ends, a gaseous mixture is introduced via feed lines into a distributor chamber 5 which can be clearly noted from the cross-sectional showing (FIG. 4). Via an adjoining constriction step 6 in the direction of emergence (arrow x), the gaseous mixture emerges with increased velocity of flow out of the distributing chamber 5 and enters into an adjoining gaseous mixture chamber 7 in which it expands. Here, the mixture quiets down, passing through a filter 8 on which solid impurities are separated out.
From the gaseous mixture chamber 7, the gaseous mixture flows through a horizontal gaseous mixture distributing ledge 9 into a combustion chamber 10. The corresponding passage takes place with uniform distribution over the entire width of the burner unit 1.
Two ramp stones 11, 12 arranged alongside of each other are determinative for the shape of the combustion chamber 10. The stones extend in the direction of travel of the goods (arrow y) lying one behind the other (see FIG. 4). The ramp stone at the bottom here bears the reference numeral 11.
As from the third embodiment, a third ramp stone designated 13 is interposed between said two ramp stones 11, 12, so that a double-slit burner unit is present.
Adjoining each combustion chamber 10 is a singe slit 2.
In accordance with the fifth and sixth embodiments, the singe slit 2 extends aligned with the combustion chamber 10. The center line 14 of the flame-jet there is perpendicular to the flat textile structure 3 passing with high speed in the direction of travel of the goods (arrow x) in front of the front surface 15 of the burner unit 1. The corresponding development is also conceivable for a burner unit 1 having only one singe slit 2. On the other hand, the double-slit version shown has the advantage of a spaced singeing and therefore one which takes place in two steps. The other embodiments show an arrangement of the said slit or slits 2 directed at an angle to the combustion chamber 10.
In accordance with the first embodiment, the center line 14 of the flame jet assumes a position oblique to the plane of the flat textile structure 3. It (14) forms an acute angle alpha of 45° with respect to the section of the flat structure 3 lying in front of the place of impingement 16.
The same applies also to the solution in accordance with the third embodiment, namely the double-slit version. The reference numerals have been applied accordingly.
A solution which employs the desired oblique course without, however, having to effect a change in direction between combustion chamber 10 and singe slit 2 consists therein that the two ramp stones 11, 12 which form the singe slit 2 and the combustion chamber 10 between them are developed with their entire front surface 15 in a corresponding oblique angle and the burner unit 1 itself is tilted into the oblique position, as can be noted from FIG. 5. In that case, also, the center line 14 of the flame jet forms the acute angle alpha of 45° with the linear extension of combustion chamber 10 and singe slit 2.
The fourth embodiment shows a mixed form of the flame-jet direction on a two-slit version. The lower suction slit 2 extends in opposite direction at an angle of 45° to the plane of the flat textile structure 3. In this way, there is produced at the bottom a singeing which is directed in direction opposite to the direction of travel of the goods (arrow x) and at the upper singe slit 2 a substantially after-acting second, grazing singeing. Since this takes place locally and in a certain sense also spaced in time, a concentration of heat onto a single point is avoided despite the double singeing. Here, an individual manner of treatment for given materials can be obtained with rather simple means.
A burner modification which goes further in this direction is described in the following individual remarks:
The corresponding basic principle consists therein that a ramp stone is arranged in adjustable movable manner in order to change the singe slit 2 and/or the combustion chamber 10. In this way, the width of the slit can be varied. This can be done in infinitely variable manner. Although, in FIG. 1, a few steps a, b, c, indicated in the region of the mouth of the slit 2 have been entered as stepwise jumps, of the order of magnitude of, for instance 3 mm, 5 mm, and 6 mm, narrower or wider steps can also be selected.
The corresponding adjustment steps are indicated on the ramp stone 11 in dash-dot and dash-dot dotted lines aside from one position which appears in solid line.
FIG. 4 indicates a variant in which also the adjacent ramp stone, designated 12, is arranged for adjustable movement in the same manner.
The means for this adjustment can be noted in FIGS. 2 and 4, and with particular clarity in FIG. 3. As can be seen, the ramp stone 11 which results in the variation of the slot width of the singe slit 2, etc. is held on a ramp-stone support 17. This is done by means of an undercut 18, a ledge-like projection 19 of the ramp stone and remote from this spot by a clamp 20. These means are described in the prior art publication from which the present invention proceeds and are applied in analogous manner here. Between this fastening place which lies in the rear of the ramp stone 11 there are heat-insulating means 21 and an elastic intermediate layer 22. Furthermore, cooling water can circulate within the ramp-stone support 17.
The ramp support 17 is itself in movable association with a burner body 23 which practically forms the housing of the burner unit 1. The displaceability results via a pivot bearing. Its geometrical axis z extends parallel in space to and in the vicinity of the centrally located gaseous mixture distributor ledge 9. To this extent, the bearing place, seen in the direction of flow of the gaseous mixture, is located clearly in front of the combustion chamber 10. The direction of flow is identical to the direction of emergence designated x.
For the arrangement of the ramp-stone support or supports 17 as close as possible to the combustion chamber, the head end of the burner body 23 leaves sufficiently large corner niches 24 on both sides of the horizontal longitudinal center plane E--E of the burner part 1. Two profiled parts 25 of essentially U-shaped cross section which surround the corresponding burner housing 23 with their U-opening directed opposite each other are shaped correspondingly and continue into wall sections 27 with due consideration of a funnel or notch-valley joint 26 which narrows down towards the gaseous mixture distributor ledge 9. On the outer side se these wall sections 27 of the profiled parts 25, there is in each case a pivot recess 28. Into it, there engages a pivot-joint projection 29 of the ramp support 17. The insertion can be effected through an open end of the pivot recess 28.
The pivot-joint projection 29 consists of a ledge-like development on the ramp support 17. The part producing the articulation is predominantly of circular cross section, namely cylindrical, except for a narrow support foot 30 to the corresponding narrow wall 31 of the ramp-stone support 17. The further exception consists of a recess or flattening 32 of the ledge having the shape of a circular segment. The recess lies outside the diameter D--D of the pivot-joint projection 29 which extends parallel to the narrow wall 31.
The pivot recess 28 is also adapted with respect to the flattening 32, to the cross section of the ledge and, accordingly, provided with a substantially straight bottom 33. Between flattening 32 and bottom 33, there remains a free space 34 which is necessary for the displaceability of the ramp stone or stones 11, 12. In order to avoid a planing action between the interrupted cylindrical outer surface of the ledge and the pivot recess 28, these transitions are convexly rounded transversely. The transverse roundings are designated 35. A slot 36 which permits the desired mobility of the ramp-stone support 17 is also present between the said narrow wall 31 and the opposite outer side of the wall section 27.
The profiled ledges 25 which form the burner body 23 are connected by means a clamping sleeve 37 which passes across the gaseous mixture chamber 7 and clamping sleeve screws 38 which act on the end on the outside.
The gaseous mixture distributor ledge 9 which is clamped in this way between the wall sections 27 is backed by guide ledges 39 on the inner side of the wall sections 27, without however lying with full surface thereon. Rather, the corresponding application is limited to the region of an outside thickening 40, which exerts a supporting action in the center. On the inside of the zone of thickening each of the guide ledges has a longitudinally extending passage ridge 41 which engages in position-securing fashion in a mating groove of corresponding shape on the outside of the distributing ledge 9.
Within the gaseous mixture distributing ledge 9 which can be provided with a flow equalizer (not shown), the stream of gas is split up. The inflow takes place via a number of centrally located, closely adjacent blind holes 42. The latter end in front of the narrow side of the distributor plate 9 lying in direction of flow. Transverse to the blind holes 42, a plurality of which are present, there extends, in the form of penetrations on the outer side in each case a longitudinal groove 43 which is open towards both broad sides of the distributor ledge 9. The longitudinal grooves act to equalize the pressure and are in fluid communication with burner slits 47 which produce a forking of the stream of gaseous mixture. Via these two rather narrow, parallel burner slits which result from the corresponding forking of the path, the gaseous mixture enters into the combustion chamber 10.
The combustion chamber 10 has a relatively long widened region at the start in the direction x, which region then passes into a short, narrow region 45. Adjoining this, the ramp stone 11, 12, 13, which are developed with silhouette symmetry in this respect, again form a widened region 46 so that approximately the same width as in 10, but of clearly reduced length, in order thereupon to again pass via a narrow region 47 into the beginning of the singe slit 2, which is of the same width as 45.
In accordance with the fifth and sixth embodiments narrow region 47 and singe slit 2 are practically identical. The mouth of the singe slit is beveled in all cases on the inner-edge side. The bevel amounts to about 45°. Also in all other embodiments the mouth is so widened in funnel shape in cross section, also in cases in which the ramp stones are developed protruding different distances in the region of the singe slit 2. With due consideration of the direction of travel of the goods (arrow y), the second ramp stone 12 is developed protruding backward in accordance with the first and third embodiments.
In accordance with the fifth embodiment, the ramp stones 11, 12 and 13 terminate practically at the same distance from the vertical extent of the flat textile structure 3. The same development is selected also with respect to the same variant of the fifth embodiment, only that, in that case, the initial portion of the combustion chamber 10 has a saw-tooth-like wall structure, designated 48, which produces an eddying of the foot of the flame in this region. The profiling shown extends over the entire width of the burner unit.
In accordance with the third embodiment, the ramp stone 11 protrudes forward, and the third ramp stone 13 present between it and the ramp stone 12 does so also. They protrude to the same extent.
From the showing of the fourth embodiment it is clear that the intermediate ramp stone 13 which acts in flame-jet diverging manner alone assumes an exposed position with respect to the two adjacent ramp stones 11, 12, which themselves protrude in the same vertical plane.
In all cases the central ramp stone 13 is stationary.
The ramp stones forming the front surface 15 of the burner unit 1 are drawn inward in trough-like manner at a distance from the edge. This trough-like, approximately trapezoidal cross-sectional structure forms an open chamber 49 which widens toward the flat textile structure 3 and is limited by edge ribs 50 and 51. With corresponding direction of the flame the heat is held here somewhat longer. The free ends of the edge ribs 50, 51 are also beveled.
With the exception of the version shown in the third embodiment, the third ramp stones 13 do not have a chamber 49 limited on its edge on both sides, at most one formed in combination with an adjacent edge, seated at the bottom in FIG. 6, of the first ramp stone 11. The corresponding chamber coming from two ramp stones is designated 49'.
With regard, now, to the second embodiment, such corresponding chambers are entirely absent. As a result of the 45° arrangement of the plane E--E of the burner unit 1, the ramp stone 12 which lies in the direction of travel of the goods (arrow y) is further in front, referred to a vertical cross-sectional plane E--E, than the ramp stone 11 located below it. The reference numerals are otherwise applied by analogy. With respect to the displacement of one or the other or both ramp stones, the detailed remarks made above apply by analogy.
A device V. sketched in FIG. 4, serves as displacement handle. It comprises a crank-actuatable screw spindle 52 which passes through a stationary bearing lug 53 which has a corresponding mating thread. With its free end, the screw spindle 52 engages on a arm 54 which extends transversely to the axis of the screw spindle. The arm acts as control arm rigidly connected with the ramp-stone support 17 which is mounted for swinging via z. The action between screw spindle 52 and the free end of the control arm takes into account the necessary joint mobility, for instance via spheres and slots.
With shortening spindle stroke, the ramp stone 11 is swung away from the plane E--E via ramp-stone support 17, with enlargement of the singe slit 2 and of the combustion chamber 10. The same applies in case of the joint mobility of the other ramp stone 12. In this way, a singeing which is excellently adapted to the particular case of treatment can be obtained.
In addition to the two singe slits 2 shown, three, four and more such slits can also be provided; the same is true with respect to the burner slits 44, that two and more distributor ledges 9 are clamped between the profiled parts 25, of course with adaptation of the clamping regions of the burner body 23. | A burner unit for the singeing of flat textile structures and the like, in particular a burner unit for singeing machines having a combustion chamber and ramp stones forming one or more singe slits, the combustion chamber being fed from a gaseous mixture chamber via preferably two or more parallel burner slits. A ramp stone is arranged adjustably movable for changing the singe slit and/or the combustion chamber. | 3 |
RELATED APPLICATION
[0001] The present application claims the benefit of prior filed co-pending U.S. Provisional Patent Application No. 61/158,964 filed on Mar. 10, 2009, the entire content of which is hereby incorporated by reference.
BACKGROUND
[0002] Refrigeration units, e.g., for refrigerated trucks or rail cars, typically include an internal combustion engine which drives a compressor of the refrigeration unit via a belt. Some refrigeration units also include means for plugging the unit into electrical mains (shore power) for powering the unit when the unit is not in transit. The shore power powers an electric motor which drives the compressor via a belt.
SUMMARY
[0003] In one embodiment, the invention provides a power system for powering a refrigeration unit. The power system includes a first set of connections, a second set of connections, and a third set of connections. The first set of connections are configured to receive power from a first power source, the first power source being a first high-voltage AC power source. The second set of connections are configured to receive power from a second power source, the second power source being a high-voltage DC power source. The third set of connections are configured to receive power from a third power source, the third power source being a second high-voltage AC power source. The power system couples the first power source to the refrigeration unit when power is received at the first set of connections, couples the second power source to the refrigeration unit when power is received at the second set of connections but not the first set of connections, and couples the third power source to the refrigeration unit when power is not available from both the first and second set of connections.
[0004] In another embodiment, the invention provides a power system for powering a refrigeration unit. The power system includes a first connection, a second connection, a third connection, and a power converter. The first connection is configured to receive power from a first power source. Where the first power source is a first high-voltage alternating current (AC) power source. The second connection is configured to receive power from a second power source. Where the second power source is a high-voltage direct current (DC) power source. The third connection is configured to receive power from a third power source. Where the third power source is a second high-voltage AC power source. The power converter is configured to supply power to the refrigeration unit. The power system couples the first power source to the power converter when power is received at the first connection, couples the second power source to the power converter when power is received at the second connection but not the first connection, and couples the third power source to the power converter when power is not available from both the first and second connections.
[0005] In another embodiment, the invention provides a system for powering a refrigeration unit coupled with a hybrid vehicle having a plurality of high-voltage batteries. The system includes a power system, a refrigeration control unit, and an engine. The power system is coupled to the plurality of high-voltage batteries and is configured to receive power from a shore power source. The refrigeration control unit is coupled to the power system, and receives an indication from the power system of the availability of power from the high-voltage batteries and the shore power source. The engine is also coupled to the refrigeration control unit. The refrigeration control unit links power from the power system to the refrigeration unit when power is available from the power system, and links the engine to the refrigeration unit when power is not available from the power system.
[0006] In another embodiment, the invention provides a method of powering a refrigeration unit. The method includes the acts of receiving at a first input a high-voltage DC power from a plurality of batteries of a hybrid vehicle, receiving at a second input a high-voltage AC power from an electric mains, connecting one of the first input and the second input to a power converter based on a position of a switch, the connecting act coupling one of the high-voltage DC power and the high-voltage AC power to the power converter thereby resulting in a coupled power, disconnecting the coupled power from the power converter when the position of the switch has changed, converting the coupled power into a second high-voltage AC power, and providing the second high-voltage AC power to the refrigeration unit.
[0007] The invention relates to systems and methods for powering a refrigeration or air conditioning unit used with a hybrid vehicle, such as a truck or bus. In one embodiment, the invention uses high-voltage power from the batteries of the hybrid vehicle to power the refrigeration unit, while maintaining the capability of using shore power or operating the compressor using an internal combustion engine when the power available from the batteries is not available.
[0008] In another embodiment, the invention provides a system for providing power to a refrigeration unit used on a hybrid vehicle. The system includes an accumulation choke, a PWM rectifier, and a frequency inverter. The accumulation choke is configured to receive a first AC power having a voltage range of about 150 to 600 VAC, a second AC power of about 150 to 600 VAC, and a DC power having a voltage range of about 263 to 408 VDC. The accumulation choke and PWM rectifier convert the received power into an intermediate DC power having a peak voltage of about 750 VDC. The PWM rectifier provides the intermediate DC power to the frequency inverter. The frequency inverter converts the intermediate DC power to a variable output AC power having a voltage of about 0 to 525 VAC and a frequency of about 0 to 100 Hertz (Hz). The frequency inverter provides the output AC power to the refrigeration unit.
[0009] In another embodiment, the invention provides a system for providing power to a refrigeration unit used on a hybrid vehicle. The system includes an accumulation choke, a PWM rectifier, and a frequency inverter. The accumulation choke is configured to receive an AC power having a voltage range of about 150 to 600 VAC and a DC power having a voltage range of about 263 to 408 VDC. The accumulation choke and PWM rectifier convert the received power into an intermediate DC power having a peak voltage of about 750 VDC. The PWM rectifier provides the intermediate DC power to the frequency inverter. The frequency inverter converts the intermediate DC power to an output AC power having a voltage of about 0 to 525 VAC. The frequency inverter provides the output AC power to the refrigeration unit. If the AC power and the DC power are not available, the refrigeration unit is driven by an internal combustion engine.
[0010] In yet another embodiment, the invention provides a method of providing power to a refrigeration unit used on a hybrid vehicle. The method includes providing to a power unit a first AC power from an external source, providing to the power unit a DC power from high-voltage batteries of the hybrid vehicle, determining if the first AC power is sufficient to power the refrigeration unit, using the first AC power to generate an output AC power if the first AC power is determined to be sufficient to power the refrigeration unit, determining if the DC power is sufficient to power the refrigeration unit, using the DC power to generate the output AC power if the first AC power is not sufficient to power the refrigeration unit and the DC power is sufficient to power the refrigeration unit, generating the output AC power from a belt driven alternator if the first AC power and the DC power are not sufficient to power the refrigeration unit, and providing the output AC power to the refrigeration unit.
[0011] In another embodiment, the invention provides a system for powering a refrigeration unit of a hybrid vehicle. The system includes an external source of power, a power unit for receiving AC power from the external source of power, a battery charger receiving AC power from the external source of power, and a plurality of batteries forming a high-voltage battery for powering the hybrid vehicle. The power unit modifies the AC power into an output AC power suitable to operate the refrigeration unit. The charger recharges the plurality of batteries.
[0012] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1A is a block diagram of a construction of a power system for a hybrid vehicle with a refrigeration unit.
[0014] FIG. 1B is a block diagram of an alternative construction of a power system for a hybrid vehicle with a refrigeration unit.
[0015] FIG. 2A is a schematic diagram of a construction of an accumulation choke and a full-control PWM rectifier for use with three-phase AC power.
[0016] FIG. 2B is a schematic diagram of a construction of an accumulation choke and a half-control PWM rectifier for use with three-phase AC power.
[0017] FIG. 3A is a schematic diagram of a construction of an accumulation choke and a full-control PWM rectifier for use with DC power.
[0018] FIG. 3B is a schematic diagram of a construction of an accumulation choke and a half-control PWM rectifier for use with DC power.
[0019] FIG. 4 is a block diagram of a construction of a system for powering a refrigeration unit of a hybrid vehicle.
[0020] FIG. 5 is a schematic diagram of a construction of a circuit of a power system for using AC or DC power to generate three-phase AC power.
[0021] FIG. 6 is a schematic diagram of a construction of a circuit for controlling the operation of the circuit of FIG. 5 .
[0022] FIG. 7 is an alternative construction of a power system for powering multiple systems.
[0023] FIG. 8 is a schematic diagram of another construction of a power system.
[0024] FIG. 9 is a schematic diagram of another construction of a power system.
[0025] FIG. 10 is a block diagram of another construction of a system for powering a refrigeration unit of a hybrid vehicle.
[0026] FIG. 11 is a schematic diagram of another construction of a circuit of a power system for using AC or DC power to generate three-phase AC power.
[0027] FIG. 12 is a schematic diagram of a construction of a full-control PWM rectifier, incorporating a pre-charge circuit, for use with three-phase AC power.
DETAILED DESCRIPTION
[0028] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof encompass direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
[0029] FIG. 1A shows a block diagram of a construction of a system 100 for powering a refrigeration unit 105 using power from a belt driven alternator 110 , from high-voltage batteries 115 of a hybrid vehicle, and from shore power 120 . A switch 125 selects which of the three power sources 110 , 115 , and 120 is used. In some constructions, the switch 125 is a manual switch, where a user selects which power source 110 , 115 , and 120 to use. In other constructions, the switch 125 is automatic, where a controller senses which power source(s) are providing sufficient power to operate the refrigeration unit 105 and selects the most appropriate power source to use. For example, in some embodiments, shore power 120 is used whenever it is available, followed by power from the high-voltage batteries 115 , and finally by power from the belt driven alternator 110 . In addition, the controller may control operation of an internal combustion engine used to drive the alternator, turning on the engine when there is insufficient power available from the shore power 120 or the high-voltage batteries 115 , and turning off the engine when there is sufficient power available from either the shore power 120 or the high-voltage batteries 115 , thus saving energy (i.e., fuel).
[0030] In some constructions, the power available from the belt driven alternator 110 is about 150 to 600 volts AC (VAC), the power available from the high-voltage batteries 115 is about 263 to 408 volts DC (VDC), and the power available from shore power 120 is about 150 to 600 VAC. In the construction shown, AC power is assumed to be three-phase, however the invention contemplates the use of single-phase AC power as well.
[0031] Depending on the position of the switch 125 , set either manually or automatically, the power from one of the power sources 110 , 115 , and 120 is applied a power converter 130 including an accumulation choke 135 , a pulse-width-modulated (PWM) rectifier 140 , and a frequency inverter 145 . The accumulation choke 135 is coupled to the PWM rectifier 140 . The accumulation choke 135 operates with the PWM rectifier 140 to convert/modify the power received from the belt driven alternator 110 , the high-voltage batteries 115 , or the share power 120 to a DC voltage having a maximum amplitude of about 750 VDC. The DC voltage is provided to the frequency inverter 145 which converts the DC voltage to a variable voltage of 0 to 525 VAC having a frequency of about 0 to 100 Hz, which is provided to the refrigeration unit 105 . In some constructions, the DC power from the PWM rectifier 140 is also used to supply a DC chopper for an electric heater. The DC chopper provides DC power having a variable voltage of about 0 to 750 V DC.
[0032] FIG. 1B shows a block diagram of an alternate construction of a system 100 ′ for powering a refrigeration unit 105 using power from a belt driven alternator 110 , from high-voltage batteries 115 of a hybrid vehicle, and from shore power 120 . Again a switch 125 ′ selects which of the three power sources 110 , 115 , and 120 is used. However, in the construction shown, the switch 125 ′ has multiple throws such that when power from the belt driven alternator 110 is selected, the alternator 110 is connected directly to the PWM rectifier 140 , bypassing the accumulation choke 135 . Except for the alternator 110 being connected directly to the PWM rectifier 140 , the operation of the system 100 ′ is the same as the operation of system 100 described above. The construction shown in FIG. 1B can be used when the inductance of the belt driven alternator 110 is great enough that the accumulation choke 135 is not necessary.
[0033] FIG. 2A shows a schematic diagram of a construction of the accumulation choke 135 and a full-controlled PWM rectifier 140 ′. The accumulation choke 135 includes a plurality of inductors 150 . The full-controlled PWM rectifier 140 ′ includes six insulated gate bipolar transistors (IGBT) 155 - 160 , each IGBT 155 - 160 having a diode 165 - 170 connected across its collector and emitter, and a capacitor 175 .
[0034] FIG. 2B shows a schematic diagram of a construction of the accumulation choke 135 and a half-controlled PWM rectifier 140 ″. The accumulation choke 135 includes a plurality of inductors 150 . The half-controlled PWM rectifier 140 ″ includes three insulated gate bipolar transistors (IGBT) 158 - 160 , each IGBT 158 - 160 having a diode 168 - 170 connected across its collector and emitter, three diodes 155 - 157 connected in an upper branch of the half-controller PWM rectifier 140 ″, and a capacitor 175 .
[0035] FIG. 3A shows a schematic representation of the accumulation choke 135 and a full-controlled PWM rectifier 140 ′ for use with DC input power from the high-voltage batteries 115 . The accumulation choke 135 and the full-controlled PWM rectifier 140 ′ include all the same components as described above with respect to FIG. 2A ; however, the DC input voltage is applied to each inductor 150 and the upper IGBTs 155 - 157 are not used (i.e., they remain open).
[0036] FIG. 3B shows a schematic diagram of a construction of the accumulation choke 135 and a half-controlled PWM rectifier 140 ″ for use with DC input power from the high-voltage batteries 115 . The accumulation choke 135 includes a plurality of inductors 150 . The half-controlled PWM rectifier 140 ″ includes three insulated gate bipolar transistors (IGBT) 158 - 160 , each IGBT 158 - 160 having a diode 168 - 170 connected across its collector and emitter, three diodes 155 - 157 connected in an upper branch of the half-controller PWM rectifier 140 ″, and a capacitor 175 .
[0037] FIG. 4 shows a block diagram of a construction of a hybrid vehicle system 200 including a refrigeration unit 205 . The system 200 includes, among other things, a 12 VDC battery 210 , a set of high-voltage batteries 215 , a vehicle controller 220 , a refrigeration unit controller 225 , a refrigeration power system 230 including a connection to shore power 240 , a refrigeration unit power switch 245 , and a generator set including an internal combustion engine 250 driving an alternator 255 . In some constructions, an internal combustion engine 250 drives a compressor and fans of the refrigeration unit 205 directly by one or more belts. In some constructions, an electric motor is powered by the shore power 240 and drives a compressor and fans of the refrigeration unit 205 directly by one or more belts.
[0038] A master switch 260 enables the entire system 200 . The power system 230 receives power from the shore power connection 240 and the high-voltage batteries 215 , and provides power, if available, from either the shore power connection 240 or the high-voltage batteries 215 to the refrigeration unit power switch 245 .
[0039] The vehicle controller 220 provides an indication to the power system 230 , via line 265 , that power is available from the high-voltage batteries 215 . The power system 230 provides to the refrigeration unit controller 225 , via line 270 , an indication that power is available from either the shore power connection 240 or the high-voltage batteries 215 , and is being provided to the refrigeration unit power switch 245 . The refrigeration unit controller 225 provides to the power unit 230 , via line 275 , an indication that the refrigeration unit 205 is on or off. The refrigeration unit controller 225 controls the refrigeration unit power switch 245 , switching between power provided by the power system 230 or, if power is not available from the power system 230 , power provided by the belt driven alternator 255 . If the refrigeration unit 205 is on, power is provided to the refrigeration unit 205 by the power system 230 if power is available from either the shore power connection 240 or the high-voltage batteries 215 . If power is not available from the power system 230 and the refrigeration unit 205 is on, the refrigeration unit controller 225 turns on the internal combustion engine 250 which drives, via a belt, the alternator 255 . The alternator 255 then provides power to the refrigeration unit power switch 245 , which is set, by the refrigeration unit controller 225 , to provide the power from the alternator 255 to the refrigeration unit 205 . In alternative constructions, there may be no alternator present in the system 200 , instead the internal combustion engine 250 drives a compressor and fans of the refrigeration unit 205 directly.
[0040] FIG. 5 shows a construction of a portion of the power system 230 . The system 230 includes an AC power connector 300 and a DC power connector 305 . The AC connector 300 includes three connections L 1 , L 2 , and L 3 for connecting three-phase shore power (if available) to the system 230 . The DC connector 305 includes a positive 310 and a negative 315 connection for connecting to the high-voltage batteries 115 . Each input line L 1 , L 2 , L 3 , 310 , and 315 is connected to the rest of the system 230 through a fuse FSUP 1 -FSUP 5 sized appropriately for the voltage and current received on its respective input line L 1 , L 2 , L 3 , 310 , and 315 . Each input line L 1 , L 2 , L 3 , 310 , and 315 is also connected to the power converter 130 through a normally-open relay 320 - 326 . As discussed below, when shore power is available, the normally-open relays 320 - 322 are closed to provide the AC shore power to the power converter 130 , and when shore power is not available and DC power from the high-voltage batteries 115 is available, the normally-open relays 323 - 326 are closed to provide the DC power to the power converter 130 . When the AC normally-open relays 320 - 322 are closed, the DC normally-open relays 323 - 326 are open, and when the DC normally-open relays 323 - 326 are closed, the AC normally-open relays 320 - 322 are open. In some constructions, an interlock module monitors relays 320 - 322 and 323 - 326 to ensure that only one of the relay groups 320 - 322 or 323 - 326 is closed at any time.
[0041] The system 230 also includes AC pre-charging circuits having normally-open relays 330 and 331 and resistors 332 and 333 , and a DC pre-charging circuit including a normally-open relay 334 and resistor 335 . The pre-charging circuits are used when power is initially applied to the power system 230 , and during a transition from AC power to DC power or from DC power to AC power. During a transition, the pre-charging circuits maintain power to the power converter 130 , and allow the AC or DC power to be completely removed before the DC or AC power, being transitioned to, is connected.
[0042] As discussed above with respect to FIGS. 1-3 , if available, AC or DC power is provided to the accumulation choke 135 and the PWM rectifier 140 of the power converter 130 . The accumulation choke 135 and the PWM rectifier 140 convert the AC or DC power to DC power having a maximum voltage of about 750 volts. The DC power is the provided to the inverter 145 which converts the DC power to three-phase AC power having a variable voltage of 0 to 525 volts and frequency of about 0 to 100 Hz. In the construction shown in FIG. 4 , this AC power is then provided to the refrigeration unit 205 via the refrigeration unit power switch 245 . In some constructions, the DC power from the PWM rectifier 140 is also used to supply a DC chopper for an electric heater. The DC chopper provides DC power having a variable voltage of about 0 to 750 V DC.
[0043] FIG. 6 shows a circuit 350 for controlling the application of AC or DC power to the power converter 130 for the system 230 shown in FIG. 5 . The circuit 350 includes an AC delay 355 having a normally-closed switch 360 and a normally-open switch 365 , a DC delay 370 having a normally-closed switch 375 and a normally-open switch 380 , and a plurality of coils 390 - 396 for closing corresponding normally-open relays 320 - 326 shown in FIG. 5 . A switch 400 selects either AC or DC power. In the construction shown, the switch 400 is a manual switch requiring an operator to select the AC or DC power. In some embodiments, the switch 400 is an automatic switch where AC power is automatically chosen if available, and if AC power is not available but DC power is available, DC power is automatically chosen. In other embodiments, DC power is automatically chosen if available and AC power is chosen if available when DC power is not available. In some embodiments, if the switch 400 is off, and neither AC nor DC power is available, an internal combustion engine drives the refrigeration unit directly when the refrigeration unit is on.
[0044] When the switch 400 is put into the AC position, power is provided to the AC delay 355 and to the AC pre-charge coil 395 . The power provided to the AC pre-charge coil 395 closes the AC pre-charge normally-open relays 330 - 331 ( FIG. 5 ) applying AC power through resistors 332 and 333 to the power converter 130 . After a delay period (e.g., five seconds), the AC delay 355 opens the AC normally-closed switch 360 and closes the AC normally-open switch 365 . When the AC normally-closed switch 360 opens, power is removed from the AC pre-charge coil 395 and the AC pre-charge normally-open relays 330 - 331 open. When the AC normally-open switch 365 closes, power is applied to the AC coil 396 and the AC normally-open relays 320 - 322 close providing three-phase AC power to the power converter 130 .
[0045] When the switch 400 is put into the DC position, power is provided to the DC delay 370 and to the DC pre-charge coil 391 , and to DC negative coil 390 . The power provided to the DC pre-charge coil 391 closes the DC pre-charge normally-open relay 334 ( FIG. 5 ) applying DC power through resistor 335 to the power converter 130 . The power provided to the DC negative coil 390 closes the normally-open relay 326 connecting the negative connection 315 from the high-voltage batteries 215 to the power converter 130 . After a delay period (e.g., five seconds), the DC delay 370 opens the DC normally-closed switch 375 and closes the DC normally-open switch 380 . When the DC normally-closed switch 375 opens, power is removed from the DC pre-charge coil 391 and the DC pre-charge normally-open relay 324 opens. When the DC normally-open switch 380 closes, power is applied to the DC coils 392 - 394 and the DC normally-open relays 323 - 325 close providing DC power to the power converter 130 .
[0046] FIG. 7 shows an alternative construction of a power converter 405 where multiple power converters 410 - 425 are employed for powering various devices such as a compressor motor 430 , an electric heater 435 , an evaporator fan 440 , and a condenser fan 445 .
[0047] FIG. 8 shows a schematic diagram of a construction of the power system 230 ( FIG. 4 ). When system power is turned on (switch 260 in FIG. 4 is closed), normally-open relay K 7 closes. If shore power is available, i.e., three-phase AC power is provided to L 1 , L 2 , L 3 , and a phase select module 450 receives power from normally-open relay K 7 and the AC power lines L 1 , L 2 , L 3 . The phase select module 450 then provides power to line 8 EA. The power on line 8 EA initiates a five second delay timer 455 and simultaneously powers coil P. The power to coil P closes normally-open relays P 1 and P 2 , and opens normally-closed relay P 2 . After five seconds, the five second delay timer 455 provides power to output MPT which is provided to the refrigeration unit controller 225 to indicate that power is available from the power system 230 ( FIG. 4 ). If the refrigeration unit controller 225 indicates that the refrigeration unit 205 is on, normally-open relay K 13 is closed providing power to coil MCA. The power to coil MCA causes normally-open relays MCA to close, supplying the AC shore power to the power converter 130 , which in turn supplies power to a condenser motor 460 (providing normally-open relays K 14 are closed).
[0048] If AC shore power is not available, normally-closed relay P 2 is closed. If the vehicle controller 220 ( FIG. 4 ) indicates that vehicle power is available, the vehicle controller 220 provides power to a five second delay timer 465 . After a five second delay, the timer 465 allows power to be applied to a coil T closing normally-open relay T 1 and providing power to output MPT, which is provided to the refrigeration unit controller 225 to indicate that power is available from the power system 230 ( FIG. 4 ). If the refrigeration unit controller 225 indicates that the refrigeration unit 205 is on, normally-open relay K 13 is closed, providing power to coil MCB. The power to coil MCB causes normally-open relays MCB to close, supplying the DC power from the high-voltage batteries 215 to the power converter 130 , which in turn supplies power to the condenser motor 460 (providing normally-open relays K 14 are closed).
[0049] If neither AC shore power nor DC power from the high-voltage batteries 215 is available, the output MPT to the refrigeration unit controller 225 is low and the refrigeration unit controller 225 starts the engine 250 which drives the refrigeration unit 205 directly.
[0050] FIG. 9 shows a schematic diagram of an alternative construction of a power system 500 .
[0051] FIG. 10 shows an alternate construction of a power system 505 . The system 505 includes a first AC power connector 510 , a second AC power connector 515 , and a DC power connector 520 . The first AC connector 510 includes three connections L 1 , L 2 , and L 3 for connecting three-phase power from the belt driven alternator 255 to the system 505 . The second AC connector 515 includes three connections L 1 ′, L 2 ′, and L 3 ′ for connecting three-phase shore power (if available) to the system 505 . The DC connector 520 includes a positive connection 525 and a negative 530 connection for connecting to the high-voltage batteries 215 to the system 505 . Each input line L 1 , L 2 , L 3 , L 1 ′, L 2 ′, L 3 ′, 525 , and 530 is connected to the rest of the system 505 through a fuse FSUP 1 -FSUP 8 sized appropriately for the voltage and current received on its respective input line L 1 , L 2 , L 3 , L 1 ′, L 2 ′, L 3 ′, 525 , and 530 . Each input line L 1 , L 2 , L 3 , L 1 ′, L 2 ′, L 3 ′, 525 , and 530 is also connected to the power converter 130 through a normally-open relay 535 - 544 . As discussed below, when shore power is available, the normally-open relays 538 - 540 are closed to provide the AC shore power to the power converter 130 , and when shore power is not available and DC power from the high-voltage batteries 215 is available, the normally-open relays 541 - 544 are closed to provide the DC power to the power converter 130 . When neither shore power nor DC power is available, the normally-open relays 535 - 537 are closed to provide AC power from the alternator 255 to the power converter 130 . Only one set of normally-open relays 535 - 537 , 538 - 540 , or 541 - 544 are closed at any time.
[0052] The system 505 also includes first AC pre-charging circuits having normally-open relays 550 and 551 and resistors 552 and 553 , second AC pre-charging circuits having normally-open relays 555 and 556 and resistors 557 and 558 , and a DC pre-charging circuit having a normally-open relay 560 and a resistor 561 . The pre-charging circuits are used when power is initially applied to the power system 505 , and during a transition between one input power to another to maintain power to the power converter 130 during the transition, and allowing the power being transitioned from to be completely removed before the power being transitioned to is connected.
[0053] As discussed above with respect to FIGS. 1-3 , if available, AC or DC power is provided to the accumulation choke 135 and the PWM rectifier 140 of the power converter 130 convert the AC or DC power to DC power having a maximum voltage of about 750 volts. The DC power is the provided to the inverter 145 , which converts the DC power to three-phase AC power having a voltage of 0 to 525 volts. In the construction shown in FIG. 4 , this AC power is then provided to the refrigeration unit 205 via the refrigeration unit power switch 245 .
[0054] FIG. 11 shows a circuit 600 for controlling the application of the first AC power, the second AC power, or the DC power to the power converter 130 for the system 505 shown in FIG. 10 . The circuit 600 includes a first AC delay 605 having a normally-closed switch 610 and a normally-open switch 615 , a second AC delay 620 having a normally-closed switch 625 and a normally-open switch 630 , a DC delay 635 having a normally-closed switch 640 and a normally-open switch 645 , and a plurality of coils 650 - 658 for closing corresponding normally-open relays 534 - 544 , 550 - 551 , 555 , 556 , and 560 shown in FIG. 10 . A switch 660 selects either the first AC power, the second AC power, or the DC power. In the construction shown, the switch 660 is a manual switch requiring an operator to select the power. In some constructions, the switch 660 is an automatic switch where the second AC power (shore power) is automatically chosen if available, and if the first AC power is not available but DC power is available, the DC power is automatically chosen. If neither the second AC power nor the DC power is available, the switch automatically chooses the first AC power. The circuit 600 operates similar to the operation of circuit 350 of FIG. 6 with the addition of a second AC power.
[0055] In some constructions, a liquid cooling system of the hybrid vehicle is used to cool one or more components of the power system 230 (e.g., the power converter 130 ) and/or one or more components of the alternator 255 (e.g., the belt driven alternator 110 ). In other constructions, a liquid cooling system of the refrigeration unit 205 is used to cool one or more components of the power system 230 and/or one or more components of the alternator 255 .
[0056] In some constructions, shore power is provided to a charging circuit, in addition to the power system 230 , for charging the high-voltage batteries 215 . In some constructions, the refrigeration unit 205 is operated exclusively using either DC power from the high-voltage batteries 215 or AC shore power 240 .
[0057] FIG. 12 shows a schematic diagram of an alternative construction of a full-controlled PWM rectifier 700 incorporating a pre-charging circuit 705 . The full-controlled PWM rectifier 700 includes six insulated gate bipolar transistors (IGBT) 155 - 160 , each IGBT 155 - 160 having a diode 165 - 170 connected across its collector and emitter, and operates the same as system 100 described above. The pre-charging circuit 705 includes a capacitor 715 , a resistor 720 , a diode 725 , and an IGBT 730 . The pre-charging circuit 705 operates to buffer a current surge encountered when switching from one power source to a second power source, and eliminates the need for the pre-charging and delay circuits described for the controllers above. The pre-charging circuit 705 operates by opening the IGBT 730 prior to transitioning the power source. Applying the second power source and removing the first power source while the IGBT 730 is open. The IGBT 730 is held open until the capacitor 715 is fully charged forcing current to travel through the resistor 720 . Once the capacitor 715 is fully charged, the IGBT 730 is closed.
[0058] Constructions of the invention are capable of being used in non-hybrid vehicles, receiving AC power from an alternator of the vehicle during operation of the vehicle and having a shore power connection for use when the vehicle is not operating.
[0059] Thus, the invention provides, among other things, systems and method for powering a refrigeration unit of a hybrid vehicle. | Systems and methods for providing power to a refrigeration unit or an air conditioner used on a hybrid vehicle. The system includes an accumulation choke, a PWM rectifier, and a frequency inverter. The accumulation choke is configured to receive a first AC power, a second AC power, and a DC power. The accumulation choke and PWM rectifier convert the received power into an intermediate DC power having a peak voltage. The PWM rectifier provides the intermediate DC power to the frequency inverter. The frequency inverter converts the intermediate DC power to an output AC power. The frequency inverter provides the output AC power to the refrigeration unit. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to coke ovens generally and, more particularly, to the recovery of naphthalene from coke oven by-product gas.
In a conventional light oil recovery plant, the oil condensate from the vapor to oil heat exchanger (primary light oil) is usually returned to the benzolized wash oil stream of the wash oil still. This minimizes the loss of wash oil and does not normally cause a significant increase in the naphthalene concentration in the debenzolized wash oil.
Such practice is carried out in plants in which a naphthalene scrubber or oil type final cooler is used in conjunction with the light oil plant. Frequently, an additional rectifying section is added to the still which strips only the naphthalene rich oil from the naphthalene scrubber or oil type final cooler with the total vapors from the wash oil still. Such practice greatly improves the removal of naphthalene.
The method of operation normally recovers about three times the amount of naphthalene removed in a conventional light oil recovery plant. For this reason, the wash oil condensed in the vapor to oil heat exchanger, which is in equilibrium with the vapor leaving the heat exchanger, contains approximately three times the concentration of naphthalene which this condensate from conventional equipment would contain. Calculations indicate a concentration of 15 to 18% naphthalene in this condensed wash oil. Even though the amount of this condensed wash oil is small, calculations indicate that the concentration of naphthalene in the debenzolized oil is increased approximately 0.4%. This value can be even higher if there is a significant mechanical carry-over from the wash oil still. This higher concentration of naphthalene in the debenzolized wash oil means a higher concentration of naphthalene in the debenzolized gas, with attendant problems due to plugging of the subsequent piping and equipment.
How the method of the present invention minimizes the naphthalene content of the debenzolized gas will be evident to those skilled in the art from the following description and drawing.
SUMMARY OF THE INVENTION
Primary light oil along with oil bled from a naphthalene scrubber or oil type final cooler is introduced into the top portion of a wash oil still.
For a further understanding of the invention and for features and advantages thereof, reference may be made to the following description and the drawing which illustrates a flow diagram of a system in accordance with the invention which is suitable for practicing the method of the invention.
BRIEF DESCRIPTION OF THE DRAWING
The drawing illustrates a flow diagram of an improved system for the removal of naphthalene from coke even gas in accordance with the present invention.
DETAILED DESCRIPTION
Referring to the drawing, oil from a naphthalene scrubber (not shown) flows in conduit 11 into a conventional wash oil still 13 which includes a group of twelve normal trays 15 for the stripping of light oil, and a group of five additional trays 17, above the normal trays 15, for the stripping of naphthalene. Steam enters the wash oil still 13 through conduit 19 about where shown in the drawing.
Oil vapors emerge from the top of the wash oil still 13 through conduit 21 and flow into a heat exchanger 23. Likewise, wash oil from conventional benzol washers flow in conduit 25 into a wash oil pump 27 which urges the wash oil through conduit 29 into the heat exchanger 23. The wash oil passes through the heat exchanger and flows therefrom in conduit 31 into a final heater 33 into which steam flows through conduit 35. From the final heater 33, the wash oil flows in conduit 37 into the wash oil still 13, at a location between the additional trays 17 and the normal trays 15.
Vapors are removed from the heat exchanger 23 and they flow in conduit 39 to a light oil rectifier (not shown). Also, primary light oil and condensed water flows from the heat exchanger 23 through conduit 41 into a primary light oil separator 43, from which water flows in conduit 45 to a suitable sump-type receptacle (not shown).
The primary light oil leaves the light oil separator 43 in conduit 47 and flows into a primary light oil tank 49. From the primary light oil tank 49, light oil is drawn by a primary light oil pump 51 through conduit 53 and is discharged from the pump 51 through a conduit 55 into either one of two conduits 29 or 57. Valve 59 in conduit 55 and valve 61 in conduit 57 control the flow of primary light oil from the primary light oil pump 51.
In accordance with the invention, the valve 59 is normally closed so that the light oil flows from the pump 51 through conduit 57 into the top portion of the wash oil still 13; entering at a level above the uppermost additional tray 17 in the still, as shown in the drawing.
Wash oil 63 collects in the bottom of the wash oil still 13 and is removed therefrom through conduit 65 connected to the suction of a wash oil pump 67. The wash oil pump 67 urges the wash oil through conduit 69 toward conventional wash oil coolers (not shown).
From the foregoing description of a system in accordance with the invention, which is suitable for practicing the method of the invention, those skilled in the art should recognize many important features and advantages thereof, among which the following are particularly significant:
That, by pumping primary light oil along with oil bled from a naphthalene scrubber or oil type final cooler to a level above the topmost additional tray of a wash oil still, the recycled naphthalene is kept out of the wash oil that flows to the benzol washers, whereby the naphthalene content of the debenzolized gas is a minimum; and
That, by so directing the primary light oil, with the resultant minimizing of the naphthalene content of the debenzolized gas, conventional problems of plugging of piping and equipment with naphthalene are practically eliminated.
Although the invention has been described herein with a certain degree of particularity, it is understood that the present disclosure has been made only as an example and that the scope of the invention is defined by what is hereinafter claimed. | A method for decreasing the naphthalene concentration in debenzolized light oil for greater naphthalene removal comprises pumping the primary light oil condensate and oil bled from a naphthalene scrubber or oil type final cooler to a level above the topmost additional tray in the top portion of a wash oil still. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional of pending U.S. non-provisional patent application Ser. No. 12/955,891, filed Nov. 29, 2010, and also claims priority to U.S. provisional patent application Ser. No. 61/265,327, filed Nov. 30, 2009, the entirety of which applications are incorporated by reference herein.
FIELD
[0002] The invention relates to pipe joints; more particularly, it relates to housing type pipe couplings for creating a sealed connection between coaxial groove ended pipes.
BACKGROUND
[0003] Housing type pipe couplings are widely used for axially joining two pipes together in such a way as to create a non-leaking union between the pipe ends. To prevent leakage, it is often desirable to prevent longitudinal, angular or rotational movement of the pipe ends within the coupling. This type of coupling is called a rigid coupling
[0004] Generally, the coupling is formed of arcuate housing segments which are fastened around the pipe ends to form a generally ring-like coupling housing. Typically, two segments are used, a pair of arcuate or generally semicircular housing halves, which are fastened together, often bolted together. Housing halves are substantially U- or C-shaped in longitudinal (axial) cross section to provide room for gasket pieces. In some models, the inwardly projecting peripheral edges of the housing halves, also referred to as shoulders, are shaped with keys or lands for interlocking within circumferential grooves now commonly provided in the pipe ends.
[0005] The coupling is secured as bolts are tightened through bolt holes until the key segments engage the circumferential grooves on the pipe ends, thus fastening the pipes together. Where the two housing halves meet around the circumference of the pipes, a mating structure is often used to lock one housing half to the other and to add stability. A rubber gasket, also frequently U-shaped or C-shaped in longitudinal (axial) cross-section, is typically arranged within the coupling in a gasket pocket formed by the U-shaped longitudinal cross section of the coupling housing, such that when the housing halves are tightened against the pipe ends the inner peripheral edges of the gasket are sealed against the pipe end portions.
[0006] Pipe ends are typically grooved using either a rolled or cut groove. A roll groove uses a rolling machine to displace the pipe walls forming a curved-edged groove containing a top corner and a bottom corner with the top corner to corner separation longer than the bottom corner to corner separation. The gasket sealing surface is the distance between the outer groove wall and the end of the pipe. A cut groove removes pipe material to form a groove with straight walls perpendicular to the longitudinal axis of the pipe and therefore has no rounded corners.
[0007] Whether rolled or cut, the groove manufacturing method must accommodate significant tolerances set by the AWWA C-606 for gasket sealing surface, groove width, groove diameter, and outer diameter. Any pipe coupling must also accommodate such dimensional variations.
[0008] Several designs are in use which attempt to minimize longitudinal, angular or rotational movement of the pipe ends within the coupling. Angled self-adjusting couplings and tongue and groove style rigid couplings have slightly oval variable internal circumferential diameters that shrink when a coupling is tightened until it grips the pipe ends eliminating angular movement caused by variable outer diameters and groove depths. However, as key width is smaller than groove width to facilitate easy installation within tolerances, space between the key and corresponding groove allows for some longitudinal movement when pipes are exposed to pressure thrusts or thermal movement. Through these designs, longitudinal movement is effectively reduced, but never completely eliminated.
[0009] It is believed that conventional or known ‘pre-assembled’ coupling designs have not taken hold in the industry because they appear to require complex in situ assembly. For many years, in situ assembly and installation of such couplings has been the rule because no better alternative appeared to be practical, and manufacturers were offering single piece round gaskets that purportedly stretched to fit the pipe at hand, or else were using multi-part gasket pieces. For instance one known pre-assembled coupling, using a single piece gasket, has advertised that assembly would be simple and easy, even in hard to reach places, because the gasket would purportedly stretch to accommodate the inserted pipe until it could be locked in and sealed by tightening the coupling's bolts. However, market research suggests that this design has not acquired a large following, and laboratory tests have shown what is believed to be an unacceptable seal failure rate, due either to incomplete or inconsistent assembly efforts on site, or to actual tears or cuts in the gasket itself believed to have been caused by the very difficult pipe insertion conditions, often requiring wild gyrations of the pipe and or the gasket to get them to come together at all.
[0010] Other conventional couplings are multi-part disassembled pipe coupling components that must be assembled on site, and in situ, typically overhead and in hard to reach places. These couplings use some kind of separate member either inside the upper and lower housing halves, or intermediate to the upper and lower housing halves, and typically integral with some kind of sealing material, in a reported attempt to apply some kind of four-way pressure to the pipe sealing material. Typically these separate members are fitted in grooves or channels provided in upper and lower arcuate housing halves. None of these previously disclosed couplings appear to be in current use, and there is reason to believe that none of them was ever effective at rigidly joining and sealing two pipe segments together. It is also believed that none of them actually deliver real four-way compression either very well, or very consistently.
[0011] None of these couplings use a one-piece sealing gasket, and none of them can be installed onto respective pipe ends without first being disassembled. Also none of the couplings have slidably engaging dihedral angular faces where bridge segments engage corresponding upper and lower housing segment faces, such that all four segments move towards the center of the coupling as the bolts and nuts are tightened.
[0012] Housing type mechanical couplings on grooved-end pipes usually have two housing segments, some kind of rubber gasket and two pairs of bolts and nuts as shown in FIG. 1 . When a coupling is installed on a pipe, it must be done in components, or a preassembled coupling unit must be broken down into those components. Then, if the sealing gasket is conventional one-piece gasket having an inner diameter smaller than the pipe it is designed to fit (see FIG. 2 ), it must be stretched and mounted it onto the pipe ends. Finally the two housing halves are placed on the gasket, bolts and nuts inserted, and the nuts fastened tight.
[0013] When a large number of such couplings are to be installed, higher work efficiency is required to shorten work time and to reduce installation costs. So assembly on site and gasket stretching, both time consuming and sometimes very difficult depending on conditions and location of joint, are inefficient and can become quite expensive.
[0014] What is needed, in order to raise efficiency of installation work, is a new type coupling to solve those technical problems, while at the same time still effectively eliminating longitudinal, angular and rotational movement of the pipe ends within the coupling housing.
SUMMARY
[0015] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended as an aid in determining the scope of the claimed subject matter.
[0016] A housing type mechanical coupling is disclosed. The coupling is installed onto respective pipe ends without first being disassembled. Such a coupling supplied direct from the factory in a pre-assembled configuration, all parts in place for installation, with only the nuts loose and ready for tightening, while still providing sufficient compression on the gasket to secure a leak-tight joint.
[0017] The rubber gasket used for the disclosed coupling preferably has an inner diameter (ID) B slightly larger than the pipe outer diameter (OD) and also has an inwardly protruding elastomeric ridge or pipe stop in the center as shown in FIG. 3 . Each respective pipe end thus abuts this protrusion and stops there when it is inserted with a preselected advantageous insertion depth.
[0018] Rubber gaskets for conventional couplings, whether one piece or multiple pieces, are designed with their ID B to be smaller than the pipe OD, as shown in FIG. 2 . This is done for reasons of supposed relatively higher sealing capability. If gasket ID B is actually slightly larger than the pipe OD as shown in FIG. 3 , the gasket can easily be mounted onto the pipe ends, or the pipe ends inserted easily into the gasket, but previously this was thought to reduce sealing capability.
[0019] To provide relatively uniform compression all around the pipe joint and thus optimize gasket sealing capacity, the disclosed coupling desirably has four housing segments as shown in FIG. 4 . There are upper and lower housing segments, and two bridges. In preferred embodiments, such as that shown in FIG. 5 , the bridges have dihedral angular faces that slidably engage corresponding upper and lower housing segment faces, such that all four segments move inwards towards the center of the coupling as the bolts and nuts are tightened.
[0020] In preferred embodiments, pipe coupling housing parts have axially inwardly projecting lands that mate with the end grooves in the pipes to be joined. FIG. 6 illustrates an embodiment of the disclosed coupling in a factory assembled form, with loose bolts and nuts, so that it can be installed directly onto the pipe without breaking it down into its components. After inserting pipe ends from both sides of the coupling, leak-proof installation is completed quickly and simply by fastening the nuts tight.
[0021] A pre-assembled pipe coupling for joining and sealing two grooved-ended pipe segments, without disassembling the coupling, is disclosed. This allows for more rapid assembly of pipe systems with more secure and more rigid pipe connections than previously possible. It also makes possible pipe system assembly in awkward, hard to reach locations, and it eliminates any risk of dropping parts during assembly, thus also saving system assembly time, and producing more uniform and consistent assembly results.
[0022] Each pre-assembled pipe coupling has a housing that includes upper and lower arcuate housing segments and left and right bridge segments. These bridge segments are disposed between the upper and lower segments. Each bridge segment has at least one set of dihedrally angled faces that engage corresponding faces each in the upper and lower housing segments. A simple embodiment of a bridge segment has two dihedral faces or planes intersecting one another at an angle that is advantageously between 75 and 105 degrees, and preferably about 90 degrees. Each of these two faces, say, for discussion, an upper bridge face and a lower bridge face, has a corresponding face in its respective upper or lower housing segment. Corresponding in this sense means roughly the same shape and area and also disposed at complimentary angles, as will be appreciated by those skilled in the art. Thus, drawing the upper and lower segments inwardly together along a first axis, such as by tightening the bolts of the coupling, creates a force along the intersection of the corresponding segment faces that, because of the angles, presses each bridge segment inward along a second axis roughly tangential to the first axis. It is believed that this four-way compression thus provided exerts a relatively and roughly uniform circumferential force around the coupling that rigidly joins and seals the two pipe segments.
[0023] All segments are desirably loosely pre-assembled with bolts and nuts into a coupling and all segments preferably each having radially inwardly projecting lands that mate with the end grooves in the pipes to be joined for more secure coupling.
[0024] Inside the pre-assembled housing there is a one-piece circular elastomeric sealing gasket. The gasket advantageously has an inward circumferential and centrally positioned elastomeric pipe stop, and this pipe stop has an inner diameter smaller than an outer diameter of the pipes to be joined, such that when pipe ends are inserted into each opening of the gasket, the pipe ends do not touch each other, but are stopped by and separated by the pipe stop.
[0025] The gasket has two circumferential sealing lips axially outward from the pipe stop, and each sealing lip has an inner diameter larger than the outer diameter of the pipe segments to be joined, so that pipe ends can readily and easily be inserted into the gasket with stretching the gasket either before or during insertion of the pipes, and without risk of tearing or dropping the gasket. When speaking of inner diameter for these sealing lips, the inner diameter is measured at the base of the lip, not the inner tip of the lip. The tips of these sealing lips are elastic and flexible and they do make contact with the pipe end, and are readily pushed inward to slide along the pipe as it is inserted, thus forming an excellent seal. The gasket body itself however does not stretch, because the pipe OD is smaller than the inner diameter of the gasket body, the pipe OD being roughly just smaller than the diameter of the gasket as measured at the base of the sealing lip.
[0026] The pre-assembled coupling is thus adapted to readily receive a grooved pipe end into each of both open ends of the coupling, with the two pipe ends thereby seated and sealed in the sealing gasket and separated only by the gasket pipe stop. Advantageously, the pipe stop has an inner diameter that is about the same as the inner diameter of the pipes to be joined, since any lesser pipe stop inner diameter will allow some pipe stop to protrude into the flow of whatever is passing through the pipes, while any greater inner diameter provides less and less of a resilient stop for the insertion of the pipes into the gasket and less seal between the pipes.
[0027] In some embodiments, each bridge segment has a second set of planar faces that engage second corresponding planar faces each in the upper and lower housing segments. This second set of bridge faces is generally contiguous with the first set of faces. By contiguous we mean each second face has at least one line of intersection with a first face. Advantageously, these second face sets, or at least planar extensions of these second faces, each also meet at their own dihedral angle. When this is the case the angle of the second set of bridge faces is desirably between 75 and 115 degrees and preferably about 100 degrees. However, these second face sets do not have to be dihedrals in their own right, but may be more complex spatially angled planes. It is believed that second sets of bridge faces provide some desirable alignment of bridge segments with upper and lower segments during final tightening of the coupling around the pipe joint.
[0028] Some coupling embodiments do not require an inward circumferential and centrally positioned pipe stop in the gasket, and some embodiments do not require lands in the bridge segments.
[0029] A method is disclosed for joining and sealing two grooved-ended pipe segments with a pre-assembled pipe coupling, without disassembling the coupling. A grooved pipe end from each pipe segment is inserted into each of both open ends of a pre-assembled pipe coupling that has a one-piece circular sealing gasket with two circumferential sealing lips axially outward from an axial center of the gasket. Each sealing lip has an inner diameter larger than the outer diameter of the pipe segments to be joined. Then roughly uniformly compression force is applied around the circumference of the coupling to rigidly join and seal the pipe segments. The roughly uniform compression force around the circumference of the coupling is advantageously provided by applying a four-way compression force to the coupling, such as by the four-way coupling described above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 depicts a one embodiment; FIG. 1 is a front elevation of a conventional assembled pipe coupling.
[0031] FIG. 2 is a schematic partial section of a conventional pipe gasket.
[0032] FIG. 3 is a schematic partial section of the disclosed pipe coupling.
[0033] FIGS. 4 a - e are front elevations of disclosed assembled pipe couplings.
[0034] FIGS. 5 a - d are schematic perspective and partial sections of disclosed pipe couplings.
[0035] FIG. 6 is a front elevation of a disclosed pre-assembled pipe coupling.
[0036] FIG. 7 is an exploded perspective of a disclosed pipe coupling.
[0037] FIGS. 8 a - c are side, plan and detail views of disclosed coupling bridge pieces.
DETAILED DESCRIPTION
[0038] The present embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which some embodiments are shown. The subject matter of the present disclosure, however, may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the subject matter to those skilled in the art. In the drawings, like numbers refer to like elements throughout.
[0039] Turning now to the drawings, the invention will be described in a preferred embodiment by reference to the numerals of the drawing figures wherein like numbers indicate like parts.
[0040] FIGS. 1 and 2 illustrate typical features of some conventional pipe couplings. Coupling 10 has upper and lower arcuate segments 1 and 2 , both enclosing gasket 3 , and fastened together by bolts 5 and nuts 4 . Pipe 20 fitted with end grooves 22 is shown for comparison of diameters with gasket 3 . Conventional pipe gasket 3 , especially if provided as a one-piece gasket, has an inner diameter B that is less than the outer diameter OD of pipe 20 . This has been reported to optimize sealing of gasket 3 on pipe 20 . The problem is that gasket 3 must first be stretched onto the end of pipe 20 , with attendant effort and risk of tearing or gouging or dropping gasket 3 , and with potential insurmountable difficulty when at least one pipe end is already in a hard to reach location.
[0041] FIG. 3 shows an unconventional comparison of diameters with pipes 20 and gasket 110 inside of pipe coupling 100 . Gasket 110 has an inner diameter B (measured at or near the base of sealing lips 112 , not at the tips of the lips) that is greater than the outer diameter OD of pipe 20 to optimize quick insertion and quick fit of pipe 20 into gasket 110 , without any sacrifice of sealing effectiveness. Abutment of pipes 20 with pipe stop 113 inside gasket 110 is schematically illustrated as well. FIG. 3 schematically illustrates the pipe insertion phase of the process, with coupling lands 122 not yet engaged or mated with pipe end grooves 22 . That happens during the coupling tightening phase. (See generally FIGS. 5 a - 5 e .)
[0042] FIG. 4 illustrates disclosed variants of a novel pre-assembled pipe coupling. Each alternative embodiment differs principally from the others only in design and placement of the various bridge segments 121 - 125 . In general each coupling 100 has upper housing segment 101 , lower housing segment 102 , fastened (in FIG. 4 a - FIG. 4 e is not yet fastened or locked, but rather in pre-assembled state) with bolts 105 and nuts 104 . Both bridge segments 121 are shown driven fully inward by the tightening action of the bolts compressing upper and lower segments 101 , 102 together, such that all four segments are fully and roughly equally providing circumferential pressure to gasket 110 and to the pipes (not shown in FIG. 4 ).
[0043] FIGS. 5 a - 5 e illustrate, among other details, the four way compressing action provided by the combination of upper and lower housing segments and bridge segments 121 between them. After pipes 20 are inserted into coupling 100 ( FIG. 5 b ), with pipe ends abutting and stopped by pipe stop 113 of gasket 110 , and sealing lips 112 flexed inward and sealing against the pipe OD, segment lands 122 are not yet engaged in pipe grooves 22 .
[0044] In FIG. 5 a , when the bolts are tightened, a compressive force is generated generally along axis 33 , which in turn, because of the complementary angular faces 126 , 127 of bridge segments with their corresponding upper and lower segment faces (see, e.g., segment face 107 in FIG. 7 ), drives bridge segments 121 generally inward along axis 32 , believed to be at least roughly tangential to axis 33 .
[0045] In FIGS. 5 c - d , bolts are fully tightened, there is generally no gap now between upper and lower housing segments (as there is in FIG. 5 a ), and bridge segments 121 are fully driven inward along axis 32 to compress against the gasket and the pipe. Coupling lands 122 are now fully engaged in pipe grooves 22 .
[0046] FIGS. 6 & 7 show an embodiment of the disclosed pre-assembled coupling in both pre-assembled and exploded perspective views. Schematically, pipe 20 is shown inserted into coupling 100 in FIG. 6 . Bolts and nuts are loose and coupling 100 is uncompressed and bridge segments 121 have not yet been driven in.
[0047] FIG. 7 's exploded view of the uncompressed but pre-assembled coupling 100 affords a more detailed view of aspects of bridge segments 121 , as does FIG. 8 . In perspective, dihedral faces 126 , and second face set 127 can be better seen, as can be corresponding segment face 107 in lower segment 102 set at an angle complementary to the lower face 127 of segment 121 . A segment face corresponding to face 126 and set at complementary angle to face 126 is not illustrated, but it is believed those skilled in the art will appreciate already where such a face will lie, given the rest of this disclosure.
[0048] FIGS. 8 a - b illustrate details of disclosed coupling bridge segments 121 in side and plan views respectively. Bridge segments 121 operate and function as described in more detail above with reference to upper 101 and lower 102 coupling housing segments, particularly with respect to applying nearly uniform circumferential radially inward pressure to the joined pipe segments 20 , or at least 4-way inward pressure to the pipe joint. Each bridge segment 121 desirably has a pair of lands 122 for mating with and applying pressure to corresponding end grooves 22 in pipe segments 20 . When present, lands 122 on bridges 121 have a geometry similar to or at least complementary to the geometry of lands 122 on the housing segments 101 , 102 .
[0049] Bridge 121 has at least one dihedral set of faces 126 . This face set 126 is comprised of two planar faces disposed to one another at dihedral angle A. In preferred embodiments this angle A is about 90 degrees. It can also be exactly 90 degrees, or can vary with good function from about 75 to 105 degrees. In FIG. 8 b the dotted circular phantom line schematically illustrates the position of bolt 105 when bridge 121 is assembled into coupling 100 . It can be seen that much of face set 126 can be cut away, such as illustrated by the cut-away for bolt 105 or by faces 128 , and still properly function. In preferred embodiments, there are additional face sets 127 , which may or may not be dihedral face sets, depending on the relationship between angle A and angle C. For the case A=C, faces 127 are also simple dihedral faces. If angle C does not equal angle A, then faces 127 form a more complex spatial planar angle with each other. Preferred embodiments have values for C that are close to or identical to A. Also, in preferred embodiments, faces 127 are not co-planar with faces 126 (though that is an option in the case A=C) but are instead, with respect to faces 126 , swept back from faces 126 at dihedral angle D (detail FIG. 8 c ).
[0050] In compliance with the statute, the invention has been described in language more or less specific as to structural features. It is to be understood, however, that the invention is not limited to the specific features shown, since the means and construction shown comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the legitimate and valid scope of the appended claims, appropriately interpreted in accordance with the doctrine of equivalents.
[0051] The present disclosure is not to be limited in scope by the specific embodiments described herein. Indeed, other various embodiments of and modifications to the present disclosure, in addition to those described herein, will be apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings. Thus, such other embodiments and modifications are in the tended to fall within the scope of the present disclosure. Furthermore, although the present disclosure has been described herein in the context of a particular implementation in a particular environment for a particular purpose, those of ordinary skill in the art will recognize that its usefulness is not limited thereto and that the present disclosure may be beneficially implemented in any number of environments for any number of purposes. Thus, the claims set forth below should be construed in view of the full breadth and spirit of the present disclosure as described herein. | A method for joining and sealing two grooved-ended pipe segments without disassembling a coupling is disclosed. The coupling has a housing with upper and lower arcuate housing segments and left and right bridge segments. Each bridge segment has at least one set of dihedrally angled faces that engage corresponding faces each in the upper and lower housing segments. Drawing the upper and lower segments inwardly together along a first axis, presses each bridge segment inward along a second axis roughly tangential to the first axis. All segments are loosely pre-assembled into a coupling which has a one-piece circular sealing gasket that has an inward circumferential and centrally positioned pipe stop that has an inner diameter smaller than an outer diameter of the pipes to be joined. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improved design of a pressure amplifier or converter for mounting above the drill bit at the lower end of a drill pipe for deep drilling, in particular for oil and gas, and for generating an increased fluid pressure by utilizing energy in a drilling fluid flow downwards through the drill string and the drill pipe. This may be, inter alia, for the purpose of obtaining an enhanced drilling effect, preferably by means of one or more high pressure jets adapted to have a cutting effect in the surrounding rock.
2. Description of the Related Art
The invention can be regarded as a further development and improvement of structures being described in Norwegian Patent Specifications Nos. 169.088, 171.322, 171.323 and 171.325. Norwegian Patent 171.323 is particularly directed to a valve assembly for this type of pressure converter, which advantageously can be replaced by new and improved designs to be described in the following description.
SUMMARY OF THE INVENTION
These new designs involve, inter alia, less wear of vital valve parts and besides better reliability and safety under the extreme conditions that the structures are subjected to in actual practice.
As in the pressure converters according the above mentioned Norwegian Patent Specifications, the present invention takes its starting point in an arrangement comprising a reciprocating piston having a pressure stroke and a return stroke between opposite end positions in a cylinder, and being at one side (low pressure side) provided with a relatively large piston area which during the pressure stroke is subjected to the drilling fluid pressure in the drill pipe, a first opposite area and a second, opposite and relatively small piston area which during the pressure stroke generates an increased pressure in a smaller portion (high pressure side) of the drilling fluid flow, valve means for controlling drilling fluid flows to and from the piston, a channel for connecting a space in front of the first, opposite piston area to the annulus outside the drill pipe at least during the pressure stroke, a second channel with a check valve, connecting said high pressure side to a high pressure channel leading forward to the drill bit, and at least one additional channel being adapted to connect the low pressure side to the annulus outside the drill pipe during the return stroke.
As an important component in the solution according to the invention there is incorporated a hydraulic motor, and in this connection it is to be noted that hydraulic motors in principle are known for use at the lower end of drill pipes for deep drilling, as for example described in U.S. Pat. No. 3.112.800, European patent publication 335.543 and international patent publication WC 83/00183. In these known uses, however, the hydraulic motor has other purposes and functions than what is contemplated in connection with the present invention.
What is novel and specific in the pressure converter according to the invention in the first place comprises therein that it comprises a hydraulic rotary motor arranged beyond the end of the cylinder and adapted to be driven by the pressure difference between the drilling fluid flows in the drill pipe and the annulus, and that a transmission mechanism is adapted to convert the rotation of the hydraulic motor into intermittent re-positioning movements of the valve means between two operative positions.
The present invention provides a pressure converter for mounting above a drill bit at a lower end of a drill pipe for deep drilling and for generating fluid pressure higher than pressure in a drilling fluid flow downwards through a drill string and the drill pipe. The pressure converter includes a reciprocating piston having a pressure stroke and a return stroke between opposite end positions in a cylinder, and being provided at one side with a main piston area which during a pressure stroke is subjected to the drilling fluid pressure in the drill pipe, a first opposite piston area, and a second opposite piston area being relatively small compared to the main piston area, which during the pressure stroke generates the higher fluid pressure in a small portion of the drilling fluid flow. The pressure converter also includes a valve device that controls drilling fluid flow to and from the piston, a channel for connecting a space in front of the first opposite piston area to an annulus outside the drill pipe at least during the pressure stroke, a second channel with a check valve, connecting the small portion of the drilling fluid flow to a high pressure channel leading forward to the drill bit, at least one additional channel providing fluid communication between the main piston area and the annulus outside the drill pipe during the return stroke, a hydraulic rotary motor arranged outside one end of the cylinder and that can be driven by a pressure difference between the drilling fluid in the drill pipe and the annulus, and a transmission mechanism that converts the rotation of the hydraulic motor into movements of the valve device between at least two operative positions.
In a further aspect of the invention, the hydraulic motor includes an output axle that is one of parallel with and coincident with a longitudinal axis of the pressure converter. The hydraulic motor can be a hydraulic gear wheel motor.
In a further aspect of the invention, a regulating device can be provided for the hydraulic motor. The regulating device preferably provides automatic control as a function of the pressure difference.
In a further aspect of the invention, the transmission mechanism converts continuous rotation of the output axle into intermittent movements of the valve device. The transmission mechanism preferably includes a Maltese cross mechanism. The Maltese cross mechanism can include a main disc mounted on the output axle of the hydraulic motor. Also, the main disc preferably includes at least one driving pin and has radial dimensions substantially larger than radial dimensions of cooperating slit wheels.
In a further aspect of the invention, the valve device includes two separate valve bodies located in a wall of the cylinder. The valve bodies preferably are diametrically positioned relative to an axis of the piston. Each valve body preferably comprises at least one valve ball that rotates approximately 90° between open and closed positions. Also, each valve body can have a longitudinal extension in parallel with an axis of the piston and corresponding in length at least to the stroke of the piston.
The present invention also provides a pressure converter group for mounting above a drill bit at a lower end of a drill pipe for deep drilling and for generating fluid pressure higher than pressure in a drilling fluid flow downwards through a drill string and the drill pipe. The pressure converter group comprises a plurality of pressure converters, wherein at least one of the pressure converters is designed in the manner stated above. The pressure converter group also includes a high pressure channel running continuously through all pressure converters in the pressure converter group, and through-running couplings for transferring rotary movements from a valve body in one pressure converter to a valve body in another pressure converter in the pressure converter group.
In a further aspect of the invention, the valve bodies in the pressure converters have alternate, mutual angular displacements (preferably 90°) about common longitudinal axes for equalizing the resulting pressure impulses in the high pressure channel.
In a further aspect of the invention, the pressure converters in the pressure converter group do not have a separate control cylinder and actuator cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following description, the new structural solutions according to the invention as well as additional advantages and specific features thereof, will be more closely explained with reference to the drawings, wherein:
FIG. 1 shows a longitudinal sectional view of an embodiment of a pressure converter according to the invention, wash the piston in a lower end position,
FIG. 2 shows a cross-sectional view along lines II--II in FIG. 1,
FIG. 3 shows a cross-sectional view similar to FIG. 2, but with a more preferred design of the hydraulic motor,
FIG. 4 shows a cross-section along the line IV--IV in FIG. 1, and
FIG. 5 schematically shows a group of pressure converters based upon an upper pressure converter according to the embodiment in FIGS. 1-4, coupled to other pressure converters which have a simplified design.
DETAILED DESCRIPTION OF THE INVENTION
Since the present pressure converter as far as the main features thereof are concerned, except for the valve arrangement, is closely related to corresponding structures according to the above mentioned Norwegian Patent Specifications, it seems to be sufficient here just to include a short discussion of these main features and functions.
As in the previously proposed designs, the embodiment of FIG. 1 comprises a generally cylindrical housing 1, 2 and 3 adapted to accomodate the piston 6. This has three active piston areas, i.e. and upper relatively large piston area 11, a first opposite piston area 13 and a second opposite and relatively small piston area 112 at the lower end of piston member 6. This is adapted to be freely movable axially under the influence of varying drilling fluid pressure on the respective piston areas.
The space or volume in front of piston area 11, can be designated low pressure space, whereas the volume in front of piston area 112 correspondingly can be denoted high pressure space. This latter space is connected through a channel 15A with a check valve 15, to a header channel (not shown in FIG. 1) for the resulting drilling fluid flow at an increased pressure. The channel runs through the whole longitudinal direction of the housing, i.e. the cylinder wall 1, for the purpose of interconnecting several such pressure converter units into a group, as will be discussed below with reference to FIG. 5.
The valve arrangement according to the invention as shown in FIGS. 1-4, comprises two rotatable valve bodies 4A and 4B each provided with respective through-flow openings 4Al, 4A2 and 4B1, 4B2. These valve bodies are provided in the cylinder wall 1 and diametrically opposite to one another. Valve bodies 4A and 4B with their respective valve balls preferrably are adapted to be rotated through an angle of about 90° between open and closed positions. In FIG. 1 there is accordingly a free opening for flow through the valve balls 4A1 and 4B2, whereas the other two are closed. A novel and specific control and actuator device for bringing about the above re-positioning movements of the valve bodies 4A and 4B, will be explained more closely below. At this point, a short discussion of the main function of the pressure converter shall be given.
Starting from the situation in FIG. 1 where piston 6 is in the lower position and valve ball 4B2 admits drilling fluid to the lower side of the piston through the inlet channel 13B, piston 6 will be urged upwards. Fluid being present in front of piston area 11 at the upper side of piston 6, thereby will flow out through channel 11A with the open valve ball 4A1 to the annulus 50 between the drill string or the cylinder wall 1 and the casing (not shown). Thus, piston 6 will be driven upwards to its top position. Accordingly this represents a return stroke of the piston. The pressure or working stroke takes place upon valve re-positioning, as will be seen without any closer explanation here.
Outside the cylinder end wall 2 at the low pressure side FIG. 1 shows the particular control and actuator apparatus according to the invention, being based on a hydraulic rotary motor 10 which has an output axle 10A. A first embodiment of the hydraulic motor is shown somewhat more in detail in FIG. 2. The motor is driven by the pressure difference between the drilling fluid flow in the drill pipe (indicated at 1A) and the annulus 50, respectively. It will be realized that only a very small proportion of the total drilling fluid flow is utilized in the hydraulic motor 10, which only serves for the movement of the valve device, as will be explained in the following description. It can be an advantage that the drilling fluid flow through the hydraulic motor, and thereby the power or rotational speed thereof, is adjustable. For that purpose there is indicated quite schematically a regulating device 55 for in-flowing drilling fluid from the drill pipe, as represented by the channel 1A, to the motor. Suitable regulation takes place as a function of the pressure difference mentioned above, so that the rotational speed varies to a lower degree than the pressure difference. Under the practical and varying operational conditions the rotary motor in the pressure converter according to the invention, will have a mechanical power, i.e. torque, for the required valve movement.
FIG. 1, moreover, shows a transmission mechanism for converting the rotation of output axle 10A into adequate valve movements in the valve device described above. The transmission mechanism is shown in cross-sectional view in FIG. 4 and in this embodiment is based upon the Maltese cross principle. On the output axle 10A there is mounted a main disc 12 having recesses 12A and 12B in the circumference, for cooperation with slit wheels 14A and 14B each being rotationally connected to a valve body 4A and 4B. Furthermore FIG. 4 shows two pins 12AC and 12BC provided on the main disc 12 and centrally outside the recess portions 12A and 12B. This Maltese cross mechanism, as known per se, during continuous rotation of output axle 10A of the hydraulic rotor and thereby the main disc 12, will cause an intermittant rotary movement by 90° for each time, by engagement between the pins 12AC and 12BC and the slits shown in the two small wheels 14A and 14B. In the time interval between the valve re-positioning movements the two small slit wheels and accordingly the valve bodies will be maintained in a substantially fixed position by cooperation between the more extended circular surfaces on the main disc 12 and the wheels 14A and 14B respectively, as also known per se.
For the purpose of obtaining a desired quick re-positioning movement of the valve device, it is an advantage that the main disc 12 with associated pin or pins 12AC, 12BC has radial dimensions being substantially larger than the radial dimensions of the cooperating slit wheels 14A, 14B. Expressed in other words this means that the angle of rotation covered by the main disc 12 with pins 12Ac and 12BC in engagement with slit wheels 14A and 14B, is very small compared to one half revolution, which in principle represents the time interval between each valve re-positioning.
Transmission mechanisms other than the one being just described here, may be able to convert the rotation of the hydraulic motor 10 into desired re-positioning movements of the valve device. For the practical design of such transmission mechanisms it is a great advantage according to the invention that the output axle 10A from the hydraulic motor 10 is parallel to and can possibly coincide with the longitudinal axis AX of the pressure converter as a whole.
Moreover it is possible to incorporate desired transmission ratios in the transmission mechanism, including the employment of planetary gears. In this connection it will usually be the question of gearing down from the rotary speed of the hydraulic motor.
Considering now more closely the cross-section in FIG. 2, it appears that the hydraulic motor 10 in this embodiment more specifically has the form of a wing motor having a number of wings or vanes 101,102,103 and so forth, being mounted for radial translation in a rotor 10B which is keyed to the output axle 10A. The rotor with the wings is arranged in a cavity 10c the circumference of which has a non-circular or oval shape being so oriented in relation to inlet 1A and outlet 50A to the annulus 50, that rotation is obtained by the pressure difference already mentioned above. This motor principle as such is previously known per se.
In practice the motor design according to FIG. 2 can be subject to drawbacks, as a consequence, inter alia, of the relatively numerous individual parts being subjected to wear and tear, and therefore according to the invention it is a much preferred embodiment to employ a gear wheel motor as illustrated in FIG. 3. This is likewise a principle known per se for a hydraulic motor, comprising two gear wheel rotors 31 and 32 for rotation in engagement with one another in a housing 30C which incorporates half-cylindrical wall portions in cooperation with the rotating tooth tops on gear wheels 31 and 32. The resulting hydraulic motor 30 preferrably has an output axle 30A carrying the gear wheel 31, located so as to coincide with the pressure converter axis AX (as shown in FIG. 1), for direct coupling to the main disc 12 in the transmission mechanism in FIGS. 1 and 4, or some other form of suitable transmission mechanism. In FIG. 3 there are more particularly also shown drilling fluid channel 1A which supplies drilling fluid under pressure as a portion of the total drilling fluid flow in the drill string and the drill pipe. With arrows at both gear wheels 31 and 32 the direction of rotation thereof during operation is indicated.
In the embodiment of FIG. 1, where there are provided valve balls both for inlets and outlets at either side of the main piston areas or surfaces 11 and 13, each valve body 4A and 4B has a longitudinal extension in parallel with the axis of piston 6, corresponding at least to the stroke of the piston. These dimensional relationships are determined by the need for supplying drilling fluid under pressure onto piston area 11 during the pressure stroke, and onto piston area 13 during the return stroke, respectively. However, a modified embodiment may be contemplated, wherein each valve body has only one valve ball, i.e. ball 4A1 and 4B1 respectively. In such a modified embodiment there is no valve function controlling in-flow or out-flow from the volume in front of piston area 13, since this volume via a fully open channel corresponding to 13A, communicates directly with the annulus 50 during all movement stages of piston 6. This is per se a solution being also previously described, inter alia, in Norwegian patent 169.088. As in the previous design the modified solution mentioned here can also comprise a return compression spring adapted to exert a pushing force against piston area 13.
Also with respect to the valve and actuator device the present invention can comprise embodiments having other structural features than those discussed above with reference to the drawings. Thus, for example the valve means or arrangement can be based un a plate-shaped, rotatable valve body as described in Norwegian patent No. 169.088. Instead of an actuator cylinder with a linear movement as shown and described herein, also other forms of hydraulic actuators can be contemplated, being controlled by a control valve as described.
Besides, the solutions being described above with reference to the figures of drawings, can be combined with some of the particular variants being shown in Norwegian patent specifications mentioned above, perhaps in particular the outlet channel according to Norwegian patent 171.322 and the inter-connection into a pressure converter group according to Norwegian patent No. 171.325.
As in the previously known designs, in particular as described in Norwegian patent specifications Nos. 169.088 and 171.325, a pressure converter according to the present invention can be incorporated in a croup of pressure converters for generating a resulting, larger drilling fluid flow at the desired, increased pressure. FIG. 5 shows such a pressure converter group, wherein an upper pressure converter 10 is illustrated in the form of the same pressure converter embodiment as in FIGS. 1-4. Moreover in FIG. 5 there is schematically shown two further pressure converters 20 and 40, which possibly can be followed by still further pressure converters below them, all being provided with valve bodies with inter-connections in the whole longitudinal direction of the group so that valve bodies 4A and 4B in the uppermost pressure converter 10, drive the whole series of valve bodies below, such as valve bodies 64A and 64B in pressure converter 20 and valve bodies 66A and 66B in pressure converter 40. These further pressure converters, for example 20 and 40 therefore can be of a simplified design without any specific means for bringing about the re-setting movement of their valves.
As in the previously described pressure converter groups the pressure converters 10, 20, 40 and so forth as illustrated here, are aligned along a common longitudinal axis 70, with a common, through-running high pressure header channel 16 and with the respective valve bodies axially aligned in relation to each other. For inter-connecting the two strings of valve bodies shown, there are provided drive axles 60A, 60B, . . . 60G with associated axle couplings as shown for example at 60AX between pressure converter 10 and pressure converter 20.
For equalizing pressure impulses in the total resulting high pressure flow in channel 16, it may be an advantage to arrange the valve bodies in the pressure converters with angular orientations being alternately opposite, as will appear from the valve positions being indicated for the respective valve bodies in pressure converters 10, 20 and 40 in FIG. 5. | A pressure amplifier can be mounted above a drill bit at the lower end of a drill pipe for generating an increased fluid pressure in a drilling fluid flow to, for example, obtain an increased drilling effect, A reciprocating piston in a cylinder has at one side (a low pressure side) a large piston area and also has a first opposite piston area and a second opposite and relatively small piston area, which generates an increased pressure. A valve device controls drilling fluid flows to and from the piston. Beyond one end of the cylinder there is provided a hydraulic rotary motor adapted to be driven by the pressure difference between the drilling fluid flows in the drill pipe and an annulus. A transmission mechanism converts the rotation of the hydraulic motor into intermittent movements of the valve device between two operative positions. | 4 |
FIELD OF THE INVENTION
The present invention relates to the field of document authentication. It is more specifically concerned with the authentication of soft-copy text documents.
BACKGROUND OF THE INVENTION
In the current environment of computer networks characterized by an exponential growth in the circulation of soft-copy or electronic text documents such as e-mail over unsecured media e.g., the Internet, a key issue is authentication. It should be possible for the recipient of a text document to make sure of its origin so that no one should be able to masquerade as someone else. Also, it should be possible to verify it has not been modified, accidentally on maliciously, en route. To this end methods have been devised to perform authentication.
The standard solution, which fits well with electronic text documents, consists in adding a MAC or Message Authentication Code to soft-copy text documents. A MAC is a digest computed with a one-way hash function over the text and which is also made dependent on a key e.g., a secret-key known only to the sender and the receiver in order this latter can check first, that what it received has well been originated by whom shares the secret-key with it and second, that the document has not been altered. For example, Secure Hash Algorithm or SHAD specified by the National Institute of Standards and Technologies, NIST, FIPS PUB 180-1, “Secure Hash Standard”, US Dpt of Commerce, May 1993, produces a 160-bit hash. It may be combined with a key e.g., through the use of a mechanism referred to as HMAC or Keyed-Hashing for Message Authentication, subject of the RFC (Request For Comment) of the IETF (Internet Engineering Task Force) under the number 2104. HMAC is devised so that it can be used with any iterative cryptographic hash function thus, including SHAD. Therefore, a MAC can be appended to the soft-copy of a text document so as the whole can be checked by the recipient. Thus, this method assumes the addition of checking information to a file which has the inconvenience of indeed separating text and checking information. Hence, this latter can easily be isolated and removed intentionally, in an attempt to cheat, or accidentally just because intermediate pieces of equipment in charge of forwarding the electronic documents are not devised to manipulate this extra piece of information. Then, the checking information should rather be encoded transparently into the body of the text document itself i.e., in a manner that does not affect text readability whatsoever, so that it remains intact across the various manipulations it is exposed to on its way to destination still enabling the end-recipient to authenticate the document.
Another type of approach to authentication, which applies mainly to soft-copy images (which thus may also be used on the image of a text document), consists in hiding data into their digital representation therefore, meeting the above requirement that checking information should better be merged into the document itself. Data hiding in images has received a considerable attention mainly because of the copyrights attached to digital multimedia materials which can easily be copied and distributed everywhere through the Internet and networks in general. A good review of data hiding techniques is in ‘Techniques for data hiding’ by W. Bender and al. published in the IBM Systems Journal, Vol. 35 Nos 3&4, 1996. As an illustration to the way data hiding may be carried out the most common form of high bit-rate encoding, reported in here above paper, is the replacement of the least significant luminance bit of image data with the embedded data. This technique which indeed meets the requirement of being imperceivable (the restored image is far to be altered to a point where this would become noticeable) may serve various purposes, similar to authentication including watermarking, aimed at placing an indelible mark on an image or tamper-proofing, to detect image alterations especially, through the embedding of a MAC into the soft-copy image.
However, having to consider a text as an image would be a very costly and inadequate solution in term of storage and bandwidth necessary to transmit it. Although, as stated in here above paper, soft-copy text is in many ways the most difficult place to hide data due to the lack of redundant information in a text file as compared to a picture the manipulation of white spaces i.e., blank characters and more specifically inter-word blank characters purposely inserted by the originator of a text document, in excess of what is strickly necessary to make a text readable (i.e., one blank between any two words), is the most simple way of marking a text that is susceptible to be authenticated without the addition of a separated MAC since the information necessary for the checking is then imbedded, somehow hidden, into the text itself, under the form of extra inter-word blanks, that the casual reader is unlikely to take notice of. Moreover, ideally (even though text is readable), the end recipient of the document should also be able to reformat the original text document exactly as it was created. Also, the addition of extra blanks should be conducted in such a way that code breakers see their job much complicated by not being able to determine in advance which ones of the extra inserted blanks, present in the coded text, are really holding the authentication data.
Therefore it is a broad object of the invention to provide a method to merge the information necessary to authenticate a text document, into the body of the document itself, under the form of extra inter-word blanks.
It is another object of the invention to permit that the recipient of the document be able to restore exactly the format, including the number of blanks, of the original text.
It is still another object of the invention to merge the extra blanks, actually carrying the authentication data, with dummy blanks so as to even confuse more an attacker.
Further objects, features and advantages of the present invention will become apparent to the ones skilled in the art upon examination of the following description in reference to the accompanying drawings. It is intended that any additional advantages be incorporated herein.
SUMMARY OF THE INVENTION
A method of marking an original text document which consists in altering the numbers of existing inter-word blank characters of the text is disclosed. First, a reversible transform is applied over the original text document in order that all inter-word intervals become exclusively comprised of odd numbers of blank characters. Then, transformed original text is split into a first and a second subset of words including their trailing inter-word intervals. An authentication pattern, fitting the number of inter-word intervals in the first subset, is then computed using the original text document and a secret-key as inputs. Hence, inter-word blank characters are added in positions corresponding to the authentication pattern. After which, from the canonical form (i.e., a form of text in which all inter-word blank characters in excess of one are stripped off) of the first subset and the secret-key, a blurring pattern is computed which fits the number of inter-word intervals too so that the numbers of inter-word blank characters are further modified thus, blurring the authentication pattern just added in first subset. Although it does not contain the authentication pattern the second subset is blurred too, in a similar way before recombining the first and the second subset thus, obtaining a marked text susceptible of authentication.
A method of authenticating a text document marked according to the here above method is also disclosed. First step consists in splitting the marked text document to retrieve the first and the second subset of words and intervals. Then, the effect of the blurring pattern is removed in both subsets. This also permits to extract the authentication pattern, that was imbedded in first subset, after which subsets are recombined. At this stage all inter-word intervals are comprised of odd numbers again and the transform used by the first method is reversed so that the exact format of the original text is recovered. Finally, as in first method, an authentication pattern is further computed which is compared with the authentication pattern extracted here above. If matching, marked text is known to be authentic.
A system carrying out the methods of the invention is also disclosed. Methods and system per the invention permit that a text document be authentic able while authentication pattern is imbedded, and deeply hidden, into the text document itself and exact original format, including the numbers of inter-word blanks, restored by the recipient.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the conventions adopted to describe the invention.
FIG. 2 depicts G function used to carry out the invention.
FIG. 3 describes the overall process to mark a text document.
FIG. 4 focuses on the transform utilized to obtain odd inter-word intervals.
FIG. 5 shows how text document can be split into a first and a second subset.
FIG. 6 depicts the process of imbedding the authentication and blurring patterns into first subset.
FIG. 7 describes the overall process to authenticate a marked text document.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 depicts what conventions are used in the rest of the description and what is the canonical form [ 120 ] of a text per the invention. To describe the invention, a text [ 100 ] is shown to be starting and ending with a delimiter i.e., a vertical bar [ 105 ]. This delimiter is not part of the text itself and is just here to bind it unambiguously. Similarly, words are separated by blanks which are shown with a caret sign [ 110 ]. Thus, a text is made of words e.g., [ 125 ] and inter-word intervals comprising at least one blank [ 110 ] although more blanks may be found [ 115 ] which does not affect readability though. Canonical form of a text [ 120 ] is just the original form of the text [ 100 ], from which all inter-word blanks in excess of one [ 115 ] have been removed.
FIG. 2 shows a function G [ 200 ], needed to carry out the invention, which can be implemented in many ways from techniques and methods well known by those skilled in the art. Irrespective of the way function G is actually implemented it is assumed to be able to generate an output S [ 205 ] which is made dependent upon three types of entries. First, S is made dependent upon an input text [ 220 ], like the ones shown in FIG. 1 . Second, output S must also depend on a key [ 230 ], shared by the parties involved in the authentication process. Third, of a set of parameters [ 210 ], aimed at conditioning the way function G must process input text and key especially, specifying what type and format of output S are expected in a particular instance of the function. As an example of the way function G is used by the invention, canonical form of the text already shown in FIG. 1 [ 220 ], assumed to be ASCII coded, is the input text. Key is e.g., an alphanumeric text string [ 230 ] that must be kept secret. Then, parameter [ 210 ] may be set to instruct function G to produce for instance, a string of 23 binary bits [ 215 ]. Those skilled in the art will recognize that function G, such as described here above, could be implemented, for example, from a one-way hash function aimed at producing a unique digest of the input text and secret key, also made dependent of input parameters, such as the number of expected bits so that output S can be tailored to fit in any particular step of the invention described in the following figures. One-way hash functions, which carry many other names like compression function, message digest, have received a considerable attention and are central to modern cryptography. A good review of this subject can be found in ‘Applied Cryptography’ a book authored by Bruce Schneier and published by John Wiley & Sons, 2nd edition, 1996. What is specific in the hash function needed to carry out the invention, with respect to the general description that exists in the here above book and in the abundant literature on the subject, is that it must accept input parameters on top of the standard input text and key especially, to allow the size of the output to be tailored to fit a particular instance of the function. Although this is different of standard hash functions, which generally produce a fixed-size digest of a keyed-text, this does not raise any outstanding problem to those skilled in the art to devise such a function either, as suggested above, from a standard hash function or through any alternate method that would better fit in a particular implementation of the invention.
FIG. 3 shows the main steps of the method per the invention. Method starts with a text [ 300 ] to be marked for authentication. First, one applies a reversible transform [ 305 ] in order that all inter-word intervals become comprised of an odd number of blanks. One way of achieving this is to add, to the number N of existing blanks, N−1 extra blanks so that if there is one inter-word blank between two words (the general case) it is unchanged after the transformation. If however, there are two blanks ther, one adds two minus one i.e., one extra blank to the two Existing ones thus, obtaining an odd three-blank interval. And so on. Therefore, at completion of step [ 305 ] ‘text’ is transformed so as it is only comprised of odd numbers of inter-word blanks. Then, transformed text is split [ 310 ] into two subsets ‘stext 1 ’ and ‘stext 2 ’ of randomly selected words, with their associated trailing blanks. This step, which .s further described in FIG. 5 hereafter, is carried out using the canonical form of text [ 300 ] generated at step [ 302 ] and a secret-key [ 312 ] as inputs, over the transformed text obtained at step [ 305 ]. Next step [ 315 ] consists in producing an authentication binary code i.e., a binary vector, length of which matches the number of inter-word intervals of ‘stext 1 ’. This is achieved in using function G described in FIG. 2 . Code is used to insert more inter-word blanks e.g., to the position matching the ones (one may decide to use the zeros as well) of the binary vector so as the number of inter-word blanks that were all odd are now either odd and even. At this point text would be authentic able by the recipient however, to make much more difficult to an attacker the task of breaking the code, the number of inter-word blanks are further altered so as to blur the pattern of inter-word blanks. To this end, starting from the canonical form of the ‘stext 1 ’ namely ‘cstext 1 ’, obtained at step [ 325 ], and the secret-key another binary vector, aimed at blurring the here above authentication pattern of blanks, is generated at step [ 330 ], in a manner similar to step [ 315 ]. Then, blurring binary vector is used at step [ 335 ] in such a way that for each inter-word position of ‘stext 1 ’ corresponding e.g., to a one, if the number of blanks is odd (1, 3 , . . . ) then one adds one extra blank however, if number is even (2, 4, . . . ) one removes one blank instead. This prevents the authentication code from being directly readable.
As far as blurring steps are concerned the same process is applied to the second subset ‘text 2 ’. Steps [ 345 ], [ 350 ] and [ 355 ] are thus identical to the equivalents steps just described for ‘stext 1 ’.
When done, marked and blurred ‘stext 1 ’ and blurred ‘stext 2 ’, are recombined [ 340 ] in a manner reverse to what was done at step [ 310 ] where transformed text, obtained at step [ 305 ], was split therefore, obtaining a marked text ‘ftext’ that can be authenticated. This last step obviously assumes that the manner split was done at step [ 310 ] be remembered so that the words (and trailing blanks) be recombined in the right order.
FIG. 4 illustrates in more details step [ 305 ] of FIG. 3 where the number of text inter-word blanks is transformed so as to get only odd numbers of blanks between any two words. In this example the function utilized to transform text [ 420 ] into text [ 425 ] adds N−1 extra blanks to the N existing blanks which results, with this particular text [ 420 ], to changing from two to three the number of blanks in only two positions [ 435 ].
FIG. 5 focuses mainly on step [ 310 ] also referring to steps [ 302 ] and [ 307 ] of FIG. 3 from where text [ 500 ] is split. Although many alternate equivalent ways are possible for these steps function G, described in FIG. 2 , is used too in a preferred embodiment of the invention. That is, using the canonical form of text and the shared secret-key as inputs, function G is set to generate a split binary vector [ 510 ] fitting the number of inter-word text intervals.
It is worth noting here that whichever method is actually used to split a text it must provide, for a given combination of ‘ctext’ and secret-key, a unique manner of splitting the text so that the recipient of an authenticated text marked according to the method of the invention will be able upon reception to obtain the same split. In practice, this requires that, in the preferred embodiment of the invention which uses function G previously described, that input parameters to be used be agreed upon in advance (or the method of unambiguously determining them) between the sender and the receiver.
Then, using the split binary vector [ 510 ], words and associated trailing blanks, corresponding to the asserted bit of the vector are said to belong to a subset e.g., ‘stext 1 ’ [ 520 ] while those corresponding to non asserted bits are said to belong to the other subset ‘stext 2 ’ [ 530 ]. As already mentioned above, split binary vector [ 510 ] must be remembered to allow proper recombination of subsets as described at step [ 340 ] of FIG. 3 .
FIG. 6 illustrates how inter-word blanks are modified at steps [ 320 ] and [ 335 ] of FIG. 3 which respectively merge the authentication vector [ 610 ] computed at step [ 315 ] and the blurring vector [ 630 ] computed at step [ 330 ]. Subset of text (‘stext 1 ’) having only odd inter-word blank numbers [ 600 ], and obtained as explained in FIG. 5 , is further modified. Extra blanks are inserted corresponding to the asserted bits of the authentication vector [ 610 ] thus, producing text [ 620 ]. This latter text is in turn modified with the blurring vector [ 630 ] which adds, in the positions corresponding to the asserted bit of the vector, one extra blank if the number of blanks is odd, and removes one blank if the number of blanks is even. The result of this transformation is text [ 640 ].
FIG. 7 depicts the authentication process to be applied on a text which is assumed to have been marked according to the overall method described in FIG. 3 . It is roughly the reverse of what is shown in this latter figure and allows to recover the text exactly as it was formatted by sender. Hence, process starts when ‘ftext’ to be authenticated is received [ 700 ]. Canonical form of this text is produced at step [ 702 ] thus, obtaining ‘ctext’ which when used with the shared secret-key [ 712 ] at step [ 707 ] allow to split ‘ftext’ into a first subset ‘sftext 1 ’ and a second subset ‘sftext 2 ’ of words with their trailing blanks at step [ 710 ]. Although trailing blank numbers would be generally different the result of the split operation must be obviously identical, as far as words split is concerned, to what was obtained at corresponding step [ 310 ] in FIG. 3 provided secret-key is indeed the same. Then, next step [ 725 ] consists in generating a canonical form of ‘sftext 1 ’ i.e., ‘csftext 1 ’ which when used with secret-key with function G [ 730 ] allows to generate a blurring vector which is used at next step [ 735 ] to erase (to reverse) what was done at step [ 335 ] of FIG. 3 to hide the authentication code. At this point, authentication vector, computed by the originator of the text, can be extracted at step [ 720 ] in reversing all the inter-word blank numbers to their closest odd number value. That is, removing a blank if even, none if odd therefore, getting an extracted authentication vector, asserted bits of which correspond to where blank characters had to be removed.
Similarly to steps [ 725 ], [ 730 ] and [ 735 ] steps [ 745 ], [ 750 ] and [ 755 ] are done on ‘sftext 2 ’ to erase the effect of the blurring vector on the other subset too.
Then, the two subsets are recombined [ 740 ] to get back the text, comprised of odd intervals only. This is followed [ 705 ] by the application of the reverse transform used at step [ 305 ] allowing to retrieve the original text i.e., ‘text’ exactly as it was formatted by the originator. Therefore, the last steps consists in authenticating ‘text’ by computing from it and the secret-key an authentication binary vector [ 715 ] which, when compared [ 760 ] to the one resulting of step [ 720 ] must match to authenticate ‘text’. If not, text is rejected as being not authentic. | A method of marking an original text document in which existing inter-word blank characters are altered is disclosed. A reversible transform is first applied so that inter-word intervals become exclusively comprised of odd numbers of blank characters. Transformed original text is then split in two subsets and an authentication pattern is merged into first subset by adding inter-word blank characters. A blurring pattern is computed which further modify the number of blank characters so as to hide the authentication pattern. Second subset is blurred too before subsets are recombined to obtain a marked text susceptible of authentication.
A method of authenticating a text document marked according to the here above method is also disclosed.
The system and the methods of the invention permit that a text document be authenticable while authentication pattern is imbedded, and deeply hidden, into the text document itself. Also, the exact original format, including the numbers of inter-word blanks, can be restored by the recipient. | 7 |
BACKGROUND
[0001] 1. Field
[0002] This invention relates to a wrap-around advertising surface, system and method of advertising and more particularly to a wrap-around advertising surface, system and method of advertising on railings or other hand support systems and for use on poles or support beams.
[0003] 2. Prior Art
[0004] Numerous types of media are used to advertise products and services in various settings. The type of advertising media used can vary depending upon the environment in which it is placed.
[0005] For example, point of purchase displays are often used to direct consumer attention to product offerings placed inside a store. Large billboards and other types of signage or displays along highways, on windows, on sides of vehicles, and the like are another advertising option and can be effective in attracting the attention of persons passing the display.
[0006] Floor graphics are a specific example of a point of purchase display. “Floor graphics” is an advertising industry term used to describe a substrate with graphics printed on the surface thereof, which is placed on the floor near a product display to direct a consumer's attention to a particular product display. Floor graphics are “billboards on the floor” that project an advertising campaign on the floor.
[0007] Various types of advertising media can also be effective to attract the attention of large numbers of people, for example, at a concert venue, a stadium, a race track, etc. As an example, billboards are often displayed at the above-mentioned places. Other examples include graphical displays on digital scoreboards, which are used in stadiums to attract the attention of a large number of people attending a particular event and billboards and/or digital graphics in moving vehicles such as buses and trains. While these methods are effective they can also be expensive and time consuming to program, display and change.
[0008] Other methods of advertising include advertising on the vertical risers of steps as disclosed in U.S. Pat. No. 6,041,533 to Lemmond, Jr. U.S. Pat. No. 4,054,001 to De Pinna describes a display device for advertising consisting of a vertical support with a unitary sheet of resilient material used for advertising hanging from the vertical support. However, the advertising methods to date are relatively expensive, installment intensive and difficult to display.
[0009] Hence there is a need for a wrap-around advertising surface, system and method of advertising which can reach a large number of people while at the same time be cost effective for the advertiser and easy to display. There is also a need for a method of advertising which is easy to apply and can be removed quickly and replaced cost effectively.
SUMMARY
[0010] The present invention is a wrap-around advertising surface, system and method of advertising on a railing, other hand support system, pole or beam. The wrap-around advertising surface of the present invention is designed to provide cost effective releasably attachable advertising on any railing, other hand support system, pole or support beam. The wrap-around surface is preferably used on a railing, other hand support system, pole or support beam.
[0011] In one aspect of the present invention, a wrap-around advertising surface is provided which is releasably adhered to a surface such as a railing, other hand support device, pole or support beam. The wrap-around advertising surface comprises a skin having a top surface and a bottom surface and a 4-way stretchable material layer having a top surface and a bottom surface. The top surface of the skin layer is imprinted with printed indicia forming a visual image. The bottom surface of the skin layer is permanently adhered from edge to edge to the top layer of the 4-way stretchable material layer. The bottom surface of the 4-way stretchable material layer is completely covered from edge to edge with a releasable adhesive. In another aspect of the invention, a backing layer with a top surface and a bottom surface is placed between the skin layer and the 4-way stretchable material layer to provide additional support. The top surface of the backing layer is permanently adhered to the bottom surface of the skin layer. The bottom surface of the backing layer is permanently adhered to the top surface of the 4-way stretchable material layer.
[0012] In another aspect, a system of advertising is presented. The system comprises a wrap-around advertising surface, which has a skin layer and a 4-way stretchable material layer with a top surface and a bottom surface. The skin layer has a top surface and a bottom surface; the top surface of the skin layer has printed indicia, which presents a visual image. The bottom surface of the skin layer is permanently adhered to the top layer of the 4-way stretchable material layer. The bottom surface of the 4-way stretchable material layer is releasably adhered to a railing. In another aspect of the system of advertising presented, a backing layer with a top surface and a bottom surface is placed between the skin layer and the 4-way stretchable material layer to provide additional support. The top surface of the backing layer is permanently adhered to the bottom surface of the skin layer. The bottom surface of the backing layer is permanently adhered to the top surface of the 4-way stretchable material layer.
[0013] In yet another aspect, a method of advertising is presented using the wrap-around advertising surface of the present invention. The method of advertising comprises providing a railing, other hand support system, pole or support beam, etc. having a length and alignment targets in a parallel line along its length. Next, placing the wrap-around advertising surface so that the center lengthwise axis of the wrap-around advertising surface is centered on the axis parallel to the length of the railing, other hand support system, pole, support beam, etc. The wrap-around advertising surface of the present invention has alignment targets disposed along an axis parallel tot he lengthwise edge of the wrap-around advertising surface and the wrap-around advertising surface folds around the railing such that the alignment targets of the wrap-around advertising surface align with the alignment targets of the railing and the edges of the wrap-around advertising surface abut when folded around the railing.
[0014] The wrap-around advertising surface, system and method of advertising will provide a cost effective advertising vehicle for advertisers who wish to provide point of sale advertising and who wish to reach large groups of consumers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is an expanded side view of a wrap-around advertising surface.
[0016] [0016]FIG. 2 is an elevated perspective view of the wrap-around advertising surface of FIG. 1.
[0017] [0017]FIG. 3 is an expanded side view of another embodiment of a wrap-around advertising surface.
[0018] [0018]FIG. 4 is an elevated perspective view of the wrap-around advertising surface of FIG. 3.
[0019] [0019]FIG. 5 shows an advertising system for presenting a visual image using the wrap-around advertising surface of FIG. 1.
[0020] [0020]FIG. 6 shows an advertising system for presenting a visual image using the wrap-around advertising surface of FIG. 3.
[0021] [0021]FIG. 7 shows a method of advertising using the wrap-around surface of FIG. 1.
[0022] [0022]FIG. 8 shows a method of advertising using the wrap-around surface of FIG. 2.
DETAILED DESCRIPTION
[0023] The present wrap-around advertising surface, system and method of advertising will be described more fully hereinafter with reference to the accompanying drawings, in which an illustrative aspect of the invention is shown. This surface, system and method of advertising may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather this embodiment is provided so that the disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
[0024] [0024]FIG. 1 discloses wrap-around advertising surface 100 for use on a railing, hand support system, pole or support beam or any other structure which can function as a support surface. Wrap-around advertising surface 100 has a skin layer 104 and a 4-way stretchable layer 112 . Skin layer 104 can be formed from a variety of materials. Examples of such materials include expanded vinyl, which is vinyl with a layer of foam that imparts a soft, textured feel, leather, plastic sheeting, plastic roll stock, any type of foam product, polyurethane, urethane, woven fabrics, rubber material, foil material or any other material which could act as a covering to a hand support system. If skin layer 104 is formed from expanded vinyl, the vinyl surface may be smooth or textured. In addition, if a vinyl material is used, the vinyl may be supported or unsupported.
[0025] Skin layer 104 has a bottom surface 106 which is affixed to the top surface 110 of 4-way stretchable material layer 112 by a permanent adhesive 108 that completely covers skin layer 104 from edge to edge. The permanent adhesive 108 can be any permanent adhesive known in the art which will permanently bond skin layer 104 to 4-way stretchable material layer 112 . An example of such a permanent adhesive is Flexicon® adhesive V-402. However, it will be clear to one skilled in the art that other similar suitable adhesives may be used.
[0026] 4-way stretchable material layer 112 has top surface 110 and a bottom surface 114 , such that top surface 110 of 4-way stretchable material layer 112 conforms to and is permanently affixed to bottom surface 106 of skin layer 104 . 4-way stretchable material layer 112 may be comprised of any material that can simultaneously stretch in four directions such as mylar. Bottom surface 114 of 4-way stretchable material layer 112 is releasably attached to the railing or hand support system by a layer of releasable adhesive 116 . Releasable adhesive 116 completely covers from edge to edge and is affixed to 4-way stretchable material layer 112 and provides releasable adhesion to the railing or hand support system. Releasable adhesive 116 provides secure adhesion to the railing or hand support system but may be removed with a minimal amount of effort by peeling wrap-around advertising surface 100 off the railing or hand support system, etc. An example of a releasable adhesive is Flexicon® V-58.
[0027] [0027]FIG. 2 is an elevated perspective view of wrap-around advertising surface 100 . Skin layer 104 has top surface 102 and bottom surface 106 . Top surface 102 of skin layer 104 has printed indicia that presents visual image 118 . Visual image 118 can be created using any printing or graphic technique known in the art suitable for placing graphic designs on the wrap-around material employed. For example, sublimation printing utilizing heat and pressure to affix preprinted graphics produces a highly durable and accurate graphic. The sublimation ink can be pretreated with UV inhibitors to prevent fading. Luminescent inks can also be used to provide a glow in the dark environment. Puff inks can be used to provide a textured surface. In addition, plastisol inks can be used in a heat transfer application for durable, long-lasting images. Wet ink printing can also be used as well as computer generated digital graphics, which are directly printed on various materials used as skin layer 104 .
[0028] [0028]FIG. 2 discloses wrap-around advertising surface 200 for use on a railing, hand support system, pole or support beam or any other structure which can function as a support surface. Wrap-around advertising surface 200 has a skin layer 204 , a backing layer 212 and a 4-way stretchable material layer 220 . Skin layer 204 can be formed from a variety of materials. Examples of such materials include, but are not limited to, expanded vinyl, which is vinyl with a layer of foam that imparts a soft, textured feel, leather, plastic sheeting, plastic roll stock, any type of foam product, polyurethane, urethane, woven fabrics, rubber material, foil material or any other material which could act as a covering to a hand support system. If skin layer 204 is formed from expanded vinyl, the vinyl surface may be smooth or textured. In addition, if a vinyl material is used, the vinyl may be supported or unsupported.
[0029] Skin layer 204 has a bottom surface 206 which is affixed to top surface 210 of backing layer 212 by a permanent adhesive 208 which completely covers bottom surface 214 of backing layer 212 from edge to edge. The permanent adhesive 208 can be any permanent adhesive known in the art which will permanently bond skin layer 204 to backing layer 212 . An example of such a permanent adhesive is Flexicon® adhesive V-402. However, it will be clear to one skilled in the art that other similar suitable adhesives may be used.
[0030] Backing layer 212 has a top surface 210 and a bottom surface 214 , such that top surface 210 of backing layer 212 conforms to and is affixed to bottom surface 206 of skin layer 204 . Backing layer 212 may be comprised of any material suitable for providing support including open cell foam, closed cell foam, felt, paper or rubber. Bottom surface 214 of backing layer 212 is permanently adhered to the top surface 218 of 4-way stretchable material layer 220 . The permanent adhesive attaching bottom surface 214 of backing layer 212 to top surface 218 of 4-way stretchable material layer 220 can be any permanent adhesive known in the art which will permanently bond the surfaces, an example of which is Flexicon® V-402. 4-way stretchable material layer 220 has the ability to stretch in all directions simultaneously. An example of a 4-way stretchable material is mylar. Bottom surface 222 of 4-way stretchable material layer 220 is releasably attached to the railing or hand support system by releasable adhesive 224 . Releasable adhesive 224 is affixed to and completely covers 4-way stretchable material layer 220 from edge to edge and provides releasable adhesion to the railing or hand support system. Releasable adhesive 224 provides secure adhesion to the railing or hand support system but may be removed with a minimal amount of effort by peeling wrap-around advertising surface 200 off the railing or hand support system. An example of a releasable adhesive is Flexicon® V-58.
[0031] [0031]FIG. 4 is an elevated perspective view of wrap-around advertising surface 200 . Skin layer 204 has top surface 202 and bottom surface 206 . Top surface 202 of skin layer 204 has printed indicia that presents visual image 226 . Visual image 226 can be created using any printing or graphic technique known in the art suitable for placing graphic designs on the wrap-around material employed. For example, sublimation printing utilizing heat and pressure to affix preprinted graphics produces a highly durable and accurate graphic. The sublimation ink can be pretreated with UV inhibitors to prevent fading. Luminescent inks can also be used to provide a glow in the dark environment. Puff inks can be used to provide a textured surface. In addition, plastisol inks can be used in a heat transfer application for durable, long-lasting images. Wet ink printing can also be used as well as computer generated digital graphics, which are directly printed on various materials used as skin layer 226 .
[0032] [0032]FIG. 5 discloses an advertising system for presenting a visual image on a railing. For convenience, the component parts of wrap-around surface 100 are numbered as in FIG. 1 designating wrap-around advertising surface 100 . The system of the present invention can be utilized with any type of railing or hand support system 120 . Wrap-around advertising surface 100 of the present invention has a 4-way stretchable material layer 116 with an inner and outer surface, skin layer 104 which has an inner layer and an out layer, the inner layer of the skin layer 104 is permanently adhered to said outer surface of said 4-way stretchable material layer 116 . 4-way stretchable material layer 116 is releasably adhered to railing 120 . Skin layer 104 and said 4-way stretchable material layer 116 each have a width substantially similar to the circumference of railing 120 , such that edges of skin layer 104 and said 4-way stretchable material layer 116 abut when wrapped around railing 120 .
[0033] Referring now to FIGS. 1 and 5, top surface 102 of skin layer 104 has printed indicia that presents visual image 118 . Visual image 118 can be created using any printing or graphic technique known in the art suitable for placing graphic designs on the wrap-around material employed. For example, sublimation printing utilizing heat and pressure to affix preprinted graphics produces a highly durable and accurate graphic. The sublimation ink can be pretreated with UV inhibitors to prevent fading. Luminescent inks can also be used to provide a glow in the dark environment. Puff inks can be used to provide a textured surface. In addition, plastisol inks can be used in a heat transfer application for durable, long-lasting images. Wet ink printing can also be used as well as computer generated digital graphics, which are directly printed on various materials used as skin layer 104 .
[0034] [0034]FIG. 6 discloses yet another advertising system for presenting a visual image on a railing. For convenience, the component parts of wrap-around surface 200 are numbered as in FIG. 3 designating wrap-around advertising surface 200 . Wrap-around advertising surface 200 of the present invention has 4-way-stretchable material layer 220 with an inner and outer surface, backing layer 212 with an inner and outer surface, and skin layer 204 which has an inner surface and an outer surface, the inner surface of the skin layer 204 is permanently adhered to said outer surface of said backing layer 212 . The inner surface of backing layer 212 is permanently adhered to 4-way stretchable material layer 220 . 4-way stretchable material layer 220 is releasably adhered to railing 230 . Skin layer 204 , backing layer 212 and 4-way stretchable material layer 220 each have a width substantially similar to the circumference of railing 230 , such that edges of said skin layer 204 , backing layer 212 and said 4-way stretchable material layer 220 abut when wrapped around railing 230 .
[0035] Referring now to FIGS. 3 and 6, top surface 202 of skin layer 204 has printed indicia that presents visual image 226 . Visual image 226 can be created using any printing or graphic technique known in the art suitable for placing graphic designs on the wrap-around material employed. For example, sublimation printing utilizing heat and pressure to affix preprinted graphics produces a highly durable and accurate graphic. The sublimation ink can be pretreated with UV inhibitors to prevent fading. Luminescent inks can also be used to provide a glow in the dark environment. Puff inks can be used to provide a textured surface. In addition, plastisol inks can be used in a heat transfer application for durable, long-lasting images. Wet ink printing can also be used as well as computer generated digital graphics, which are directly printed on various materials used as skin layer 204 .
[0036] [0036]FIG. 7 discloses a method of advertising using wrap-around around advertising surface 100 . Wrap-around around advertising surface 100 has alignment targets 122 along axis 124 parallel to lengthwise edge 126 of wrap-around around advertising surface 100 . Next alignment targets 128 are placed on railing 130 . Next, wrap around surface 100 is placed on railing 130 so that the center lengthwise axis of wrap-around surface 100 is centered on the axis parallel to the length of railing 130 . Next, wrap-around advertising surface 100 alignment targets 122 are aligned with railing 130 alignment targets 128 . Finally, wrap-around advertising surface 100 has a width substantially similar to the circumference of railing 130 such that when wrap-around advertising surface 100 is folded around railing 130 edges 126 of wrap-around advertising surface 100 abut.
[0037] [0037]FIG. 8 discloses a method of advertising using wrap-around around advertising surface 200 . Wrap-around around advertising surface 200 has alignment targets 232 along axis 234 parallel to lengthwise edge 236 of wrap-around around advertising surface 200 . Next, alignment targets 238 are placed on railing 230 . Next, wrap around surface 200 is placed on railing 230 so that the center lengthwise axis of wrap-around surface 200 is centered on the axis parallel to the length of railing 230 . Next, wrap-around advertising surface 200 alignment targets 232 are aligned with railing 230 alignment targets 238 . Finally, wrap-around advertising surface 200 has a width substantially similar to the circumference of railing 230 such that when wrap-around advertising surface 200 is folded around railing 230 edges 236 of wrap-around advertising surface 200 abut. | A wrap-around advertising surface, system and method of advertising on railings or other hand support systems and for use on poles or support beams. The wrap-around advertising surface includes a skin layer permanently adhered to a 4-way stretchable material layer. The 4-way stretchable material layer is releasably adhered to a railing or other hand support system. A backing layer between the skin layer and the 4-way stretchable material layer can be inserted for support. The wrap-around advertising surface of the present invention is designed to be releasably attachable to the railing or other hand support system. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is related to and claims priority to Japanese Applications No. 2004-254954 filed Sep. 1, 2004, and No. 2004-236831 filed Aug. 16, 2004, in the Japanese Patent Office, the contents of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to mobile stations, such as mobile stations in a mobile wireless communication system using a W-CDMA communication protocol.
[0004] 2. Description of the Related Art
[0005] Currently, standardization of the W-CDMA (UMTS) protocol, a protocol for third generation mobile communication systems, is proceeding under the 3GPP (3rd Generation Partnership Project). HSDPA (High Speed Downlink Packet Access), which provides a maximum downlink transfer speed of approximately 14 Mbps, has been specified as one of the themes for standardization.
[0006] HSDPA is characterized in that it employs an adaptive modulation and coding (AMC) scheme, switching for example between the QPSK modulation scheme and 16-QAM scheme adaptively according to the wireless environment between the base station and mobile station.
[0007] Furthermore, HSDPA employs an H-ARQ (Hybrid Automatic Repeat ReQuest) scheme. Under H-ARQ, when a mobile station detects an error in data received from a base station, a retransmission request is made by the mobile station in question to the base station. The base station performs retransmission of data upon receiving this retransmission request, and thus the mobile station performs error correction decoding using both the already received data and the retransmitted received data. In this way, H-ARQ increases the gain of error correction decoding and reduces the number of retransmissions by effectively utilizing already received data, even if it contains errors.
[0008] The main wireless channels used in HSDPA include HS-SCCH (High Speed-Shared Control Channel), HS-PDSCH (High Speed-Physical Downlink Shared Channel) and HS-DPCCH (High Speed-Dedicated Physical Control Channel).
[0009] HS-SCCH and HS-PDSCH are both downlink (i.e. in the direction from the base station to the mobile station) shared channels. HS-SCCH is a control channel for transmitting various parameters relating to the data transmitted on HS-PDSCH. In other words, it is a channel which notifies (announces) that data is to be transmitted via HS-PDSCH.
[0010] The various parameters include, for example, modulation scheme information indicating which modulation scheme is used to transmit data on HS-PDSCH, the spreading code allocation number (code number), information on the rate matching pattern applied to the transmitted data, etc.
[0011] Furthermore, HS-DPCCH is an uplink (in the direction from the mobile station to the base station) dedicated control channel, which is used by the mobile station for sending ACK or NACK signals to the base station depending on whether or not there was an error in the data received via HS-PDSCH. Namely, it is a channel used for transmitting the reception result for data received via HS-PDSCH. If the mobile station fails to receive data (if the received data has a CRC error, etc.), a NACK signal will be transmitted from the mobile station and the base station will accordingly perform retransmission control.
[0012] In addition, HS-DPCCH is used by a mobile station, which has determined the reception quality (e.g. SIR) of the signal received from the base station, to transmit the results thereof periodically to the base station as CQI (Channel Quality Indicator) information. The base station judges the goodness of the downstream wireless environment based on the received CQI information, and if it is good, switches to a modulation scheme allowing transmission of data at higher speed, or switches to a modulation scheme which transmits data at a lower speed if the wireless environment is not good (i.e., performs adaptive modulation).
[0013] Channel Structure
[0014] Next, the channel configuration of HSDPA will be described.
[0015] FIG. 1 is a drawing which illustrates the channel configuration of HSDPA. Since W-CDMA employs a code division multiplexing scheme, the individual channels are separated by code.
[0016] First, the channels which have not been explained will be briefly described.
[0017] CPICH (Common Pilot Channel) and SCH (Synchronization Channel) are downlink shared channels.
[0018] CPICH is a channel for transmitting a so-called pilot signal, and is used by the mobile station for channel estimation, cell search and as timing reference for other downlink physical channels in the same cell. SCH strictly speaking includes P-SCH (Primary SCH) and S-SCH (Secondary SCH), and is a channel transmitted in bursts in 256 chips at the head of each slot. SCH is received by mobile stations which perform three-step cell search and is used for establishing slot synchronization and frame synchronization.
[0019] Next, the timing relationship of the channels will be described using FIG. 1 .
[0020] As shown in the drawing, in each channel, one frame (10 ms) consists of 15 slots (each slot comprises a 2560 chip length). As described above, CPICH is used as a reference for other channels, so the head of the P-CCPCH and HS-SCCH frames is aligned with the head of the CPICH frame. Here, the head of the HS-PDSCH frame is delayed by 2 slots relative to HS-SCCH, etc., which is to make it possible for the mobile station to perform demodulation of HS-PDSCH with the modulation scheme corresponding to the received modulation scheme after receiving modulation scheme information via HS-SCCH. Furthermore, HS-SCCH and HS-PDSCH comprise sub-frames of 3 slots.
[0021] HS-DPCCH is an uplink channel. Its first slot is used for transmitting an ACK/NACK signal indicating the HS-PDSCH reception result from the mobile station to base station approximately 7.5 slots after the HS-PDSCH reception. Furthermore, the second and third slots are used for periodically transmitting CQI information as feedback for adaptive modulation control to the base station. Here, the transmitted CQI information is calculated based on the reception environment (e.g. the SIR determination result for CPICH) as determined in the period from 4 slots until 1 slot before the CQI transmission.
[0022] The ACK and NACK signals used for notifying whether reception of HS-PDSCH was or was not possible may be repeated multiple times depending on the settings.
[0023] Namely, as illustrated in FIG. 1 , having received an HS-PDSCH transmission announcement in the first sub-frame (A) of HS-SCCH, the mobile station demodulates and decodes HS-PDSCH (first sub-frame E), which is delayed by two slots, performs a CRC check, and detects if any error is present.
[0024] Here, in the case where a determination of no error was made, as shown in the drawing, an ACK signal is transmitted in the first slot (slot C in the drawing) of the sub-frame delayed by approximately 7.5 slots from the HS-PDSCH reception, and transmission of the same ACK signal is repeated in the first slot (slot D in the drawing) of the subsequent sub-frame. Of course, if there was an error, a NACK signal would be repeatedly transmitted.
[0025] It is of course also possible to not have the reception result transmitted repeatedly, but repeating the transmission of the ACK signal or NACK signal N times in this manner (N is a natural number) ensures more reliable reception of the ACK signal or NACK signal by the base station and prevents unneeded retransmission control.
[0026] However, in order for transmission of the ACK signal or NACK signal to be repeated in the next sub-frame, HS-PDSCH cannot be transmitted to the same mobile station in the following N sub-frames, including the next sub-frame (F).
[0027] This is in order to prevent losing the ability to distinguish between whether the ACK signal (slot D in the drawing) is the repeated transmission of the reception result (ACK or NACK signal) relating to the first sub-frame E of HS-PDSCH corresponding to the first sub-frame A of HS-SCCH, or the initial transmission of the reception result (ACK or NACK signal) relating to the second sub-frame F of HS-PDSCH corresponding to the second sub-frame B of HS-SCCH.
[0028] Next, the content and coding procedure of the data transmitted on HS-SCCH will be described.
[0029] Data Transmitted on HS-SCCH
[0030] The following data are transmitted on HS-SCCH. These data are used for reception processing of HS-PDSCH, which is transmitted after a 2 slot delay.
( 1 ) X ccs (Channelization Code Set information) ( 2 ) X ms (Modulation Scheme information) ( 3 ) X tbs (Transport Block Size information) ( 4 ) X hap (Hybrid ARQ Process information) ( 5 ) X rv (Redundancy and constellation Version) ( 6 ) X nd (New Data indicator) ( 7 ) X ue (User Equipment identity)
[0038] ( 1 ) through ( 7 ) will now be described.
[0039] ( 1 ) Xccs is a datum indicating the spreading code used for transmitting data on HS-PDSCH (e.g. a datum indicating a multi-code number and code offset combination), and consists of 7 bits.
[0040] ( 2 ) Xms is a datum indicating that the modulation scheme used on HS-PDSCH is either QPSK or 16-QAM, and consists of 1 bit.
[0041] ( 3 ) Xtbs is a datum used for computing the transport block size of data transmitted on HS-PDSCH (the size of data transmitted in one HS-PDSCH sub-frame), and consists of 6 bits.
[0042] ( 4 ) Xhap is a datum indicating the H-ARQ process number, and consists of 3 bits. The base station is unable to judge whether or not data was successfully received by the mobile station until the base station receives an ACK or NACK. However, if one were to wait until receiving an ACK or NACK before transmitting a new data block, the transport efficiency would drop. Thus, to allow transmission of new data blocks before an ACK or NACK is received, a process number is defined for each data block transmitted in a sub-frame, and the mobile station discriminates the reception processing it performs according to the process number. In other words, when performing retransmission, the base station assigns a process number to transport blocks under the condition that the same process number is assigned as that of the previously sent block, and transmits it via HS-SCCH as Xhap.
[0043] Therefore, the mobile station classifies the data received via HS-PDSCH based on the Xhap it has received, distinguishing between new transmission and retransmission within a data stream for which the same process number was provided via HS-SCCH based on Xnd, which will be discussed under ( 6 ), combining new data with retransmitted data, and the like.
[0044] ( 5 ) Xrv is a datum indicating the redundancy version (RV) parameters (s, r) and constellation version parameter (b) for HS-PDSCH retransmission, and consists of 3 bits.
s is a bit which indicates whether or not systematic bits are to be prioritized in the rate matching, which will be described later. For example, if s=1, the systematic bits are prioritized, and if s=0, the systematic bits are not prioritized. r indicates the bit pattern of puncture and repetition and b indicates the constellation rearrangement pattern for rate matching.
[0046] During retransmission, considering the combining on the receiving side, it is desirable to vary the transmitted bits or change the constellation arrangement, so Xrv is used by cycling it between 0 and 7. Furthermore, since there is no need to change Xrv for each initial transmission, the initial value for new transmissions can be fixed.
[0047] ( 6 ) Xnd is a datum indicating whether the block transmitted on HS-PDSCH is a new block or a retransmitted block, and consists of 1 bit. For example, when transmitting a new block, it would be switched from 0 to 1 or from 1 to 0, and for retransmission, it would not be switched and the same value would be used.
[0048] For example, when performing new transmission, retransmission, new transmission, retransmission, retransmission and new transmission in that order, the bits would change as follows: 1, 1, 0, 0, 0, 1.
[0049] ( 7 ) Xue is a datum indicating mobile station identification information, and consists of 16 bits.
“Coding of data transmitted on HS-SCCH”
[0051] FIG. 2 is a drawing illustrating the coding procedure (coding device) for the aforementioned data ( 1 ) through ( 7 ) which are transmitted on HS-SCCH. This coding is performed mainly by the base station.
[0052] In the drawing, 1 is a coding unit, 2 is a rate matching unit, 3 is a multiplier, 4 is a CRC computation unit, 5 is a multiplier, 6 is a coding unit, 7 is rate matching unit, 8 is a coding unit and 9 is a rate matching unit.
[0053] Next, the operation of each block will be explained.
[0054] ( 1 ) Xccs, represented by 7 bits (x 1 , 1 ˜x 1 , 7 ), and ( 2 ) Xms, represented by 1 bit (x 1 , 8 ), are input into the coding unit 1 as a datum of 8 bits total. Here, the first number of the subscript signifies that this relates to data transmitted in the first part (first slot), and the second number, separated by a comma (,), indicates the number of the bit.
[0055] Coding unit 1 appends 8 tail bits to the input data and performs convolution coding with a code rate of ⅓ on the total of 16 bits. Therefore, the coded data becomes a total of 48 bits, and is supplied as z 1 , 1 ˜z 1 , 48 to the rate matching unit 2 . Rate matching unit 2 performs puncture or repetition processing or the like on specific bits to adjust them to a bit number that will fit into the first slot (here, assumed to be 40 bits), and outputs the result (r 1 , 1 ˜r 1 , 40 ).
[0056] Data from the rate matching unit 2 is multiplied with c 1 ˜c 40 by the multiplier 3 and output as s 1 , 1 ˜s 1 , 40 , and is transmitted in the first slot (first part), which is the slot at the head of the sub-frame of HS-SCCH in FIG. 1 .
[0057] Here, c 1 ˜c 40 are obtained by taking data from ( 7 ) Xue (xue 1 ˜xue 16 ), appending 8 tail bits thereto and then convolution coding with a coding rate of ½ in coding unit 8 to obtain b 1 ˜b 48 , and further performing the same sort of bit adjustment in rate matching unit 9 as was done in rate matching unit 2 .
[0058] Meanwhile, the 6-bit ( 3 ) Xtbs (x 2 , 1 ˜x 2 , 6 ), 3-bit ( 4 ) Xhap (x 2 , 7 ˜x 2 , 9 ), 3-bit ( 5 ) Xrv (x 2 , 10 ˜x 2 , 12 ) and 1-bit ( 6 ) Xnd (x 2 , 13 ) are input as a total of 13 bits y 2 , 1 ˜y 2 , 13 together with the 16-bits y 2 , 14 ˜y 2 , 29 , for a total of 29 bits y 2 , 1 ˜y 2 , 29 , into coding unit 6 .
[0059] Here, y 2 , 14 ˜y 2 , 29 are obtained by performing CRC computation processing on the total of 21 bits of ( 1 ) through ( 6 ) in the CRC computation unit 4 and multiplying c 1 ˜c 16 , as the result of the computation, by ( 7 ) Xue (xue 1 ˜xue 16 ).
[0060] The y 2 , 1 ˜y 2 , 29 which are input into coding unit 6 have 8 tail bits added thereto and are convolution coded with a ⅓ coding rate and input as 111-bit data z 2 , 1 ˜z 2 , 111 into the rate matching unit 7 .
[0061] The rate matching unit 7 outputs 80 bits, r 2 , 1 ˜r 2 , 80 , by means of the aforementioned puncture or other such processing, and these r 2 , 1 ˜r 2 , 80 are transmitted in the second part (second and third slots) in 1 sub-frame on HS-SCCH in FIG. 1 .
[0062] As described above, the data of ( 1 ) and ( 2 ) are transmitted in the first slot, while ( 3 ) through ( 6 ) are transmitted in the second through third slots, thus being transmitted distinctly in separate slots; on the other hand, the CRC computation is carried out on them in common, with the CRC computation result being transmitted within the second slot, so detection of reception error becomes possible once both the first and second parts are completely received.
[0063] Furthermore, since the data to be transmitted in the first slot is convolution coded by coding unit 1 and then multiplied by ( 7 ) Xue in the multiplier 3 , when data addressed to another station is received in the first slot, the likelihood generated in the decoding process will be smaller compared to if the data were addressed to the receiving station, thus making it possible to know if there is a high probability of the data not being addressed to the receiving station by comparing the likelihood to a reference value.
“Coding of data transmitted on HS-PDSCH”
[0065] Next, the process until the transmission data is transmitted via HS-PDSCH will be described using a block diagram.
[0066] FIG. 3 is a diagram illustrating a wireless base station.
[0067] In the drawing, 10 represents a control unit which successively outputs the transport data to be transmitted via HS-PDSCH (the data transmitted within one sub-frame) as well performing control of the various units ( 11 through 26 , etc.). The values of ( 1 ) through ( 7 ) explained in FIG. 2 are given by this control unit 10 .
[0068] Since HS-PDSCH is a shared channel, it is permitted for the successively output transport data to be addressed to different mobile stations.
[0069] 11 represents a CRC attachment unit which performs CRC computation on the successively input transport data (data transmitted within the same wireless frame) and attaches the results of CRC computation to the tail of the transport data, and 12 represents a bit scrambling unit which imparts randomness to the transmitted data by applying a bit-unit scramble to the transport data with the CRC computation results attached thereto.
[0070] 13 represents a code block segmentation unit which segments (e.g. into two equal parts) the input bit-scrambled transport data if it exceeds a certain data length, for the purpose of preventing the computation load of the receiving side decoder from increasing due to excessive length of the data to be coded in the subsequently performed channel coding, or for other purposes. The drawing shows a case where the input data length exceeded a specific data length and the output has been split into two equal parts (segmented into a first data block and second data block). Of course, cases where the number of segments segmented into is other than two are also possible, as are cases where the segments are not equal parts but have different data length.
[0071] 14 represents a channel coding unit which performs error correction coding individually on each segmented datum. It is preferable to use a turbo coder for the channel coding unit 14 .
[0072] Thus, the first output, for the first block, contains the important systematic bits (U) which are the same data as the data subjected to coding, the first redundancy bits (U′) obtained by convolution coding of the systematic bits (U), and the second redundancy bits (U″) obtained by interleaving and then similarly convolution coding the systematic bits. Likewise, the second output contains the systematic bits (U), first redundancy bits (U′) and second redundancy bits (U″) for the second block.
[0073] 15 represents a bit separation unit which separates the first block and second block serially input from the channel coding unit 14 (turbo coder) into systematic bits (U), first redundancy bits (U′) and second redundancy bits (U″) and outputs them.
[0074] 16 represents a first rate matching unit which performs rate matching, such as puncturing (thinning), on the input data so that the input data (in cases where data is segmented into multiple blocks, all the data of the segmented blocks) will be of a quantity that fits into a specific region of the subsequent virtual buffer unit 17 .
[0075] 17 represents a virtual buffer unit wherein a region is established by the control unit 10 according to the reception processing capacity of the mobile station to be transmitted to, in which region data rate-matched by the first rate matching unit 16 is buffered. For retransmission, by outputting the buffered data, the processing from the CRC attachment unit 11 to the first rate matching unit 16 can be omitted, but in cases where one wishes to modify the coding rate for retransmission or the like, it is desirable to re-output the transmission data stored in the control unit 10 and not use the buffered data. It is also possible to actually provide no buffer for the virtual buffer 17 and simply make it pass-through. In this case, retransmitted data would be re-output from the control unit 10 .
[0076] 18 represents a second rate matching unit for adjusting data to a length that can fit into a sub-frame designated by the control unit 10 ; it adjusts the data length of input data by performing puncture (thinning) and repetition processing so as to obtain the designated data length.
[0077] This second rate matching unit 18 performs rate matching according to the previously explained RV parameters.
[0078] Namely, depending on the RV parameters, when s=1, rate matching is performed so as to leave as many systematic bits as possible, and when s=0, it is permitted on the contrary to reduce the systematic bits and leave more redundancy bits. Furthermore, puncture and rate matching are preformed by a pattern that follows r.
[0079] 19 represents a bit collection unit which arranges the data from the second rate matching unit 19 into a plurality of bit sequences. Namely, data of the first block and data of the second block are arranged according to a specific bit arrangement method to output a plurality of bit sequences for designating signal points on a phase plane. Since a 16-QAM modulation scheme is used in this embodiment example, the bit sequence consists of 4 bits. When using a 64-QAM modulation scheme, the bit sequence would be made 6 bits, and when using a QPSK modulation scheme, the bit sequence would be made 2 bits.
[0080] 20 segments and outputs the bit sequences into the same number of branches as the spreading code number indicated by the control unit 10 . Namely, it represents a physical channel segmentation unit which, when the code number in the transmission parameters provided by the control unit 10 is N, maps and outputs the input bit sequence sequentially to branches 1 through N.
[0081] 21 represents an interleaving unit which performs interleaving on the bit sequences of N branches and outputs the result.
[0082] 22 represents a constellation rearrangement unit for 16-QAM, which is capable of rearranging bits within each input bit sequence. Bit rearrangement is performed according to the previously described constellation version. Examples of bit rearrangement include swapping the high order and low order bits. It is preferable to perform bit swapping for multiple bit sequences according to the same rule.
[0083] 23 represents a physical channel mapping unit which maps the bit sequences of N branches onto the corresponding spreading block of the subsequent spreading unit 24 .
[0084] 24 represents a spreading unit which comprises multiple spreading blocks, each of which outputs a corresponding I and Q voltage based on each bit sequence of N branches and performs spreading thereon with different spreading codes and outputs the result.
[0085] 25 represents a modulating unit which combines the signals spread by the spreading unit 24 , performs e.g. 16-QAM modulation scheme amplitude phase modulation on the result thereof, amplifies it by means of a variable gain amplifier, further frequency-converts it to a wireless signal, and then outputs it to the antenna side as a wireless signal to enable transmission.
[0086] Under HSDPA, it is possible to multiplex signals addressed to other mobile stations within sub-frames of the same timing by means of a spreading code, so it is desirable to provide a plurality of sets of 10 through 25 , variable gain amplifier, etc. (these will be referred to as transmission sets), combine the output signals of the variable gain amplifiers, frequency-convert them together, and then transmit the result to the antenna side. Of course, since there is a need to separate by code, for the spreading code used by the spreading unit 24 of each transmission set, a different spreading code would be used so as to allow separation.
[0087] 26 represents a receiving unit, which receives signals from the mobile station received via HS-DPCCH or the like, and provides ACK and NACK signals, CQI, etc. to the control unit 10 .
[0088] As discussed above, if an ACK signal is received, the next new data is transmitted, but in the case of a NACK signal or a DTX state where there is no response, the control unit 10 performs retransmission control so as to retransmit the transmitted data.
[0089] Of course, as described above if the mobile station repeats the transmission of ACK and NACK signals, control would be performed so that data addressed to that mobile station will not be transmitted in the HS-PDSCH sub-frame corresponding to the repeated ACK signal or NACK signal transmitted by the mobile station, and retransmission control would be performed based on the repeatedly transmitted ACK signal or NACK signal.
[0090] Retransmission is limited to the maximum number of retransmissions that is set, and if no ACK signal is received from the mobile station upon reaching the maximum number of retransmissions, control is provided to switch to transmission of the next new data.
[0091] In cases where a maximum number of retransmissions is not defined, it is possible to start a timer from a new transmission and switch to transmission of the next new data when a specific time period is detected to have elapsed and no ACK signal has been received.
[0092] The foregoing was a description of the names and operation of the various units.
[0093] Matters relating to HSDPA as discussed above are disclosed for instance in 3G TS 25.212 (3rd Generation Partnership Project: Technical Specification; Group Radio Access Network; Multiplexing and channel coding (FDD)) and in 3G TS 25.214 (3rd Generation Partnership Project: Technical Specification; Group Radio Access Network; Physical layer procedures (FDD)).
SUMMARY OF THE INVENTION
[0094] According to the background art described above, the mobile station receives a channel (HS-SCCH) which notifies that data is to be transmitted, and performs reception of data (HS-PDSCH) upon receiving a notification addressed to the station in question, and to this end, the mobile station performs reception processing (demodulation, decoding, etc.) of the channel (HS-SCCH) via which notifications are conducted, but the reception processing leads to substantial power consumption.
[0095] Thus, an objective of the present invention is to reduce power consumption in the mobile station by controlling reception of the channel (HS-SCCH) which notifies that data is to be transmitted.
[0096] Providing beneficial effects, not limited to the above objective, derived from the various components of the best mode for practicing the invention as described below and which cannot be obtained from the prior art can also be positioned as an objective of the present invention.
[0097] (1) The present invention employs a mobile station which receives a first datum and transmits a first reception result with a first timing when a first notification was received via a channel which notifies that data is to be transmitted, and receives a second datum and transmits a second reception result with a second timing when a second notification with a different timing was received via said channel, said mobile station being characterized in that it comprises: a repeat transmission unit which, upon receiving said first notification, transmits said first reception result with said first timing, and repeats the transmission with said second timing; and a control unit which imposes a restriction on the reception processing with said different timing of said channel which notifies that data is to be transmitted when said first notification is received.
[0098] (2) A mobile station as set forth in (1), characterized in that said restriction is a discontinuation of demodulation or decoding.
[0099] (3) A mobile station as set forth in (1), characterized in that said restriction is that demodulation or decoding is not performed.
[0100] (4) An HSDPA-compatible mobile station which, upon detecting that a message addressed to that mobile station was transmitted via HS-SCCH, receives the corresponding HS-PDSCH sub-frame, and which, when transmitting the reception result, repeats the transmission of said reception result n times, said mobile station being characterized in that it comprises: a control unit which performs control to restrict demodulation or decoding of the first part of the next sub-frame after the HS-SCCH sub-frame on which said detection was performed.
[0101] (5) A mobile station as set forth in (4), characterized in that, when said n is 2 or greater, said control unit performs control such that demodulation and decoding are not carried out on the first part of the second and subsequent HS-SCCH sub-frames after the sub-frame on which said decoding was performed.
[0102] According to the present invention, power consumption in the mobile station is reduced by controlling reception of the channel which notifies that data is to be transmitted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0103] FIG. 1 is a drawing illustrating the channel configuration of HSDPA.
[0104] FIG. 2 is a drawing illustrating the HS-SCCH coding unit.
[0105] FIG. 3 is a drawing illustrating a transmission device (wireless base station).
[0106] FIG. 4 is a drawing illustrating a mobile station according to the present invention.
[0107] FIG. 5 is a drawing illustrating the HS-SCCH reception processing in the mobile station according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0108] Below, modes for practicing the present invention are described by referring to the drawings.
(a) Description of First Embodiment
[0109] FIG. 4 is a drawing illustrating an example of a mobile station according to the present invention. Here, in particular, a mobile station used in an HSDPA-compatible W-CDMA communication system as described above is presented as an example. The present invention can of course also be applied to mobile stations in other communication systems so long as the principles of the present invention are followed.
[0110] The wireless communication device with which wireless communication is conducted can be a wireless base station as illustrated in FIG. 3 , the operation of which is as described above.
[0111] In the drawing, 30 represents an antenna, 31 represents a duplexer, 32 represents an orthogonal detection unit, 33 represents and A/D conversion unit, 34 represents a CPICH reception processing unit, 35 represents an HS-SCCH reception processing unit, 36 represents an HS-PDSCH reception processing unit, 37 represents a storage unit, 38 represents a control unit, and 39 represents a transmission processing unit.
[0112] The mobile station receives downlink channels (e.g. CPICH, P-CCPCH, HS-SCCH, HS-PDSCH) by means of the antenna 30 and inputs the received signal via the duplexer 31 into the orthogonal detection unit 32 to perform orthogonal detection.
[0113] Subsequent to orthogonal detection, the signal is converted by the A/D conversion unit 33 into a digital signal. This makes it possible to perform subsequent processing in the digital domain.
[0114] The received signal, having been converted to a digital signal, is provided to the CPICH reception processing unit 34 , HS-SCCH reception processing unit 35 and HS-PDSCH reception processing unit 36 .
[0115] The CPICH reception processing unit 34 determines the reception environment used for specifying the CQI information which serves as a parameter used in adaptive modulation control at the base station. As an example, the SIR of the CPICH downlink signal may be determined. Furthermore, the CPICH reception processing unit 34 , making use of the fact that the received CPICH is a known signal, computes a channel estimate for compensating for phase rotation, attenuation, etc. of the signal in the propagation path (channel compensation), and provides the channel estimate to the HS-SCCH reception processing unit 35 and HS-PDSCH reception processing unit 36 . It is well known that a channel estimate is obtained by evaluating how much the received signal is displaced from a known signal point on a phase plane.
[0116] The reception environment is determined regularly, for example in the period from 4 slots until 1 slot before the slot in which CQI information is transmitted. Various cycles of determination are possible. For instance, one can perform the determination once per 20 ms, transmit the same determination result repeatedly in the first through fourth sub-frames, cease transmitting it in the remaining six sub-frames, perform one determination for the next wireless frame, and similarly perform transmission in specific sub-frames.
[0117] The HS-SCCH reception processing unit 35 is a reception processing unit for receiving signals transmitted via HS-SCCH as shown in FIG. 1 , which performs reception processing such as de-spreading and decoding using a channel estimate for each first slot (first part) of HS-SCCH and provides the decoding result to the control unit 38 .
[0118] The first slot (first part) is a slot in which a signal is transmitted which is obtained by convolution coding Xccs (Channelization Code Set information) and Mms (Modulation Scheme information) and multiplying by Xue (User Equipment identity). The HS-SCCH reception processing unit 35 , after de-spreading, uses the given station's own Xue to perform the reverse of that computation, and then performs decoding, such as Viterbi decoding, and outputs the decoding result to the control unit 38 .
[0119] If the control unit 38 determines based on the decoding result that the message was addressed to the station in question, a demodulation and decoding instruction for the second part will be issued by the control unit 38 , so de-spreading and decoding will be performed on the remaining second and third slots (second part) of HS-SCCH, perform error detection (CRC error detection) processing on the decoded data, and output the decoding result and error detection result to the control unit 38 .
[0120] The data obtained as the decoding result for the second part of HS-SCCH contains Xtbs (Transport Block Size information), Xhap (Hybrid ARQ Process information), Xrv (Redundancy and constellation Version), Xnd (New Data indicator), etc.
[0121] When the HS-SCCH reception processing unit 35 receives a message addressed to the station in question, the HS-PDSCH reception processing unit 36 is instructed by the control unit 38 to execute reception processing.
[0122] Therefore, following that instruction, it performs demodulation (de-spreading) and decoding on the received HS-PDSCH, performs error detection (CRC check result) processing on the decoded data, and outputs the decoding result and error detection result to the control unit 38 .
[0123] Here, the information needed to perform reception processing is obtained by receiving it via HS-SCCH and is indicated via the control unit 38 . For example, the control unit 38 may instruct the HS-PDSCH reception processing unit 36 to perform de-spreading with the de-spreading code set indicated by Xccs and to perform demodulation by the demodulation scheme corresponding to the modulation scheme indicated by Xms.
[0124] If the error detection result for HS-SCCH is that there was an error, there is a large possibility that the message was not addressed to the receiving station, and thus it is possible to discontinue demodulation and decoding of HS-PDSCH.
[0125] The storage unit 37 is used for storing data needed by the control unit 38 . For instance, it may store a CQI table. The CQI table contains correlations between reception environment and the parameters (CQI values) used for adaptive modulation control.
[0126] The control unit 38 controls the operation of the various units (for example, by controlling the possibility of the operation by giving an enable signal or disable signal), acquires the reception SIR from the CPICH reception processing unit 34 , acquires the decoding result and CRC check result from the HS-SCCH reception processing unit 35 and the decoding result and CRC check result from the HS-PDSCH reception processing unit 36 , and executes specific processing based on these data.
[0127] For example, the control unit 38 may acquire CQI information corresponding to the acquired SIR by looking up information stored in the storage unit 37 and provide it to the transmission processing unit 39 , thereby causing it to be transmitted in the second and third slots; determine if there is a message addressed to the mobile station in question based on the decoding result from the HS-SCCH reception processing unit 35 , and if so, instruct the HS-PDSCH reception processing unit 36 to perform demodulation and decoding; and generate an ACK signal or NACK signal according to the CRC check result from the HS-PDSCH reception processing unit 36 and provide that signal to the transmission processing unit 9 .
[0128] As discussed above, the determination of the presence of a message addressed to the station in question can also be performed based on whether the path metric generated by the decoding is below a specific value.
[0129] The transmission processing unit 39 transmits the CQI information and ACK signal or NACK signal from the control unit 38 in a specific HS-DPCCH slot.
[0130] When the wireless base station instructs (for instance, via an announcement channel) that repeated transmission of ACK signals and NACK signals be performed, this instruction would be received by an unillustrated announcement channel reception unit, and based on this instruction, the control unit 38 would shift to repeat transmission mode, and instruct the transmission processing unit 39 to repeatedly transmit ACK signals and NACK signals.
[0131] Preferably, the instruction from the wireless base station will contain the number of repeated transmissions (n), but if such notification is not provided by the wireless base station, one may also preset it (e.g., by storing a flag indicating repeat transmission mode and the number of repeated transmissions (n) in the storage unit 37 ) and have the control unit 38 refer to this to find out that repeat transmission mode is on and what the number of repeated transmission (n) is.
[0132] When in repeat transmission mode, if it is detected that a message addressed to the receiving station was transmitted via HS-SCCH (notification detection), the control unit 38 of the mobile station controls the HS-SCCH reception processing unit 35 such that, when receiving the corresponding HS-PDSCH sub-frame and transmitting the reception result, the reception result will be repeatedly transmitted n times, but demodulation or decoding will be restricted for the first part of the next sub-frame after the HS-SCCH sub-frame in which the notification was detected (preferably, for n sub-frames after the HS-SCCH sub-frame in which the notification was detected).
[0133] As explained above, when the wireless base station has instructed that repeat transmission be performed or when the mobile station has been preset to repeat transmission mode, ACK signals and NACK signals are transmitted repeatedly from the mobile station.
[0134] Thus, if HS-PDSCH was transmitted to the mobile station in question, the wireless base station performs control such that data is not transmitted via HS-PDSCH to the same mobile station until transmission of the number of sub-frames corresponding to the number of repeats (n) has been completed. Consequently, with regard to HS-SCCH as well, it is assumed that the wireless base station will not transmit messages addressed to the same mobile station until transmission of the number of sub-frames corresponding to the number of repeats (n) has been completed. Therefore, it may be favorable, with respect to reducing the power consumption of the mobile station, to actively restrict reception of HS-SCCH in the mobile station.
[0135] The foregoing was an overview of the operation of the units shown in FIG. 4 .
[0136] Moreover, the base station, based on the CQI information received via HS-DPCCH, performs subsequent transmissions using the corresponding transmission (modulation) scheme, transmits the next new data upon receipt of an ACK signal, and performs retransmission of the transmitted data in case of receiving a NACK signal or if no ACK signal is received within a specific time period after transmission. Here, in cases where the response signal is transmitted repeatedly, if an ACK signal is received once, it can be judged to mean that overall an ACK signal was transmitted, or the reception result which is received most over the repeated transmissions can be judged as being correct.
[0137] HS-SCCH Reception Processing
[0138] Next, the HS-SCCH reception processing procedure in the mobile station will be described in detail using FIG. 5 . The decision processing here is performed in the control unit 38 .
[0139] First, the control unit 38 determines whether repeat transmission mode is on (step 1 ).
[0140] As explained previously, there are cases where there will be an instruction from the wireless base station to shift to repeat transmission mode, cases where the mode is preset in the control unit 38 , and the like.
[0141] If repeat transmission mode was determined to be on, the control unit 38 next attempts demodulation and decoding of the first part of HS-SCCH in step 2 . The demodulation and decoding is performed by the control unit 38 by controlling the HS-SCCH reception processing unit 35 (e.g. by issuing an enable signal).
[0142] Being controlled to perform demodulation and decoding, the HS-SCCH reception processing unit 35 performs de-spreading with a de-spreading code corresponding to HS-SCCH for the first slot of each HS-SCCH sub-frame as shown in FIG. 1 , performs decoding, such as Viterbi decoding, on the de-spread signal, and outputs the decoding result to the control unit 38 . Based on the decoding result, the control unit 38 determines if there is a message (notification of data transmission) addressed to its station.
[0143] To further increase the precision of detection of the presence/absence of notification, one can also determine if Xccs and Xms are undefined bits or are within the capabilities of the mobile station, and judge there to be a notification if they are defined bits or are within the capabilities of the mobile station, or judge there to be no notification if they are undefined bits or are beyond the capabilities of the mobile station.
[0144] Here, if it is determined that a notification is present, one proceeds to step 4 , and if it determined that there is no notification, one returns to step 2 to perform reception processing of the first part of the next HS-SCCH sub-frame.
[0145] In step 4 , the HS-SCCH reception processing unit 35 is controlled to perform demodulation and decoding of the second part of HS-SCCH, and the HS-PDSCH reception processing unit 36 is controlled to perform demodulation and decoding of HS-PDSCH. Furthermore, preferably, the control unit 38 itself is set to avoid demodulation (decoding) of HS-SCCH.
[0146] Thus, the HS-SCCH reception processing unit 35 de-spreads and decodes the second and third slots which follow the first slot of HS-SCCH.
[0147] Furthermore, the HS-PDSCH reception processing unit 36 performs de-spreading using the de-spreading code indicated by HS-SCCH and performs decoding, such as turbo decoding, on HS-PDSCH, while is transmitted with a two-slot delay relative to HS-SCCH.
[0148] Once decoding of the second part of HS-SCCH is completed by the processing of step 4 , the HS-SCCH reception processing unit 35 performs a CRC error check on the entire HS-SCCH sub-frame, and it is determined if the decision in step 3 was correct or not (step 5 ).
[0149] Here, if there was an error (if a CRC error is present), the detection of notification in step 3 is taken to be erroneous, so if HS-PDSCH demodulation and decoding was being executed, it is discontinued and one returns to step 2 to perform reception processing of the next HS-SCCH sub-frame.
[0150] The setting of HS-SCCH demodulation (decoding) avoidance, which was set in step 4 , is preferably cancelled. Even if it is not canceller, there will be no operational problems, since avoidance will not be carried out if one does not proceed to step 7 .
[0151] If it is determined in step 5 that there is no error (CRC error), one proceeds to step 7 , determines if avoidance of demodulation or decoding of HS-SCCH has been completed, and if it is determined to have been completed, one returns to step 2 , while if it has not been completed, one repeats the decision of the step 7 until it has been completed.
[0152] In other words, the control unit 38 gives a disable signal to the HS-SCCH reception processing unit 35 , thereby controlling it such that demodulation or decoding of HS-SCCH is not performed until avoidance has been completed. In this case, the HS-PDSCH reception processing unit 36 is also controlled to not perform demodulation or decoding of HS-PDSCH until avoidance has been completed by giving it a disable signal.
[0153] Completion of avoidance can be determined by detecting the fact that at least demodulation or decoding was not carried out on a number of sub-frames corresponding to the number of repeats n (a natural number) indicated by the wireless base station or preset in the mobile station (e.g. stored in storage unit 37 ).
[0154] For example, subtracting the number, of sub-frames for which demodulation and decoding were avoided from n, avoidance can be judged to have been completed at the stage where n becomes 0.
[0155] Here, in addition to not demodulating and/or decoding all n sub-frames, one can also not demodulate and/or decode 1 out of n sub-frames. Furthermore, if n is 2 or greater, providing control such that demodulation and decoding is not performed on all sub-frames starting with the second of the n sub-frames will greatly reduce power consumption. This is because here, with respect to the first sub-frame, HS-SCCH error detection processing has not been completed, so demodulation of the first part could be initiated.
[0156] Finally, the case where the number of repeats is 1 will be described using FIG. 1 .
[0157] In FIG. 1 , when a message (notification) addressed to this mobile station is transmitted in the first sub-frame (A) of HS-SCCH, the mobile station transmits the reception result (ACK signal or NACK signal) in slot C of HS-DPCCH, and repeats the transmission of the same reception result once in slot D.
[0158] The wireless base station has transmitted data addressed to this mobile station in the first sub-frame E of HS-PDSCH, and thus performs control so that data is not transmitted to this mobile station in the following second sub-frame F, as was explained above.
[0159] Thus, it becomes possible to reduce power consumption by controlling the mobile station such that it does not perform demodulation or decoding on the second sub-frame B of HS-SCCH.
[0160] Here as well, if error detection processing of HS-SCCH is not completed on time before initiation of the reception processing for the next HS-SCCH sub-frame, reception processing of the next HS-SCCH may be initiated.
[0161] In other words, in cases where the error detection result for the first sub-frame A of HS-SCCH in FIG. 1 is output during reception of the first slot (first part) of the second sub-frame or the like, demodulation processing (de-spreading) of the first slot of the second sub-frame B will have been initiated already, so it would be preferable to either discontinue de-spreading and control the HS-SCCH reception processing unit 35 to not perform decoding after the error detection result was determined to be error-free, or else control the HS-SCCH reception processing unit 35 to discontinue decoding or not perform decoding.
[0162] In this way, by discontinuing the operation before reception processing (demodulation, decoding) of the first part has been fully completed, it becomes possible to at least somewhat reduce the power consumption of the HS-SCCH reception processing unit 35 .
[0163] Under non-repeat mode processing of step 8 , the processing of steps 2 through 7 of FIG. 5 would be performed while omitting step 4 , in which HS-SCCH demodulation (decoding) avoidance is set, and step 7 .
[0164] Furthermore, while in this example, HS-SCCH demodulation (decoding) avoidance was set in step 4 , it also possible to not make this setting and rather execute the processing whereby demodulation and decoding is not performed (or is discontinued if demodulation or decoding has been initiated already) in step 7 , for the number of HS-SCCH sub-frames corresponding to the number of repeats, if a determination of no error is made in step 5 .
[0165] Although specific embodiments of the present invention have been described, it will be understood by those of skill in the art that there are other embodiments that are equivalent to the described embodiments. Accordingly, it is to be understood that the invention is not to be limited by the specific illustrated embodiments, but only by the scope of the appended claims. | A mobile station receives a first datum and transmits a first reception result with a first timing when a first notification was received via a channel which notifies that data is to be transmitted, and receives a second datum and transmits a second reception result with a second timing when a second notification with a different timing was received via said channel, said mobile station being characterized in that it comprises: a repeat transmission unit which, upon receiving said first notification, transmits said first reception result with said first timing, and repeats the transmission with said second timing; and a control unit which imposes a restriction on the reception processing control of said second notification when said first notification has been received. | 7 |
BACKGROUND
The instant invention is in the field of plumbing apparatus and more specifically the instant invention is in the field of plumbing apparatus for draining and cleaning waste lines.
The plumbing system of a building usually has pressurized hot and cold water lines and gravity flow waste lines. A “cleanout” is typically installed at the end of each horizontal run of waste line plumbing. The cleanout usually consists of a wye fitting having a threaded plug in line with the horizontal run of waste line plumbing. If the horizontal run of waste line plumbing becomes restricted, then the threaded plug can be removed so that, for example, a plumbers “snake” can be run down the waste line to clear the restriction.
Clogged waste lines hold water with a volume and pressure that is unpredictable and even uncontainable upon removal of the threaded plug of the cleanout fitting. Once the cleanout plug is removed, the entire drainage system above the cleanout is released. Clean up of such a release can take longer than clearing the restriction in the waste line. Thus, it would be an advance in the plumbing art if a system were devised that provided for a controlled release of backed up waste water from a restricted waste line and/or for facile pressure clearing of a restricted waste line.
SUMMARY OF THE INVENTION
The instant invention is an apparatus providing a solution to the above stated problems. The instant invention provides a system for the controlled release of backed up waste water from a restricted waste line and/or for facile pressure clearing of a restricted waste line. More specifically, the instant invention comprises four elements. The first element is a pipe. The second element is a valve attached to one end of the pipe and in fluid communication therewith. The third element is a seal having a bore therethrough, the pipe positioned in and sealed to the bore of the seal. The fourth element is a first pipe connector having a bore therethrough, the pipe positioned through and sealed to the bore of the first pipe connector at a position of the pipe between the valve and the seal.
When the apparatus of the instant invention is installed in a wye cleanout fitting and positioned so that the seal is positioned near and sealed in the cleanout plug passageway of the wye cleanout fitting, then the valve of the instant invention can be opened to controllably drain the waste line. When the apparatus of the instant invention is installed in a wye cleanout fitting and positioned so that the seal is positioned near and sealed in the horizontal waste line passageway of the wye cleanout fitting, then pressurized water can be flowed through the valve of the instant invention to clear the restriction in the waste line. The apparatus of the instant invention can also be installed in a wye fitting installed in a waste line so that a portion of the waste line can be isolated when the seal is positioned in the crotch of the wye fitting.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view, part in full and part in cross-section, of a preferred embodiment of the instant invention employing a ribbed cylinder shaped rubber sealing element;
FIG. 2 is a side view, part in full and part in cross-section, of another embodiment of the instant invention employing a spherical shaped rubber sealing element;
FIG. 3 is a side view, part in full and part in cross-section, of the installation of the apparatus of FIG. 1 in a cleanout wye in position for pressure cleaning of a waste line;
FIG. 4 is a side view, part in full and part in cross-section, of the installation of the apparatus of FIG. 1 in a cleanout wye in position for draining a waste line;
FIG. 5 is a side view, part in full and part in cross-section, of the installation of the apparatus of FIG. 2 in a wye installed in a waste line, the apparatus being in position to isolate a portion of the waste line;
FIG. 6 shows the installation of a hose adapter and anti-siphon device on the valve of the instant invention; and
FIG. 7 is a side view, part in full and part in cross-section, of another preferred embodiment of the instant invention.
FIG. 8 is an end view of the seal designated 13 in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1 , therein is shown a side view, part in full and part in cross-section, of a preferred apparatus 10 of the instant invention including a one half inch internal diameter, five eights inch outside diameter copper pipe 11 . The pipe 11 is attached at one end thereof to ball valve 12 . The other end of the pipe 11 is positioned in and sealed in the bore of a ribbed bulbous cylinder shaped rubber seal 13 , i.e. a bored sphere. The pipe 11 is flared at retain the seal 13 on the pipe 11 . The pipe 11 is positioned through and sealed to the bore of a first pipe fitting 14 having external threads thereon, said threads being substantially coaxial with said bore. The valve 12 has a valve stem 15 , a valve handle 16 and an outlet 17 threaded for a rubber hose connection.
Referring still to FIG. 1 , the pipe 11 is positioned in the bore of a bushing 18 . The bore of the bushing 18 has a threaded portion 19 dimensioned to engage with the external threads of the first pipe fitting 14 . The pipe 11 is also positioned in and sealed to the bore of a second pipe fitting 20 having external threads thereon substantially coaxial with said bore. The threads of the second pipe fitting 20 are dimensioned to engage with a second threaded portion 21 of the bore of the bushing 18 . A gland 22 retains an o-ring 23 to seal the pipe 11 to the bushing 18 .
Referring now to FIG. 4 , therein is shown a side view, part in full and part in cross-section, of the installation of the apparatus 10 of FIG. 1 in a cleanout wye 24 having a threaded adapter 25 in position for draining waste line 26 by opening the valve 12 to controllably drain the waste water into a bucket, not shown. The apparatus 10 is placed in the position shown in FIG. 4 by withdrawing the apparatus 10 from the bushing 18 and then rotating the apparatus 10 in a counter clock wise manner so that the threads of the second pipe connector 20 engage the corresponding threads in the bore of the bushing 18 . The outside diameter of the ribs of the seal 13 are dimensioned to be a compression fit in the inside diameter of the wye 24 .
Referring now to FIG. 3 , therein is shown a side view, part in full and part in cross-section, of the installation of the apparatus 10 of FIG. 1 in a cleanout wye 24 having a threaded adapter 25 in position for pressure cleaning waste line 26 by attaching a pressurized water rubber hose to valve 12 and then opening valve 12 . Alternatively, a partial vacuum can be applied to waste line 26 by attaching a vacuum hose to valve 12 . The apparatus 10 is placed in the position shown in FIG. 3 by sliding the apparatus 10 into the bushing 18 and then rotating the apparatus 10 in a clock wise manner so that the threads of the first pipe connector 14 engage the corresponding threads in the bore of the bushing 18 . Referring now to FIG. 6 , when a rubber hose is connected to the valve 12 , code requires an anti-siphon device 27 which can be adapted to the valve 12 by way of a female/female rubber hose adapter 28 .
Referring now to FIG. 2 , therein is shown a side view, part in full and part in cross-section, of another apparatus 29 of the instant invention similar to the embodiment 10 of FIG. 1 but employing a spherical shaped rubber sealing element 30 and no second pipe connector . In addition, the apparatus shown in FIG. 2 uses an industry standard one and one half inch male adapter 32 and an industry standard one and one half by one half inch national pipe thread bushing 31 . There is no O-ring seal used in the bushing 31 . The apparatus shown in FIG. 2 can be used in much the same way as the apparatus shown in FIG. 1 . In addition, the apparatus shown in FIG. 2 can be used as shown in FIG. 5 .
Referring now to FIG. 5 , therein is shown a side view, part in full and part in cross-section, of the installation of the apparatus of FIG. 2 in a wye 24 installed in a waste line in position to isolate one portion 34 of the waste line from the other portion 35 of the waste line. The apparatus shown in FIG. 2 is installed in the wye 24 by way of a threaded adapter 36 . The apparatus 29 is placed in the position shown in FIG. 5 by sliding the apparatus 29 into the bushing 31 and then rotating the apparatus 29 in a clock wise manner so that the threads of the first pipe connector of the apparatus 29 engage the corresponding threads in the bore of the bushing 31 so that the spherical shaped rubber sealing element 30 is sealed in the crotch of the wye fitting to isolate the one portion 34 of the waste line from the other portion 35 of the waste line. Of course, the apparatus 29 can also be used to drain or flush the waste line in the position shown in FIG. 5 as well as if the apparatus 29 is placed in a withdrawn position with spherical shaped rubber sealing element 30 sealed in the blind bore 37 of the wye 33 .
Referring now to FIG. 7 , therein is shown a side view, part in full and part in cross-section, of another preferred embodiment of the instant invention using the apparatus 10 of FIG. 1 installed in a PVC bushing 38 , a PVC fitting 39 and a rubber ring 40 . The use of the rubber ring 40 is more preferred than the use of the O-ring 23 of FIG. 1 .
The seal of the instant invention can be of any suitable shape even though the shapes disclosed above are preferred. Preferably, the seal of the instant invention is a resilient seal comprising an elastomer such as neoprene or silicone rubber. However, a ball shaped PVC seal, for example, dimensioned to be slightly larger in diameter than the internal diameter of a cleanout wye can be used as the seal of the instant invention. The seal of the instant invention is preferably mounted at the end of the pipe away from the valve.
The valve of the instant invention is preferably a ball valve but can be any type of valve such as a gate valve. The first pipe fitting of the instant invention is preferably integral with the valve, i.e., a “boiler drain” valve. When a brass boiler drain valve is used with a copper pipe in the instant invention, then it is preferable to solder the pipe in the first pipe fitting of the boiler drain valve. However, it should be understood that the first pipe fitting need not be integral with the valve and need not be positioned at the end of the pipe.
The use of a second pipe fitting is preferred in the instant invention to help retain the seal in position of the pipe and to better retain the apparatus of the instant invention in the bushing in the position shown in FIG. 4 . Although not necessary in the instant invention, it is preferred to use an O-ring to seal the pipe with the bushing. The pipe of the instant invention can be made of any suitable material such as polyvinylchloride (PVC), iron, galvanized iron or copper. It is contemplated that the pipe, pipe fitting(s) and valve body of the instant invention can be integral and molded of PVC.
Preferably, the external threads on the first and second pipe fittings are perfectly or essentially coaxial with the longitudinal-axis of the pipe. However, of course, the external threads on the first and second pipe fittings can be substantially coaxial with the longitudinal axis of the pipe, i.e., sufficiently coaxial to permit rotation of the apparatus of the instant invention when it is threaded into position as shown in FIGS. 3 , 4 and 5 . The first pipe connector of the instant invention is preferably an externally threaded pipe fitting. However, the first pipe connector of the instant invention can be other connectors such as a quick-disconnect fitting or a bayonet fitting.
In conclusion, it is readily apparent that although the invention has been described above in detail in relation with its preferred embodiments, it should be understood that the instant invention is not limited thereby but is intended to cover all alternatives, modifications and equivalents that are included within the scope of the invention as defined by the following claims. | A system for the controlled release of backed up waste water from a restricted waste line and/or for facile pressure clearing of a restricted waste line. The apparatus of the instant invention can be installed in a wye cleanout fitting and positioned so that the seal is positioned near and sealed in the cleanout plug passageway of the wye cleanout fitting. Then the valve can be opened to controllably drain the waste line. | 4 |
FIELD OF THE INVENTION
This invention generally relates to polyolefins. In particular, this invention relates to a method of controlling the amount (and rate) of shrink that polyolefin undergoes during processing.
BACKGROUND OF THE INVENTION
Polyolefin compositions and various processes for making these compositions are known in the art. However, because of the unique characteristics of various polyolefin compositions, and the unique applications for which these polyolefins are variably suitable, interest in these materials remains a constant concern of the plastics industry and its numerous customers.
It is known in the art that polyolefins can be nucleated to improve its optical and other properties. There is some teaching in the art about the mechanism of nucleation, the selectivity of nucleants, and on the effects of nucleating. While it is generally known that nucleation does affect the rate and amount of shrink that polyolefins undergo, it is not known how these effects can be either pre-determined or controlled. The availability of such knowledge will be beneficial to polyolefin processors because it will enable them to customize their finished products. This in turn will result in improved processing efficiency, including reduced processing cost
SUMMARY OF THE INVENTION
This invention provides a method for controlling the shrinkage of nucleated semi-crystalline polyolefins involving the addition of nucleant(s) in an amount of from 0.0001 to 5 weight percent of the nucleated semi-crystalline polyolefin. This enables control of the crystallization temperature (Tc) and crystallization rate (Tr).
The benefits of this invention include but are not limited to cost reduction due to an increase in the production rate resulting from a reduction in processing cycle time; and that it permits processors to tailor their processes in order to meet the specific parts requirements of their various customers This flexibility in processing conditions avoids or minimizes the need to purchase additional equipment.
DETAILED DESCRIPTION OF THE INVENTION
In very generalized terms, the practice of this invention involves adding a suitable amount of nucleant(s) to a semi-crystalline polyolefin prior to processing to form finished parts. This results in or enables the shrinkage of the polyolefin to be controlled, an outcome that is sometimes referred to as controlled shrinkage.
By the term "controlled shrinkage" is meant the ability to control the dimensions of the final product produced from nucleated polyolefins. This depends in part on the effectiveness of nucleation, which is in turn dependent on both the type and amount of nucleant(s). These factors result in changes in the shrink rate, and in the final amount of shrink experienced by the nucleated polyolefin.
Generally speaking, all semi-crystalline polyolefins are suitable in the practice of this invention. These polyolefins are exemplified by polyethylene, polypropylene, polybutylene, polyisoprene, and their copolymers. Preferred among these polyolefins is polybutene-1.
The preferred polybutene-1 can be isotactic, elastomeric, syndiotactic, or it can have any characteristic that is known or expected of polybutene-1 polymers Particularly preferred is isotactic polybutene-1 polymer. These polybutene-1 polymers including their methods of preparation, and their properties are very well known in the art. The interested reader is directed to exemplary references such as U.S. Pat. Nos. 4,645,792 and 4,886,849.
Still generally speaking, all nucleating agents that are capable of nucleating the polyolefin polymers are useful in the practice of this invention. Such a nucleating agent(s) generally has one or more of the following properties; a higher melting point than the polyolefins; good melt stability, i.e. with minimal or no crosslinking or degradation upon melting; insolubility in polyolefins; and a chemical structure that contains both polar and non-polar groups, is non-reactive with polyolefin; and does not volatilize during melt processing.
Suitable nucleants can be broadly classified into organic and inorganic compounds. Organic nucleants include sorbitol, carbon black, metallic salts of organic acids, such as calcium stearate, zinc stearate, sodium benzoate, lithium benzoate, amides, and other polyolefins. The organic nucleants generally work better and are preferred.
Useful inorganic nucleants include talc, zinc oxide, titanium oxides, aluminum silicate, and clay.
The nucleant(s) are present in the nucleated polyolefin in an amount within the range of from 0.0001 to 5 weight percent. However, an amount of from about 0.1 to 1 weight percent is preferred.
Although the organic nucleants are preferred, the operability of this invention is independent of the particular nucleant(s) used. To be redundant, all suitable nucleants are appropriate for use.
Conventional additives such as oxidative, thermal, or U.V. stabilizers, lubricants and mold release agents, and combustion inhibitors may be added to the nucleated polyolefin composition. The particular additive to be added, the amount to be added, and when to be added, are discretionary options that can competently be exercised by a skilled artisan.
PROCESS
The process of practicing this invention involves forming a mixture of a semi-crystalline polyolefins with a premeasured amount of a nucleant(s), and then dry blending the mixture in a suitable device, such as a tumbler. Following this, the mixture is melt compounded in any suitable melt device, such as an extruder or a Brabender mixer, operating at a temperature of about 110°-500° C., preferably 130°-250°. A die is attached to the melting device, and the molten material pushes through the die to form a part The die used depends on the type of part desired to be formed
The parts are formed using conventional methods such as injection molding, blow molding, and pipe/sheet extrusion. Typically, these parts are formed as the molten material cools
The dimension of the formed part are measured after solidification. These dimensions are measured at intervals until no change is observed At this point, the ultimate dimension of the formed part (L, W, or H) is known. This ultimate dimension, is controlled by the amount of pre-added nucleant(s).
Without wishing to be bound by theory, it is believed that the amount and type of nucleant(s) utilized, influences the crystallization temperature and rate. This in turn permits controlling the shrinkage rate and amount of the formed part(s), which can be determined by the final dimensions of the formed part(s).
The invention is further illustrated by the following non-limiting examples.
EXAMPLE 1
60 grams of isotactic polybutylene was blended with each of the nucleation packages outlined in Table 1. All samples were mixed on a batch-type Brabender mixer under nitrogen at 190° C. for 10 minutes at 100 rpm rotation speed.
TABLE 1______________________________________ NUCLEATIONFORMULATION PACKAGE USED WT. %______________________________________1 HDPE, talc, titanium dioxide 2.952 HDPE, talc, titanium dioxide, 2.95 calcium stearate3 HDPE, titanium dioxide, calcium 0.50 stearate______________________________________
EXAMPLE 2
One hundred pounds of each of the formulations described in Example 1 was melted in a single screw extruder at 215° C. and passed through an annulus die at 225° C. Subsequent to passing through the die, a parison was formed which was blow molded to the final part, a large capacity (>50 gal.) water heater tank. Shrinkage was measured along the maximum length of the tank. The thermal properties of the three formulations were also measured. These results are shown in Table 2.
TABLE 2______________________________________FOR- CRYST. 1/2 SHRINK- TIME TOMU- CRYST. TIME @ AGE REACH 95% OFLATION TEMP. 95° C. (inch/inch) SHRINKAGE______________________________________1 75° C. 26 minutes 0.024 6.6 days2 83° C. 6 minutes 0.026 4.0 days3 88° C. 2 minutes 0.029 3.0 days______________________________________
Formulation 2 has improved nucleation over Formulation 1 because of the addition of calcium stearate, an organic nucleant. Formulation 3 achieves even greater nucleation because of the removal of talc, a less effective inorganic nucleant. These formulations contain a nucleating package that is within the inventive range, and all formulations illustrate the controlled shrinkage that is desired by the practice of this invention.
While this invention has been described in detail for the purpose of illustration, it is not to be construed as limited thereby but is intended to cover all changes and modifications within the spirit and scope thereof. | It is herein disclosed a method for controlling the shrinkage of parts formed from semi-crystalline polyolefin involving the addition of a suitable nucleant(s), in a suitable amount. This method results in reduced processing costs primarily due to reduced processing cycle time and to greater flexibility in the use of processing equipment. | 2 |
TECHNICAL FIELD
[0001] The present invention relates to an automatic press-molded article manufacturing system using a double robot line for a tandem press line, and more specifically, to an automatic press-molded article manufacturing system using a double robot line for a tandem press line, which enables automatically controlled, seamless transfer and supply of raw materials or press-molded articles, thus leading to a high yield of press-molded articles.
DISCUSSION OF RELATED ART
[0002] Press molding is a technique in which, a raw material, e.g., an iron plate, is forced into a mold in order to take the shape of the mold. Conventionally, the process has been conducted manually by people, but is now being automated for higher productivity and lower occurrence of industrial accidents.
[0003] A recently developed automatic manufacturing system adopts multi-axis driving robots to carry raw materials or press-molded articles from one processing stage to another.
[0004] Such conventional system is deployed so that each one of the multi-axis driving robots is positioned between two neighboring ones of multiple presses, overall configuring a single raw material supply line. Press molding by the presses is done relatively faster than the transfer or supply by the robots. Thus, the presses may be left idle until they are reloaded by the robots, resulting in a poor yield of final products.
SUMMARY
[0005] The present invention has been conceived to address the above issues, and an object of the present invention is to provide an automatic press-molded article manufacturing system using a double robot line for a tandem press line, which includes a plurality of destackers, a plurality of positioners, and pairs of robots for transferring and supplying raw materials and press-molded articles and carrying out the press-molded articles, each robot pair having two robots positioned apart from each other. The paired robots may alternately move, accelerating the stages of supplying and transferring the raw materials or press-molded articles to catch up with the processing stages by the presses. Thus, a higher yield of final products may be obtained.
[0006] Since each pair of robots is in charge of its respective stage of supplying, transferring, and carrying out the raw materials or press-molded articles, one of the paired robots may function as a redundancy in preparation of when the other breaks down, which allows the system into a seamless operation
[0007] According to the present invention, an automatic press-molded article manufacturing system using a double robot line for a tandem press line comprises: a plurality of destackers positioned apart from each other at a predetermined distance and loaded with multiple raw materials; a pair of raw material transfer robots transferring the raw materials loaded on the destackers while holding the raw materials by suction; a plurality of positioners positioned between the raw material transfer robots to position the raw materials transferred by the raw material transfer robots; a pair of raw material supply robots positioned apart from each other behind the raw material transfer robots and alternately moving to supply the raw materials from the positioners to a press while holding the raw materials by suction; a plurality of presses sequentially positioned behind the raw material supply robots and press-molding the raw materials received from the raw material supply robots into press-molded articles; a plurality of pairs of press-molded article supply robots, each pair of press-molded article supply robots positioned between a first press and a second press of the plurality of presses and alternately moving to supply the press-molded articles from the first press to the second press, wherein the press-molded article supply robots in each pair is spaced apart from each other; a pair of product carrying-out robots positioned apart from each other behind a rearmost press of the presses and alternately moving to carry out final press-molded articles; and a controller configured to control the raw material transfer robots, the raw material supply robots, the presses, the press-molded article supply robots, and product carrying-out robots.
[0008] According to the present invention, an automatic press-molded article manufacturing system using a double robot line for a tandem press line includes a plurality of destackers, a plurality of positioners, and pairs of robots for transferring and supplying raw materials and press-molded articles and carrying out the press-molded articles, each robot pair having two robots positioned apart from each other. The paired robots may alternately move, accelerating the stages of supplying and transferring the raw materials or press-molded articles to catch up with the processing stages by the presses. Thus, a higher yield of final products may be obtained.
[0009] Since each pair of robots is in charge of its respective stage of supplying, transferring, and carrying out the raw materials or press-molded articles, one of the paired robots may function as a redundancy in preparation of when the other breaks down, which allows the system into a seamless operation.
BRIEF DESCRIPTION OF DRAWINGS
[0010] FIG. 1 is a plan view illustrating a deployment of an automatic press-molded article manufacturing system using a double robot line for a tandem press line, according to the present invention.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0011] According to the present invention, an automatic press-molded article manufacturing system using a double robot line for a tandem press line comprises: a plurality of destackers positioned apart from each other at a predetermined distance and loaded with multiple raw materials; a pair of raw material transfer robots transferring the raw materials loaded on the destackers while holding the raw materials by suction; a plurality of positioners positioned between the raw material transfer robots to position the raw materials transferred by the raw material transfer robots; a pair of raw material supply robots positioned apart from each other behind the raw material transfer robots and alternately moving to supply the raw materials from the positioners to a press while holding the raw materials by suction; a plurality of presses sequentially positioned behind the raw material supply robots and press-molding the raw materials received from the raw material supply robots into press-molded articles; a plurality of pairs of press-molded article supply robots, each pair of press-molded article supply robots positioned between a first press and a second press of the plurality of presses and alternately moving to supply the press-molded articles from the first press to the second press, wherein the press-molded article supply robots in each pair is spaced apart from each other; a pair of product carrying-out robots positioned apart from each other behind a rearmost press of the presses and alternately moving to carry out final press-molded articles; and a controller configured to control the raw material transfer robots, the raw material supply robots, the presses, the press-molded article supply robots, and product carrying-out robots.
[0012] Hereinafter, preferred embodiments of the present invention are described in detail with reference to the accompanying drawings.
[0013] FIG. 1 is a plan view illustrating a deployment of an automatic press-molded article manufacturing system using a double robot line for a tandem press line, according to the present invention.
[0014] Referring to FIG. 1 , the automatic press-molded article manufacturing system using a double robot line for a tandem press line, according to the present invention, includes destackers 1 , raw material transfer robots 2 , positioners 3 , raw material supply robots 4 , presses 5 , press-molded article supply robots 6 , product carrying-out robots 7 , and a controller 8 .
[0015] According to the present invention, the manufacturing process including transferring and supplying raw materials, pressing, and carrying out products may be performed under automatic control, not on manual, thus enabling a yield of about twenty press-molded articles per minute. The transfer and supply of raw materials, pressing, and carry-out of press-molded articles may be continuously conducted, thus leading to a reduced manufacturing time together with a significantly increased yield of products.
[0016] Provided are a plurality of destackers 1 that are arranged apart from each other at a predetermined distance and that use, e.g., a forklift, to load multiple metallic materials thereon.
[0017] The plurality of destackers 1 , respectively, are positioned adjacent to the plurality of raw material transfer robots 2 . A first one of the destackers 1 is positioned at a rear side of one of the raw material transfer robots 2 , and a second one of the destacker 1 is positioned at a front side of the other raw material transfer robot 2 , thus free from mutual interference when the raw material transfer robots 2 are in operation. However, the deployment may be varied without being limited thereto. Two more destackers 1 (third and fourth destackers) may be provided in preparation for the exhaustion of the ram materials loaded on the first and second destackers 1 . The third and fourth destakers 1 are positioned to respectively correspond to the first and second destakers 1 . The destackers 1 arranged at the front sides of the raw material transfer robots 2 preferably form an angle of about 30 to about 45 degrees therebetween, so as to avoid interference between the raw material transfer robots 2 .
[0018] The destackers 1 are hydraulic equipment that are put in wide use. Each destacker 1 includes a support elevating means and multiple rollers on the top on which raw materials are loaded. As the raw materials are sequentially supplied and thus run out, the support elevating means of the destacker ascends.
[0019] The raw material transfer robots 2 are provided in pair. The pair of raw material transfer robots 2 are spaced apart from each other. The raw material transfer robots 2 transfer the raw materials loaded on the destackers 1 , while holding the raw materials by suction.
[0020] The raw material transfer robots 2 and all the other robots to be described below are equipment for transferring and supplying metallic materials or press-molded articles, and each may have multiple axes. The robots may be industrial robots that may be operated under the control of the controller 8 . The robots are being widely used in electronic or machine industries, and thus, detailed descriptions thereof are omitted.
[0021] The plurality of positioners 3 are arranged between the raw material transfer robots 2 , and the positioners 3 place, thereon, the raw materials transferred by the raw material transfer robots 2 . For example, the positioners 3 are installed in an operation range of the raw material transfer robots 2 , in which the raw materials may be transferred by the raw material transfer robots 2 . Each positioner 3 includes a plurality of vertical legs and an upper table plate that is supported by the vertical legs.
[0022] The upper table plate is inclined inward and downward. The inclined angle of the positioners 3 is preferably about 10 degrees to about 45 degrees.
[0023] Each positioner 3 primarily plays a role to place the raw materials in position to fit the operation range of the robot stationary at a side thereof so that the robot may transfer the raw materials to a predetermined position between the upper and lower pieces of mold of its corresponding press 5 , with the raw materials suctioned to the raw material transfer robot 2 .
[0024] Specifically, the raw materials carried from the destackers 1 to the upper portions of the positioners 3 by the raw material transfer robots 2 slide down along the edges of the positioners 3 and are thus placed in position. The raw materials may be then supplied from the positioners 3 to predetermined positions of the presses 5 by the raw material supply robots 4 .
[0025] The raw material supply robots 4 are provided in pair. The pair of raw material supply robots 4 , respectively, are positioned at the respective rear sides of the raw material transfer robots 2 . The raw material supply robots 4 alternately move, holding the raw materials on the positioners 3 by suction and supplying the raw materials to the presses 5 .
[0026] As such, a pair of raw material supply lines, each including a raw material transfer robot, a raw material supply robot 4 , a plurality of destackers 1 , and a positioner 3 , may be built up, resulting in a higher yield as compared with the conventional art.
[0027] A plurality of presses 5 are sequentially arranged behind the raw material supply robots 4 . The foremost press of the presses 5 receives the raw materials from the raw material supply robots 4 and forces the raw materials into a mold to form the raw materials into press-molded articles of desired shapes.
[0028] Although four presses 5 are shown in FIG. 1 , more presses 5 may be provided depending on types or shapes of final press-molded articles. The presses 5 may be controlled by the controller 8 and by their own respective manual controllers.
[0029] The press-molded article supply robots 6 are provided in pairs. Each pair of press-molded article supply robots 6 are spaced apart from each other between the presses 5 . The press-molded article supply robots 6 alternately move, supplying the press-molded articles from one press to another.
[0030] The press-molded article supply robots 6 are arranged corresponding to each other in a space between the presses 5 respectively for first and second forming stages, and the press-molded article supply robots 6 may continuously supply the article formed by the press 5 for the first forming stage to the press 5 for the second forming stage.
[0031] The product carrying-out robots 7 are provided in pair. The pair of product carrying-out robots 7 are spaced apart from each other. The product carrying-out robots 7 are positioned behind the rearmost press 5 of the presses 5 . The product carrying-out robots 7 alternately move, carrying out the final press-molded articles. A conveyor 9 is preferably provided between the product carrying-out robots 7 to guide the conveyance of the final press-molded articles.
[0032] The controller 8 controls the operation of the raw material transfer robots 2 , the raw material supply robots 4 , the presses 5 , the press-molded article supply robots 6 , and the product carrying-out robots 7 . The controller 8 may be placed in a separate control room at the foremost side of the system to keep out of reach of others except the worker.
[0033] Now described is a process for manufacturing a press-molded article by an automatic press-molded article manufacturing system using a double robot line for a tandem press line according to the present invention.
[0034] First, a pair of raw material transfer robots 2 individually transfer the raw materials loaded on the destackers 1 to the positioners 3 .
[0035] The raw materials transferred to the positioners 3 are alternately supplied to the foremost press 5 by a pair of raw material supply robots 4 .
[0036] The raw materials are formed into a predetermined shape by the foremost press 5 , and the resultant articles are then supplied to a next press 5 for a subsequent stage by a pair of press-molded article supply robots 6 . In this case, the number of presses 5 may be not less than two and not more than N (N is a natural number). As the number of forming stages by the presses 5 increases, more presses 5 may be needed.
[0037] While one of the paired robots 6 transfers a press-molded article from a first press 5 for a first forming stage to a second press 5 for a second forming stage subsequent to the first forming stage, while holding the press-molded article by suction, the other robot 6 , after unloading another press-molded article to the second press 5 , returns to the first press 5 , empty-handed, for another transfer. As such, the paired robots 6 alternately transfer and supply press-molded articles to a next forming stage while moving in opposite directions thereof, significantly reducing transfer time.
[0038] Having undergone the multiple forming stages by the presses 5 for desired shapes, the final press-molded articles are guided via the rearmost press 5 to the conveyor 9 by the product carrying-out robots 7 , and are then carried out by the conveyor 9 .
[0039] While the inventive concept has been shown and described with reference to exemplary embodiments thereof, it will be apparent to those of ordinary skill in the art that various changes in form and detail may be made thereto without departing from the spirit and scope of the inventive concept as defined by the following claims. | The present invention relates to an automatic press-molded article manufacturing system using a double robot line for a tandem press line and, more specifically, to an automatic press-molded article manufacturing system using a double robot line for a tandem press line, wherein a plurality of destakers and positioners are disposed, each group having two robots is separately disposed and moves alternately, so as to continuously and rapidly transfer and supply the raw material in proportion to a press working time, in a raw material transfer process, a material supply process, an article supply process, and a product withdrawal process. | 1 |
BACKGROUND
Active pixel sensors are well known in the art. A basic description of the active pixel sensors found in U.S. Pat. No. 5,471,515, the disclosure of which is incorporated by reference to the extent necessary for proper understanding.
An active pixel sensor, and many other image sensors, have inherent trade-offs. Typically, the trade-off is made between sensitivity, versus motion resolution, versus space resolution.
For example, we obtain sensitivity by increasing the integration time. However, with a higher integration time, motion becomes more choppy, and hence motion sensitivity is decreased. Sensitivity can also be increased by increasing the pixel size. However, space resolution then decreases, again supporting the trade-off.
Integrated circuit designers continually attempt to put more circuitry on a chip. Lines on the chip are becoming smaller: for example, current technology may use a 0.11 micron process for digital circuitry. However, the image sensor, which is effectively analog, may be subject to a physical minimum size. A pixels that has too small a size and/or high gain, would have insufficient capacitance to allow the sensor to obtain the signal to noise ratio required for quality image acquisition.
SUMMARY
The inventor recognized that memory size can form an effective tradeoff against pixel size. The present specification describes receiving information in an analog photosensor array, and integrating that information in on-chip digital memory. According to this system, an analog array is placed on the same substrate with a digital memory. The information from the analog array is sampled periodically, and the integration is carried out in the digital memory.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a basic block diagram; and
FIGS. 2 and 3 respectively show more detailed block diagrams of the circuitry.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The basic system is shown in FIG. 1 . An analog image detector 100 , preferably a CMOS image sensor, reads out the image at some time period, e.g., between 1 microsecond and 1 millisecond. Each pixel is coupled to a digital memory 110 . Digital memory integrates the instantaneous information received from the pixels.
Current frame times are preferably either approximately 33 milliseconds for a 30-frames per second system, or approximately 16 milliseconds for high motion resolution of 60 frames per second.
In addition to the other advantages noted above, this architecture allows pixel capacitance to be reduced and pixel gain to be increased, since the pixel need provide only instantaneous values, and does not need to integrate the incoming charge.
The signal integration process is divided into two parts: an analog part in the active pixel sensor 100 and a digital part in digital random access memory 110 .
A first embodiment is shown in FIG. 2 . FIG. 2 shows the active pixel sensor array 100 , coupled with an analog signal processor 202 , column A/D converters 204 , a digital processor 206 , and a digital memory array 110 a of the digital memory 110 . The analog signal processor 202 includes column analog double sampling circuitry for sampling both signals and references to decrease the pixel fixed pattern noise. Preamplifiers with adjustable gains, can also be used to increase the sensitivity and provide an automatic exposure control, as is known in the art.
The system as described herein uses column parallel A/D conversion, where one separate A/D converter is provided for each column of the active pixel sensor array. In this system, digital integration may be used for oversampling the A/D converter. Digital sampling can reduce the quantization noise density, and hence increase the effective resolution of the system proportionally to arise of the frame bit. Preferably the system operates with an AC input noise of about half of the least significant bit.
The digital signal processor (DSP) 206 provides arithmetic operations such as addition, subtraction, division, and multiplication, and also includes a buffer memory to maintain intermediate results. DSP 206 can also act to digitally correct column digital fixed pattern noise. FIG. 3 shows a system similar to that in FIG. 2 but with twice as many digital memory arrays 110 a and processing circuits 206 .
In operation, the sensor is preferably a CMOS image sensor that is of a sufficiently small size that it cannot integrate for a desired frame period. The information from the sensor is sampled by the column A/D converts 204 at an oversampled rate. Each sample is stored in the digital memory array 110 a , and the values are integrated in that memory 110 a . A digitally integrated value can be subsequently read from the digital memory array 110 a.
Although only a few embodiments have been disclosed in detail above, other modifications are possible in the preferred embodiment. | An active pixel sensor includes mixed analog and digital signal integration on the same substrate. The analog part of the array forms the active pixel sensor, and the digital part of the array does digital integration of the signal. | 7 |
TECHNICAL FIELD
The current invention is generally related to condensing photovoltaic electricity generating technology, in which sun light is concentrated and projected to condensing lens and compound-eye lens condenser of photovoltaic batteries. The current invention is further related to a compound-eye concentrating-type solar cell assembly based on above mentioned condensing lens and compound-eye lens condenser.
BACKGROUND ART
Concentrating photovoltaic electricity generation technology is widely accepted as an effective way to reduce cost of photovoltaic electricity generation. At present, a complete system for concentrating photovoltaic electricity generation mainly comprises a compound-eye concentrating photovoltaic assembly, a sun-tracker, and electric energy storage or inversion equipment. As a photo-electric conversion element, the compound-eye concentrating photovoltaic assembly comprises a compound-eye lens condenser and a circuit board installed with photovoltaic wafers.
The compound-eye lens condenser comprises a plurality of planar-arrayed condensing lens. During operation, the sun-tracker keeps the condensing lenses facing the sun perpendicularly for most of the time, then the condensing lenses focus the sun light and project it to the receiving surfaces of corresponding photovoltaic wafers on the circuit board to generate electric current in each of the photovoltaic wafer, then the electric current is exported by the circuits on the circuit board.
The concentrating solar cell assembly disclosed in patent application with disclosure number CN101640502A is very typical. The point-focusing Fresnel lens implemented in the assembly is widely recognized as the optimal option for condensing lens. There are additional references that disclose concentrating Fresnel lens as the condensing lens for concentrating photovoltaic electricity generation, such additional references are not included herein.
Actually, implementing Fresnel lens is not without shortcomings. For example, manufacturing defects on the surface texture of Fresnel lens cause loss in incoming light, resulting in a relatively low transmission rate of around 75%; such manufacturing defects are very hard to avoid under current technologies. As another example, Fresnel lens can be considered a combination of multiple co-axis convex lenses; as a result, the energy distribution of the focus light spot produced by Fresnel lens is not sufficiently uniform.
Replacing Fresnel lens with widely used ordinary spherical lens can solve the problem of low transmission rate. Spherical lens can only, however, focus light on the focal point of the lens, so no matter where the photovoltaic wafer is located, either in the front of the focal point, or further away from the focal point, uneven energy distribution will result on the receiving surface of the photovoltaic wafer, in the center and on the rim of the light spot, causing internal voltage difference in the wafer, producing internal current, such internal current is partially consumed inside the wafer, resulting in reduced output power from the wafer; additionally, internal current is the major cause for wafer internal temperature rise, while wafer internal temperature rises in term reduces efficiency of concentrating photovoltaic assembly.
DETAILED DESCRIPTION
The current invention offers technical solution by providing a condensing lens that provides a high transmission rate and produces uniformly distributed energy on the focus spot after condensing; the current invention further provides a compound-eye lens condenser that utilizes the condensing lens.
The technical solution provided in the current invention is implemented by: a condensing lens, in which, the lens is a convex lens that refracts parallel incoming light to a receiving surface located on the outer side of the lens to form a light spot, which is characterized by: assuming x being the perpendicular distance between the point of intersection, where an arbitrary incoming light intersecting the lens, and the optical axis of the lens, m being the perpendicular distance between the projection point, generated by the refracted incoming light projecting on the receiving surface, and the center of the light spot, a being the radius of the lens, b being the radius of the light spot, then the lens satisfies the following condition: x/m=a/b.
As a preferred embodiment of the above technical solution, the lens having a rotating convex surface with the optical axis as the rotating axis and a flat end surface opposite to the rotating convex surface, the curve on the intersection between the rotating convex surface and an arbitrary longitudinal section which crosses the lens optical axis is a curve which can refract incoming light, said light is radially distributed within the longitudinal section and parallel to the optical axis, to the receiving surface to form a focal line, the curve function for the curve, in a planar coordinate system located on the longitudinal sectional surface with the origin of the coordinate system being the center of the flat end surface, can be described as follows:
( h + y ) n ⅆ y ⅆ x 1 + ( ⅆ y ⅆ x ) 2 - ⅆ y ⅆ x 1 - n 2 ( ⅆ y ⅆ x ) 2 1 + ( ⅆ y ⅆ x ) 2 1 - n 2 ( ⅆ y ⅆ x ) 2 1 + ( ⅆ y ⅆ x ) 2 + n ( ⅆ y ⅆ x ) 2 1 + ( ⅆ y ⅆ x ) 2 = ( 1 + b a ) x
where, the coefficient h is the distance between the flat end surface and the receiving surface; coefficient a is the radius of the lens; coefficient b is the half length of the focal line; coefficient n is the refractive index of the lens; variable x is the horizontal distance between an arbitrary point on the curve and the lens optical axis, variable y is the longitudinal distance between the point and flat end surface.
It should be pointed out, that the curve function cannot be obtained through limited number of experiments conducted by the applicant under the guidance of existing technology. In fact, the curve function is based on applicant's creative realization that, in order to produce uniformly distributed energy on the focus spot after condensing, a better solution is to proportionally condense light onto the receiving surface through the rotating convex surface of the lens. That is, after incoming light passes through an arbitrary point on the curve and is refracted to the receiving surface, the ratio between x and m, x being the x coordinate of the point on the curve function, m being horizontal distance between the projection point on the receiving surface and optical axis of the lens, should be equal to the ratio between a and b, a being the radius of the lens, b being the half length of the projection line, i.e., x/m=a/b. Based on known rules of refraction for lens and above equations, the following equations can be obtained:
x / m = a / b ( 1 ) sin ( θ ) = n sin ( β ) ( 2 ) x - m = ( h - y ) tan ( β - θ ) ( 3 ) tan ( θ ) = ⅆ y ⅆ x ( 4 )
in which, variables and β represent respectively angle of incidence and angle of refraction when light beam passes through the curve. Other coefficients and variables are already explained above. Based on the above equations, the above curve function can be obtained through mathematical derivation.
The shape of the rotating convex surface determined by the curve function can be fully achieved in industrial engineering settings. Currently, lenses are typically manufactured through molding; the molded shape of the rotating convex surface is controlled by design of the mold. During the process of mold design, it is as simple as entering the above curve function into the mold design software, then the curve is generated from the curve function, then the curve is rotated to generate the theoretical digital model of the rotating convex curve surface; during the process of mold manufacturing, the corresponding mold cavity is manufactured by CNC machine tool.
The applicant further points out, that the condensing lens with the special curve function disclosed above is an example of the condensing lenses claimed in the current invention, the example is to be understood for illustration purpose only. Actually, the condensing lens characterized by the special curve is a plano-convex lens, so incoming light parallel to the optical axis of the lens is refracted only once by the rotating convex surface of the lens, accordingly, x is the perpendicular distance between the point of intersection, where an arbitrary incoming light intersecting the lens, and the optical axis of the lens, x is also the abscissa of the point where incoming light crossing the curve function; b is the radius of the light spot, or the half length of the focal line formed by refracting the parallel incoming light and focusing them on the receiving surface; m is the perpendicular distance between the projection point, generated by the refracted incoming light projected on the receiving surface, and the center of the light spot.
In spite of the fact that plano-convex lens is structurally simple and has the advantage of being easy for design and manufacturing, other equivalent designs can be implemented to replace the curve function disclosed above. For example, double convex lens with two rotating convex surfaces can be implemented. As long as the condition x/m=a/b is satisfied (in which, x is the perpendicular distance between the point of intersection, where an arbitrary incoming light intersecting the lens, and the optical axis of the lens, x is also the abscissa of the point where incoming light crossing the curve function; m is the perpendicular distance between the projection point, generated by the refracted incoming light projected on the receiving surface, and the center of the light spot; b is the radius of the light spot, or the half length of the focal line formed by refracting the parallel incoming light and focusing them on the receiving surface; a is the radius of the lens), with additional known lens refractive rules, curve functions of the two rotating convex curve surface can be derived, and accordingly the theoretical digital model of the two rotating convex curve surface.
The compound-eye lens condenser, in which, a plurality of planar arrayed condensing lenses are adhered on a transparent glass panel, combined with circuit board, to form a box-structured compound-eye concentrating-type solar cell assembly. The condensing lenses can also be one piece with the glass panel.
Specifically, each of the condensing lens has a rotating convex surface with the optical axis as the rotating axis and a flat end surface opposite to the rotating convex surface, the curve on the intersection between the rotating convex surface and an arbitrary longitudinal section which crosses the lens optical axis is a curve which can refract incoming light, which is radially distributed within the longitudinal section and parallel to the optical axis, to the receiving surface to form a focal line, the curve function for the curve, in a planar coordinate system located on the longitudinal sectional surface with the origin of the coordinate system being the center of the flat end surface, can be described as follows:
( h + y ) n ⅆ y ⅆ x 1 + ( ⅆ y ⅆ x ) 2 - ⅆ y ⅆ x 1 - n 2 ( ⅆ y ⅆ x ) 2 1 + ( ⅆ y ⅆ x ) 2 1 - n 2 ( ⅆ y ⅆ x ) 2 1 + ( ⅆ y ⅆ x ) 2 + n ( ⅆ y ⅆ x ) 2 1 + ( ⅆ y ⅆ x ) 2 = ( 1 + b a ) x
where, the coefficient h is the distance between the flat end surface and the receiving surface; coefficient a the radius of the lens; coefficient b is the half length of the focal line; coefficient n is the refractive index of the lens; variable x is the horizontal distance between an arbitrary point on the curve and the lens optical axis, variable y is the longitudinal distance between the point and flat end surface.
Further, the edge of each the lens is cut into polygon structure with at least three cylindrical surfaces; any two neighboring condensing lenses in the compound-eye lens condenser are adhered together at their adjacent cylindrical surfaces. Evidently, that the purpose for doing so is for the convenience of forming planar arrays of condensing lenses to produce a compound-eye lens condenser.
Specifically, the edge of each of the individual lens is cut into quadrilateral structure with four cylindrical surfaces, in which, neighboring cylindrical surfaces are perpendicular to each other; any two neighboring condensing lenses in the compound-eye lens condenser are adhered together by their adjacent cylindrical surfaces to form a rectangular array of the condensing lenses for the compound-eye lens condenser. Additional benefit of cutting the edge of the condensing lens into quadrilateral structure is that the shape of focused light spot through the lens is quadrilateral, making it practical to make corresponding photovoltaic wafers quadrilateral during manufacturing. Quadrilateral structure is easy to process during wafer cutting and such quadrilateral cutting saves large amount of wafer materials.
The current invention further provides a compound-eye concentrating-type solar cell assembly that implements the compound-eye lens condenser.
The advantages of the current invention include: the transmission rate of the condensing lens is proved by optical simulation to be as high as 90% to 93%, and the energy distribution curve of the focused light spot is almost saddle-shaped, that is, the light spot energy is uniformly distributed. The condensing lens disclosed in the current invention can not only be used in focusing photovoltaic electricity generation, it can also be utilized in other optical equipment where uniform focusing is required.
DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic illustration of the compound-eye lens condenser.
FIG. 1( a ) is the overall schematic illustration of the compound-eye lens condenser.
FIG. 1( b ) is the schematic illustration of a single condensing lens in the compound-eye lens condenser.
FIG. 2 is an amplified view of FIG. 1( b ).
FIG. 3 is a full cut away view of FIG. 2 in A direction (section is longitudinal section 2 ).
FIG. 4 is the energy distribution figure of a light spot obtained through traditional spherical convex lens. In FIG. 4 , brightness of light pot illustrated the level of energy, the brighter the higher energy.
FIG. 5 the energy distribution curve of a light spot obtained through traditional spherical convex lens. In FIG. 5 , abscissa is the width of light spot, ordinate is energy intensity. Accordingly, FIG. 5 can be considered as light spot energy distribution observed on the horizontal section or longitudinal section of FIG. 4 .
FIG. 6 is the light spot energy distribution figure of the condensing lens disclosed in the current invention.
FIG. 7 is the light spot energy distribution curve of the condensing lens disclosed in the current invention. In FIG. 7 , abscissa is the width of light spot, ordinate is energy intensity. Accordingly, FIG. 7 can be considered as light spot energy distribution observed on the horizontal section or longitudinal section of FIG. 6 .
FIG. 8 is the illustration of another embodiment of the condensing lens disclosed in the current invention.
FIG. 9 is the structural illustration of the compound-eye concentrating-type solar cell assembly disclosed in the current invention.
EMBODIMENTS
The current invention is further described with reference to the figures.
FIG. 9 illustrates a compound-eye concentrating-type solar cell assembly, which is a box structure comprising: a compound-eye lens condenser ( 5 ) and a plurality of photovoltaic wafer ( 7 ) installed on a circuit board ( 6 ); in which, as illustrated in FIGS. 1-3 , the compound-eye lens condenser ( 5 ) comprising a plurality of planar arrayed condensing lens ( 1 ), each of the condensing lens ( 1 ) is a convex lens which is capable of refracting incoming light ( 3 ) parallel to the optical axis ( 103 ) to a receiving surface ( 4 ) of a photovoltaic wafer ( 7 ) located on the outer side of the lens to form a light spot; in which, as illustrated in FIGS. 2-3 , the lens has a rotating convex surface ( 101 ) with the optical axis ( 103 ) as the rotating axis and a flat end surface ( 102 ) opposite to the rotating convex surface ( 101 ), the curve ( 104 ) on the intersection between the rotating convex surface ( 101 ) and an arbitrary longitudinal section ( 2 ) which crosses the lens optical axis ( 103 ) is a curve which can refract incoming light ( 3 ), which is radially distributed within the longitudinal section ( 2 ) and parallel to the optical axis ( 103 ), to the receiving surface ( 4 ) to form a focal line, the curve function for the curve ( 104 ), in a planar coordinate system located on the longitudinal sectional surface ( 2 ) with the origin of the coordinate system (A) being the center of the flat end surface ( 102 ), can be described as follows:
( h + y ) n ⅆ y ⅆ x 1 + ( ⅆ y ⅆ x ) 2 - ⅆ y ⅆ x 1 - n 2 ( ⅆ y ⅆ x ) 2 1 + ( ⅆ y ⅆ x ) 2 1 - n 2 ( ⅆ y ⅆ x ) 2 1 + ( ⅆ y ⅆ x ) 2 + n ( ⅆ y ⅆ x ) 2 1 + ( ⅆ y ⅆ x ) 2 = ( 1 + b a ) x
where, the coefficient h is the distance between the flat end surface ( 102 ) and the receiving surface ( 4 ); coefficient a the radius of the lens; coefficient b is the half length of the focal line; coefficient n is the refractive index of the lens; variable x is the horizontal distance between an arbitrary point (B) on the curve ( 104 ) and the lens optical axis ( 103 ), variable y is the longitudinal distance between the point (b) and flat end surface ( 102 ).
The curve function is based applicant's creative realization that, in order to produce uniformly distributed energy on the focus spot after condensing, a better solution is to proportionally condense light onto the receiving surface ( 4 ) through the rotating convex surface ( 101 ) of the lens. That is, after incoming light ( 3 ) passes through an arbitrary point (B) on the curve ( 104 ) and is refracted to the receiving surface ( 4 ), the ratio between x and m, x being the abscissa of the point on the curve function, m being horizontal distance between the projection point on the receiving surface and optical axis of the lens, should be equal to the ratio between a and b, a being the radius of the lens, b being the half length of the projection line, i.e., x/m=a/b. Based on known rules of refraction for lens and above equations, the following equations can be obtained:
x / m = a / b ( 1 ) sin ( θ ) = n sin ( β ) ( 2 ) x - m = ( h - y ) tan ( β - θ ) ( 3 ) tan ( θ ) = ⅆ y ⅆ x ( 4 )
in which, variables and β represent respectively angle of incidence and angle of refraction when light beam passes through the curve. Other coefficients and variables are already explained above. Based on the above equations, the above curve function can be obtained through mathematical derivation.
As illustrated in FIG. 2 , the edge of each of the individual lens ( 1 ) is cut into polygon structure with at least three cylindrical surfaces ( 105 ); any two neighboring condensing lenses ( 1 ) in the compound-eye lens condenser are adhered together by their adjacent cylindrical surfaces ( 105 ). Evidently, that the purpose for doing such is for the convenience of forming planar arrays of condensing lenses ( 1 ) to produce a compound-eye lens condenser.
Specifically, the edge of each of the individual lens ( 1 ) is cut into quadrilateral structure with four cylindrical surfaces ( 105 ), in which, neighboring cylindrical surfaces ( 105 ) are perpendicular to each other; any two neighboring condensing lenses ( 1 ) in the compound-eye lens condenser are adhered together by their adjacent cylindrical surfaces ( 105 ) to form a rectangular array of the condensing lenses ( 1 ) for the compound-eye lens condenser.
Additional benefit of cutting the edge of the condensing lens ( 1 ) into quadrilateral structure is that the shape of focused light spot through the lens is quadrilateral, making it practical to make corresponding photovoltaic wafers ( 7 ) quadrilateral during manufacturing. Quadrilateral structure is easy to process during wafer cutting and such quadrilateral cutting saves large amount of wafer materials.
The following is a comparison of the energy distribution in the focused light spot between a spherical convex lens and the condensing lens ( 1 ) disclosed in the current invention, which is implemented in the compound-eye lens condenser of compound-eye concentrating-type solar cell assembly disclosed in the current invention. The focused light spot energy distribution of an ordinary spherical convex lens is illustrated in FIG. 4 , the brightness is the highest in the center of the light spot, and the brightness decreases abruptly toward the edge; a wave curve with abrupt drop is illustrated in FIG. 5 . FIGS. 4-5 show that energy is concentrated in the center of the light spot and not uniformly distributed. As illustrated in FIG. 6 , the rectangular light spot produced by the condensing lens ( 1 ) disclosed in the current invention has an uniformly distributed brightness; as illustrated in FIG. 7 , the curve is almost saddle-shaped, showing that the energy levels in different locations of the light spot are all close to the peak of the saddle-shaped curve, thus energy distribution is relatively uniform.
Further, the transmission rate of the condensing lens is proved by optical simulation to be as high as 90% to 93%, while the transmission rate of Fresnel lens is around 75%. It shows that the condensing lens disclosed in the current invention has a good transmission rate.
Additionally, it should be pointed out that the total energy of incident light in the above two experiments is adjusted to the same level, and the areas of light spot on the receiving surface are kept the same. As illustrated in FIG. 7 , the peak of the curve is not very smooth and fluctuates in certain range, the reason for that is, in the simulation; solar spectrum is simulated whose energy does not have a uniform distribution.
The condensing lens ( 1 ) disclosed in the current invention can also be implemented as illustrated in FIG. 8 . FIG. 8 show a double-convex lens with two rotating convex surfaces. Curve 106 and curve 107 , as illustrated in FIG. 8 , are produced by crossing between any longitudinal section ( 2 ) which contains the lens optical axis ( 103 ) and those two rotating convex surfaces. If, as illustrated in FIG. 8 , F is set as origin of the coordinate system (optical center of the lens), a is the radius of the lens, b is the perpendicular distance between the optical axis 103 and projection point on receiving surface 4 produce by the light beam refracted by the lens, point C(x, y) is the point of intersection between curve 106 and an arbitrary incoming light 3 , point D(x 1 , y 1 ) is the point of intersection between curve 107 and the incoming light 3 which has already been refracted by curve 106 , the incoming light 3 is refracted twice by the lens to produce a projection point E(m, h) on the receiving surface, γ is the angle between optical axis 103 and the normal line at point D on the curve 107 , is the incident angle, β is the refractive angle, ε is the incident angle at point D, α is the refractive angle at point D, where γ, , β, ε and α are all unknown variables, the following equations can be obtained:
x
/
m
=
a
/
b
(
1
)
sin
(
θ
)
=
n
sin
(
β
)
(
2
)
tan
(
θ
)
=
ⅆ
y
ⅆ
x
(
3
)
tan
(
θ
-
β
)
=
(
x
-
x
1
)
/
(
y
+
y
1
)
(
4
)
sin
(
a
)
=
n
sin
[
γ
+
(
θ
-
β
)
]
(
5
)
tan
(
a
-
γ
)
=
(
x
1
-
m
)
/
(
h
-
y
1
)
(
6
)
tan
γ
=
ⅆ
y
1
ⅆ
x
1
(
7
)
In addition, the following boundary conditions are satisfied because both surfaces of the condensing lens are rotating convex surfaces:
If x=0, tan =0; if x 1 =0, tan γ=0.
The curve functions of curves 106 and 107 can thus be derived.
According to the two embodiments discussed above, the key to current invention is the idea that: x is the perpendicular distance between the point of intersection, where an arbitrary incoming light 3 intersecting the lens, and the optical axis 103 of the lens, m is the perpendicular distance between the projection point, generated by the refracted incoming light projected on the receiving surface 4 , and the center of the light spot, a is the radius of the lens, b is the radius of the light spot, then the condition x/m=a/b is satisfied by the lens. | A condensing lens, compound-eye lens condenser, and compound-eye concentrating-type solar cell assembly. The condensing lens is a convex lens that can reflect mutually parallel incident lights ( 3 ) onto a receiving surface ( 4 ) on the outer side of the lens and thus form spots. If the vertical distance from the contact point of any incident lights ( 3 ) contacting the lens to a light axis ( 103 ) of the lens is x, the vertical distance between a projection point formed from the incident light ( 3 ) reflecting onto the receiving surface ( 4 ) and the center of the spot is m, the radius of the lens is a, and the radius of the spot is b, then the lens meets the following condition: x/m=a/b. The condensing lens has a high transmission rate, and the energy distribution of the spots is more even after condensing, the transmission rate is 90% to 93%, and the energy distribution curve of the spots transmitted through the condensing lens is similar to saddle-shaped. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority of German Patent Application No. 10 2004 042 642.2, filed Sep. 3, 2004, which application is incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to a process and a device for preventing the engagement of an impermissible speed in an automated gearbox with a gear-switching member that can be moved along a gear-selection speed range and out of it into the speed step ranges.
BACKGROUND OF THE INVENTION
Modern motor vehicles are increasingly equipped with automated gearboxes because they not only improve the driving comfort but because one can also reduce consumption.
DE 103 16 442 A1 discloses a method for recognizing a fault during selection and/or switching of the gear actuator unit of the gear control of an automated gearbox, where a plausibilization of measured and deposited signals is performed. A fault message is issued in case there is no plausibilization of measured and deposited signals. The abovementioned publication furthermore deals with the practical triggering of a switching actuator during the different phases involved in the setting of a speed, especially during synchronization.
DE 103 12 401 A1 describes a gear actuator and a method for performing a referencing of the gear geometry in an automated gear. In this case, at least one learned value of the gear geometry is compared to at least one actual value of the gear geometry, whereby an implausible value is replaced by a predetermined value.
DE 197 07 141 A1 discloses an arrangement for the acquisition of actuation or switching states in a gear actuation device, where a gear-switching member can be moved in one gear-selection speed range and three gear-step speed ranges, which extend perpendicularly away from the gear-selection speed range. A regulating distance of a sensor that acquires the movement of a gear-switching member in a gear-step speed range is subdivided into several sectors that correspond to the phases or functions of the setting of a speed out of the gear-selection speed range or the neutral position.
SUMMARY OF THE INVENTION
The object of the invention is to create a possibility by means of which the setting of a faulty speed can be recognized and prevented in a simple manner, in particular, when the potential setting of an impermissible speed is caused by a fault in the system control of the automated gearbox.
This problem is solved with a process for the prevention of the setting of an impermissible speed in an automated gearbox with a gear-switching member that can be moved along a gear-selection speed range and out of this into the speed step ranges containing the following steps:
acquiring the speed step range in which the gear-switching member is moved, acquisition of the momentary vehicle speed, checking as to whether the speed, belonging to the particular speed step range related to the momentary vehicle speed, is permissible, acquisition of the triggering of a gear-switching actuator in case of an impermissible speed and triggering of a fault reaction upon the activity of the gear-switching actuator toward the setting of the speed that is recognized as impermissible.
In a preferred embodiment of the process, a speed is evaluated as impermissible when it is too small with relation to the momentary vehicle speed.
Advantageously, the gear-switching actuator is deactivated in case of a fault reaction.
As an alternative and/or in addition, a control device of the gear-switching actuator can be reset in case of a fault reaction.
In a preferred embodiment of the invention-based method, the acquisition of the triggering of a gear-switching actuator lasts as long as the gear-switching member is in the speed step range of an impermissible speed.
Here is another solution to the problem involved in the invention: A device is provided for the prevention of the setting of an impermissible speed in an automated gearbox containing a selection actuator for the purpose of moving a gear-switching member along a gear-selection speed range, a gear-switching actuator for moving the gear-switching member along gear-step speed ranges, a sensor device for the acquisition of a vehicle speed and a control device for controlling the selection actuator and the gear-step speed actuator.
With the help of the invention, it is possible to anticipate situations that are critical in terms of the safety of the passengers and the environment that can be caused by the faulty functions of a processor contained in a gear control unit. Such situations that are critical in terms of safety can arise in many different ways.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained below by way of example and in further detail with reference to the diagrams.
The figures represent the following:
FIG. 1 illustrates parts of a known actuation device for an automated gearbox;
FIG. 2 is a circuit diagram of an automated gearbox; and,
FIG. 3 is a flow chart to explain the invention-based process.
DETAILED DESCRIPTION OF THE INVENTION
According to FIG. 1 , a known automated gearbox, not shown, includes a device with parts inside the gear and an actuation device outside the gear. The parts inside the gear in the example illustrated contain two mutually parallel, movably arranged sliding selector shafts 10 , 12 with one gearshift fork 14 , 16 each and a gear-switching block 18 , 20 with a recess 22 , 24 on the top.
Provided for an engagement in one of the recesses 22 , 24 each is a gear-switching finger 26 that can be moved by means of a gear-selection actuator 28 in an X direction laterally with respect to the direction of movability of the sliding selector shafts 10 , 12 and that can be moved with a gear-switching actuator 30 parallel to the direction of movability of the sliding selector shafts 10 , 12 in a Y direction. Gear-switching finger 26 in the known manner is fixed upon a rod that is attached in a movable and swingable manner on a housing of the gear, which can be shifted with the help of the gear-selection actuator 28 and that can be rotated around its longitudinal axis with the help of the gear-switching actuator 30 .
Here is how the gear-switching is done: The gear-switching finger, which after actuation of the gear-selection actuator 28 is in one of the recesses 22 , 24 according to the figure. by way of example, is shifted or swung to the left, where the pertinent gear-switching fork shifts a coupling sleeve fastened upon a gear shaft so that a synchronization is brought about, subsequent to which, a new speed can be set. Stops 32 , 34 , 36 and 38 for the gear-switching device inside the gear are provided to monitor the function of the actuation device and especially for purposes of referencing and these stops limit the movability of the gear-switching forks 14 , 16 in one or the other Y direction. Reaching a stop is detected, for example, by the sudden rise of the current consumption of the gear-switching actuator or by the latter's standstill. The detection of a stop can in each case be used for referencing an incremental counter that is connected to the gear-switching actuator. As an alternative, or in addition thereto, one can provide stops 42 , 44 directly on the gear-switching actuator 30 , and these stops 42 , 44 will limit the movability of said actuator and will be used for referencing. Similar stops inside or outside the gear for the movement of the gear-switching finger 26 in the X direction (gear-selection speed range) by means of the gear-selection actuator 28 can be provided.
A control device 40 is used to control actuators 28 and 30 and that control device contains a microprocessor with pertinent memories in which driving programs are stored, corresponding to which—as a function of the operating states of the vehicle—the operation of actuators 28 and 30 is controlled. Control unit 40 advantageously acquires the momentary speed of the vehicle, for example, from a wheel revolution number sensor 46 , the engine rpm, the position of a driver pedal, not shown, a selection lever, not shown, for the activation of various control programs as well as normally the position of the gear-switching member 26 in the X and Y directions from which one can draw conclusions as to the particular set speed or the position of the gear actuator unit as a whole.
Let us now assume that, as a consequence of a processor fault, the gear-switching finger 26 is moved into the hachured sector of the gear-step speed range in which synchronization takes place, that is to say, the pertinent gear shaft is brought to the rpm of the speed brink [limit]. When the gear-switching finger is moved out of the gear-selection speed range into the beginning section of gear-step speed range 2 , that is to say, into the synchronization sector, then in control unit 40 , one examines whether the second speed is a permissible speed at the momentary vehicle speed. If this is not the case, that is to say, if speed 2 is evaluated as being too slow, then the control unit acquires the triggering of the gear-switching actuator 30 , for example, by the integration of the voltage that is applied, so that one can determine whether the gear-switching actuator—in spite of the fact that the speed is recognized as impermissible—continues to try to engage the second speed. If this is the case, then after a short time, for example, when the voltage integral exceeds a boundary value, a fault reaction is triggered that leads to a situation where the gear-switching actuator 30 is deactivated and/or it will trigger a reset of the control device 40 .
In the example illustrated upon the recognition of a speed as impermissible, one may not wait until the gear-switching finger has been moved by the gear-switching actuator in the direction of the setting of a speed, that is to say, into the synchronization sector of the second speed, because both speeds of the particular gear-step speed range, that is to say, speeds 1 and 2 , are impermissible at 120 km/hr. In other words, from the movement of the gear-switching finger along the gear-selection speed range into the position corresponding to the gear-step speed range 1 / 2 , one can draw a conclusion as to the impermissibility of a subsequent speed that is to be engaged and the monitoring of the triggering of the gear-switching actuator can begin.
The above process will be explained in greater detail with reference to the flow chart in FIG. 3 .
In step 1 , the control device on the basis of the present operating parameters decides on a resetting, for example, from speed 5 to speed 4 . The occurring actuations of a clutch, not shown, will not be explained below because they are known as such. After the decision to change speed in step 60 , gear-switching actuator 30 moves the gear-switching finger 20 into the gear-selection speed range and then, in step 62 , the gear-selection actuator 28 moves the gear-switching finger 26 into the target gear-step speed range, which, in the example at hand, should be gear-step speed range 3 / 4 . But gear-step speed range 1 / 2 is engaged due to a fault in the control device. Then gear-switching actuator 30 is actuated and it moves the gear-switching finger 26 out of the gear-selection speed range into a synchronization sector of the target speed step range (in this case, 4 as such; but in fact, however, 2 ) (step 64 ). The moment the gear-switching actuator has moved the gear-switching finger into the speed step range, one can—in step 66 by comparing the started speed step range (position of gear-switching finger 26 ) with the vehicle speed—determine whether the started speed step range involves an impermissible or a permissible speed. If the speed is impermissible, then in step 68 , the further gear-switching action takes place in a normal manner and the speed is engaged.
If it is determined in step 66 that the speed is impermissible (in the example illustrated, at 120 km/hr, the second speed), then in step 70 , one checks to see whether the gear-switching actuator 30 keeps trying to engage the speed that is recognized as impermissible. This is possible due to the movability of the gear-switching finger 26 that is delayed by the synchronization procedure, whereby the movement of the gear-switching actuator 30 can be acquired directly or indirectly, for example, by the temporal integration of the applied voltage. If it is determined in step 70 that the gear-switching actuator 30 continues to try to engage the impermissible speed, then in step 72 , a fault message is triggered, which leads to a situation where, for example, the gear-switching actuator 30 is deactivated or where the electronic control device is reset in that the latter device starts or newly references a safe initial position.
If it is found in step 70 that the gear-switching actuator no longer tries to engage the impermissible speed, then the system further returns to step 66 so that the monitoring of the gear-switching actuator with regard to the latter's attempt to set the faulty speed will last until it is recognized that the gear-selection actuator 28 moves the gear-switching finger out of the faulty gear-step speed range or the faulty speed step range or where, in a prior step (not shown), the gear-switching actuator 30 moves the gear-switching finger out of the synchronization sector back out into the gear-selection speed range (neutral position) so that one cannot recognize any further impermissible speed that is to be engaged or that the vehicle speed has decreased so much that the hitherto impermissible speed becomes permissible.
The described process or the illustrated strategy of processor monitoring offers the advantage that no required position of the gear-switching finger inside the speed step range need be acquired after the start of synchronization and so that it will work independently of the mode of the attitude regulator (position regulation, power regulation, speed regulation, etc.).
Any impermissible engagement of the reverse speed when the vehicle is running forward can also be intercepted or prevented if the reverse speed is fully synchronized.
The process described is suitable not only for preventing the engagement of an excessively small speed or the faulty engagement of the reverse speed but can also be used to prevent the engagement of an excessively fast speed when this leads to a severely below-speed revolution of the engine that overloads the power train and/or to an excessively small available power output. The process can be used for all types of automated gearboxes, including dual clutch gearboxes or parallel gearboxes.
LIST OF REFERENCE
10 Sliding selector shaft
12 Sliding selector shaft
14 Gearshift fork
16 Gearshift fork
18 Gear-switching block
20 Gear-switching block
22 Recess
24 Recess
26 Gear-switching member
28 Gear-selection actuator
30 Gear-switching actuator
32 Stop
34 Stop
36 Stop
38 Stop
40 Control unit
42 Stop
44 Stop
46 rpm sensor | A process for preventing the engagement of an impermissible speed in an automated gearbox with a gear-switching member, which can be moved along a gear-selection speed range and out of it into speed step ranges containing the following steps: acquiring the speed step range in which the gear-switching member is moved; acquisition of the momentary vehicle speed; checking as to whether the speed, belonging to the particular speed step range related to the momentary vehicle speed, is permissible; acquisition of the triggering of a gear-switching actuator in case of an impermissible speed; and, triggering of a fault reaction upon the activity of the gear-switching actuator toward the setting of the speed that is recognized as impermissible. A device for implementing the method is also disclosed. | 5 |
FIELD OF INVENTION
The invention relates to a pontoon-type floating structure.
BACKGROUND
As population and urban development expand in land scarce island countries (or countries with long coastlines), city planners and engineers may resort to land reclamation to ease the pressure on existing heavily-used land and underground spaces. Using fill materials from seabed, hills, deep underground excavations, and even construction debris, engineers are able to create relatively vast and valuable land from the sea. However, land reclamation has its limitations. It is only suitable when the water depth is shallow (less than 20 m). When the water depth is large and/or the seabed is extremely soft, land reclamation may no longer be cost effective or even feasible. Moreover, land reclamation may destroy the marine habitat and may even lead to the disturbance of toxic sediments.
Very Large Floating Structures (VLFS) are an alternative method to create “land” on the sea. There are two types of VLFS; the semisubmersible-type and the pontoon-type. Semi-submersible type floating structures are raised above the sea level using column tubes or ballast structural elements to minimize the effects of waves while maintaining a constant buoyancy force. Thus they can reduce the wave induced motions and are therefore suitably deployed in high seas with large waves. Floating-platforms used for drilling for and production of oil and gas are typical examples of semi-submersible-type VLFSs. When these semi-submersibles are attached to the seabed using vertical tethers with high pretension as provided by additional buoyancy of the structure, they are referred to as tension-leg platforms.
In contrast, pontoon-type floating structures lie on the sea level and are typically for use in calm waters, often inside a cove or a lagoon and near the shoreline. The larger category of pontoon-type floating structures or Mega-Floats have at least one length dimensions greater than 60 m.
When a Mega-Float is heavily loaded, in the central portion for example, the floating structure will deflect with the centre vertically displaced relative to the corners. The resulting differential deflection may cause equipment to malfunction, the superstructure on the floating structure to be subjected to additional stresses or in extreme cases may lead to structural failure under high stress conditions.
A need therefore exists to address at least one of the above problems.
SUMMARY OF THE INVENTION
In accordance with a first aspect of the present invention there is provided a pontoon-type floating structure comprising an upper deck that is to be maintained above water level and that is to receive and support a load by the load resting thereon; and a horizontal array of chambers disposed underneath the upper deck, with the chambers providing a first set of chambers that provide the structure with buoyancy, and a second set of chambers with water having access thereto so that the second set of chambers, under steady state conditions, do not provide buoyancy.
A plurality of walls preferably depend from the upper deck and co-operate therewith to provide the chambers separated by the walls.
Said walls are preferably generally perpendicular to said deck, with the walls including a first set that are generally parallel and transversely spaced and a second set, with the walls of the second set being generally parallel and transversely spaced and generally normal to the first set so that the chambers in horizontal transverse cross-section are generally square or rectangular.
The chambers preferably have respective bottom walls, the bottom walls being displaced from the upper deck, with the bottom walls of said second set of chambers having an aperture providing for the flow of water.
Said second set of chambers are preferably located adjacent a periphery of said structure.
Said second set of chambers are preferably aligned in rows adjacent said periphery.
Each row is preferably displaced from the periphery by at least one chamber of the first set.
Said structure is preferably square or rectangular in configuration when viewed in plan so as to have four sides, with each row extending generally parallel to one of said sides.
Said structure is preferably formed of one or more of a group consisting of steel, concrete, and reinforced concrete.
Said structure preferably includes a generally horizontally oriented bottom slab that is to be submerged and that is generally parallel and co-terminus with respect to said top deck but vertically spaced therefrom.
Said array of chambers is preferably a first array, and said structure includes a second horizontal array of chambers located beneath the first array of chambers, the first and second chambers separated by a generally horizontally oriented middle slab and that is generally parallel and co-terminus with respect to said top deck but vertically spaced therefrom.
Said top deck preferably has apertures and/or is air pervious to provide for the flow of air with respect to the chambers of the second set.
BRIEF DESCRIPTION OF THE DRAWINGS
Example embodiments of the invention will be better understood and readily apparent to one of ordinary skill in the art from the following written description, by way of example only, and in conjunction with the drawings, in which:
FIG. 1 is a schematic side elevation view of a floating structure according to an example embodiment.
FIG. 2 is a cross sectional schematic view of a section of the floating structure of FIG. 1 .
FIG. 3 a is a schematic bottom view of a zero-buoyancy chamber of the floating structure of FIG. 1 .
FIG. 3 b is a schematic bottom view of another zero-buoyancy chamber of the floating structure of FIG. 1 .
FIG. 4 shows a plurality of schematic side elevations of different mooring arrangements for the floating structure of FIG. 1 .
FIG. 5 is a schematic plan view of a floating structure according to another example embodiment (dimensions in metres).
FIG. 6 a is a schematic cross sectional view of a water tight chamber of the floating structure of FIG. 5 .
FIG. 6 b is a schematic cross sectional view of a zero-buoyancy chamber of the floating structure of FIG. 5 .
FIG. 7 a shows a deflection surface of a floating structure without zero-buoyancy chambers and subjected to a 7-tier container loading (deflections in metres).
FIG. 7 b shows a deflection surface for the floating structure of FIG. 5 and subjected to a 7-tier container loading (deflections in metres).
FIG. 8 a shows a stress contour of a bottom slab for the major principal stresses in a floating structure without zero-buoyancy chambers and subjected to a 7-tier container loading (stresses in MPa).
FIG. 8 b shows a stress contour of the bottom slab for the major principal stresses in the floating structure of FIG. 5 and subjected to a 7-tier container loading (stresses in MPa).
FIG. 9 a shows a stress contour of a top slab for the major principal stresses in a floating structure without zero-buoyancy chambers and subjected to a 7-tier container loading (stresses in MPa).
FIG. 9 b shows a stress contour of the top slab for the major principal stresses in the floating structure of FIG. 5 and subjected to a 7-tier container loading (stresses in MPa).
DETAILED DESCRIPTION
FIG. 1 shows a floating structure 100 according to an example embodiment. The floating structure 100 may be moored to a mooring facility 102 and may include an access connection 104 to land 108 , another structure or a vessel. A breakwater 106 may be optionally provided to reduce large wave forces impacting the floating structure 100 .
FIG. 2 shows a schematic cross sectional drawing of a section of the floating structure 100 . The structure 100 includes a top deck 200 provided by a top slab in the example embodiment. Depending from the deck 200 are a plurality of walls e.g. 202 , 204 . The walls 202 , 204 extend generally perpendicular to the deck 200 so as to provide a plurality of chambers e.g. 206 , 208 . The chambers 206 , 208 are arranged in a horizontal array underneath the deck 200 . A horizontal bottom wall or slab 210 is provided. The walls 202 , 204 , as well as the slab 210 are made from a water impervious material, with each of the walls 202 , 204 sealingly connected to the horizontal bottom slab 210 . In this respect it will be appreciated that the majority of the chambers e.g. 206 are sealingly enclosed so that water may not enter them. At the same time, apertures 212 , 214 are provided in the bottom slab 210 in the area of selected chambers 208 , allowing water to enter those chambers e.g. 208 . To facilitate the venting of air from the chambers 208 as the water enter, the deck 200 may be provided with apertures (not shown) or may be otherwise air pervious, at least in areas of the chambers 208 . Under steady state conditions, the chambers 208 are thus filled with water up to a level, indicated at 216 , equivalent to the sea level, indicated at numeral 218 .
As the water is free to flow in and out of the chambers 208 , those chambers, which may be referred to as gill cells, provide zero-buoyancy to the floating structure 100 . At the same time, the remaining chambers 206 provide buoyancy to the structure 100 . Thus, buoyancy forces are acting on the bottom slab 210 , apart from areas underneath the chambers 208 .
In the example embodiment, the chambers 208 are provided along an edge 216 of the structure 100 , and as a result of the zero-buoyancy of the chambers 208 , a restraint to vertical movement of the edge 216 is provided. This was found to decrease the differential deflection of the edge 216 when loads are applied at or near the centre of the floating structure 100 . By adjusting the number and geometry of the chambers 208 , the floating structure 100 can be designed to maintain the differential deflection within acceptable limits under varying loads.
In the example embodiment, the apertures 212 , 214 are designed such that the structural integrity of the bottom slabs 210 is maintained. The aperture size is chosen to be sufficiently large to allow water to freely enter so that the water level in the chamber is equal to the sea water level.
FIGS. 3 a and 3 b show example apertures 300 , 302 for individual zero-buoyancy chambers 304 , 306 . In choosing aperture designs, sharp points in the apertures may be avoided as they can cause starting points for cracks. The size of the apertures may be balanced between avoiding weakening of the chambers' structure, and blockage of particularly small apertures.
In the example embodiment the walls and slabs are constructed from steel, concrete, reinforced concrete such as stell reinforced concrete, or any other suitable watertight material with the requisite stiffness and strength. Since watertightness of concrete avoids or limits corrosion of the reinforcement, either watertight concrete or offshore concrete may be used. For example high-performance concrete containing fly ash and silica fume would be suitable. It will be appreciated that other combinations of structural materials may be used in different embodiments.
Corrosion protection techniques may be applied to the reinforcing and other steel work using for example coatings, cathodic protection, corrosion allowance and corrosion monitoring. In areas where marine organisms are active, antifouling coatings may be used to reduce marine growth. In areas of potential severe low corrosion, such as directly beneath the mean low water level, cathodic protection may be applied, while coating methods may be applied for remaining parts shallower than the depth of 1 m below the mean low water level. Coating methods may include painting, titanium-clad lining, stainless steel lining, thermal spraying with zinc, aluminium and aluminium alloy.
Returning now to FIG. 1 , the mooring facility 102 ensures that the floating structure 100 is kept in position so that the facilities installed on the floating structure can be reliably operated. Preventing the structure 100 from drifting away under critical sea conditions and storms is an example design consideration for a mooring facility 102 . A free or drifting floating structure 100 may lead to damage to the surrounding facilities and may also lead to the loss of human life in a collision with vessels. FIG. 4 shows a number of types of mooring systems such as the dolphin-guide frame system 400 , mooring by cable and chain 402 , tension leg method 404 and pier/quay wall method 406 . Choice of the type of mooring system depends on the local conditions and the performance requirements.
Once the type of mooring system is chosen, the shock absorbing material, the quantity and layout of devices to meet the environmental conditions and the operating conditions and requirements can be determined. Layout of mooring dolphins for example may be such that the horizontal displacement of the floating structure is adequately controlled and the mooring forces are appropriately distributed. The layout and quantity of the mooring dolphins may be adjusted so that the displacement of the floating structure and the mooring forces do not exceed the allowable values.
In order to reduce the wave forces impacting the floating structure, optionally one or more breakwaters 106 , may be constructed nearby. A breakwater may be useful if the significant wave height is greater than 4 m.
In the following, results of calculations illustrating the performance of an example embodiment of the present invention will be described. FIG. 5 shows a schematic top view of a floating container terminal 500 according to the example embodiment, and used for the calculation discussed below. In FIG. 5 , a central container area 502 is provided, as well as a rail area 504 at one edge of the structure 500 . Dimensions indicated in FIG. 5 are in meters. The location of the zero-buoyancy chambers are schematically indicated at numerals 506 , 508 , and 510 .
A finite element method (FEM) calculation was used to compare the structure 500 against the same structure without zero-buoyancy chambers. An example concern is the differential deflection between the corners and the middle portion of the floating structure 500 . For example a quay crane may not be able to operate if the between-rail 504 gradient goes above certain gradient specification, for example 0.4%.
For the calculations, the structure 500 is assumed to be of a double layer structure, which will now be briefly described. FIGS. 6 a and b show schematic cross-sectional views of a water tight chamber 600 , and a zero-buoyancy chamber 602 of the structure 500 ( FIG. 5 ) respectively. In FIG. 6 a , the water tight chamber 600 is partitioned by a middle slab 604 disposed between the top and bottom slabs 606 , 608 respectively. Similarly, as shown in FIG. 6 b , the zero-buoyancy chamber 602 is partitioned by the middle slab 604 disposed between the top and bottom slabs 606 , 608 respectively. Apertures 610 , 612 are provided in the bottom slab 608 in areas of the zero-buoyancy chamber 602 , with corresponding apertures 614 , 616 provided in the middle slab 604 . Beam stiffeners 618 , 620 are provided underneath the top slab 606 and on top of the bottom slab 608 respectively, and extend in two orthogonal sets of horizontally spaced rows across the top and bottom slabs 606 , 608 .
Table 1 summarises the data adopted for the calculation including the dimensions and construction material properties of the example floating structure, the selfweight and weight of quay cranes.
TABLE 1 Data Adopted for Calculation Data Units Dimensions of Floating Structure Total length 470 m Total width 520 m Total height 10 m Thickness of top and bottom slabs 0.4 m Thickness of intermediate level slab 0.2 m Thickness of vertical walls 0.3 m Width of beam stiffeners 0.5 m Depth of beam stiffeners 1.0 m Material Properties and Allowable Stresses Density of high performance concrete 1900 kg/m 3 Modulus of high performance concrete 22.9 GPa Poisson's ratio of high performance concrete 0.2 Compressive stress 70 MPa Flexural tensile stress 7.2 MPa Splitting tensile stress 4.3 MPa Allowable compressive stress 42 MPa Allowable flexural tensile stress 4.32 MPa Allowable splitting tensile stress 2.58 MPa Dead Loads Total selfweight of container terminal 737250 ton Weight of one quay crane 1360 ton Number of quay cranes 8
ABAQUS software was used for the calculation. The model for the calculation consists of
4-node thin-plate elements for the top, middle and bottom slabs and the vertical walls. Each element for the slab has dimensions 5 m×5 m with different thicknesses and each element for the vertical wall has dimensions 5 m×4.8 m 2-node beam elements for modelling the beam stiffeners. Each beam stiffener has a length of 5 m. Lateral springs are attached to the nodes of the bottom plate elements to model the buoyancy forces. The spring coefficient is taken as 250 kN/m (=1.03×9.81×5×5), which is equivalent to the buoyancy force.
FIGS. 7 a and b show the calculated deflection surfaces 700 , 702 for the floating structure without zero-buoyancy chambers, and with zero-buoyancy chambers according to the example embodiment, respectively. The deflection surfaces 700 , 702 were calculated under 7-tier container loading, and the quay crane load and the terminal selfweight as listed in Table 1. As can be seen from a comparison of FIGS. 7 a and b , the floating structure in accordance with the example embodiment ( FIG. 7 b ) experiences significantly reduced differential deflection of the floating structure, as illustrated by the substantially “flat” deflection surface 702 .
FIGS. 8 a and b show the calculated stress contours 800 , 802 of the bottom slab for the major principal stresses for the floating structure without zero-buoyancy chambers, and with zero-buoyancy chambers according to the example embodiment, respectively. The stress contours 800 , 802 were calculated under 7-tier container loading, and the crane load and selfweight as listed in Table 1. As can be seen from a comparison of FIGS. 8 a and b , the floating structure in accordance with the example embodiment ( FIG. 8 b ) experiences significantly reduced stresses.
FIGS. 9 a and b show the calculated stress contours 900 , 902 of the top slab for the major principal stresses for the floating structure without zero-buoyancy chambers, and with zero-buoyancy chambers according to the example embodiment, respectively. The stress contours 900 , 902 were calculated under 7-tier container loading, and the crane load and selfweight as listed in Table 1. As can be seen from a comparison of FIGS. 9 a and b , the floating structure in accordance with the example embodiment ( FIG. 9 b ) experiences significantly reduced stresses.
Tables 2 and 3 summarise the deflections calculated for the floating structure without zero-buoyancy chambers, and with zero buoyancy chambers according to the example embodiment, respectively.
TABLE 2
Differential Deflection (m)
Corner with
Edge with
Deflection (m)
respect to
respect to
Tiers
Corner
Edge
Centre
centre
centre
0
−3.53
−3.06
−2.89
−0.64
−0.17
1
−3.43
−3.62
−3.58
0.15
−0.04
2
−3.53
−3.85
−4.26
0.73
0.41
3
−3.53
−4.27
−4.95
1.42
0.68
4
−3.53
−4.67
−5.64
2.11
0.97
7
−3.52
−5.90
−7.70
4.18
1.8
Allowable
−7.5
−7.5
Deflection
Draft
OK since deflection
Check
is less than
allowable deflection
TABLE 3
Differential Deflection
Deflection (m)
Corner w.r.t.
Edge w.r.t.
Tiers
Corner
Edge
Centre
centre (m)
centre (m)
5
−6.15
−6.74
−6.27
0.12
−0.47
6
−6.48
−7.02
−6.93
0.45
−0.09
7
−6.69
−7.15
−7.61
0.92
0.46
Allowable
−7.5
−7.5
Deflection
Draft
OK since deflection
Check
is less than
allowable deflection
ADVANTAGES
The zero-buoyancy chambers in example embodiments are passive since the water flows in and out naturally from the chambers. There may be no need for pumps and expensive operating costs as in an active ballast system. The zero-buoyancy chambers may allow the floating structure to have the same draft even when loaded unevenly, provided the acceptable draft is not exceeded. This may lead to cost savings because of uniformity of modules across the whole floating structure. The lower buoyancy chambers may lead to a lighter and cheaper floating structure since the thickness of structural sections may be reduced (due to the reduced stresses and differential deflection) without compromising on the serviceability and strength capacities. The lower buoyancy chambers, being partially filled with water, may also provide hydrodynamic damping, thereby making the floating structure more resistant to movement caused by wave forces and water currents.
INDUSTRIAL APPLICABILITY
Embodiments may be used in
a floating container terminal, a floating cruise centre, a floating hotel, a floating restaurant, a floating pier/berth or a floating airport,
mooring buoys,
spars,
semi-submersibles,
rafts or mat foundations on soft soils, and
other floating structures such as multi-body floating structures, and comb-type floating structures.
It will be appreciated by a person skilled in the art that numerous variations and/or modifications may be made to the present invention as shown in the example embodiments without departing from the spirit or scope of the invention as broadly described. The example embodiments are, therefore, to be considered in all respects to be illustrative and not restrictive. | A pontoon-type floating structure comprising an upper deck that is to be maintained above water level and that is to receive and support a load by the load resting thereon; and a horizontal array of chambers disposed underneath the upper deck, with the chambers providing a first set of chambers that provide the structure with buoyancy, and a second set of chambers with water having access thereto so that the second set of chambers, under steady state conditions, do not provide buoyancy. | 1 |
CROSS REFERENCE TO OTHER APPLICATIONS
This is a non-provisional patent specification submitted for an official filing receipt under Code Section 111(a) and which claims priority under Code Section 119 ( ) and 37 C.F.R. Section 1.78(3)from my provisional specification filed Sep. 14, 2000, being given U.S. Serial No. 60/232,509, and having the same title.
BACKGROUND OF THE INVENTION
The art has disclosed a number of devices that qualify as target resetting systems. Hoy U.S. Pat. No. 4,949,988 (1990) is to a multiplicity of upright target assemblies, in which, when a first target is knocked down and held deflected by a latch, then as to a second reset target upon striking same, it moves to unlatch the first knocked down target. However, the inherent target resistance level is not adjustable and requires a minimum level of projectile velocity to be activated.
Rosellen U.S. Pat. No. 5,263,722 (1993) is another resettable target, but with the single reset target being aligned diametrically opposite from the main target array. Moreover, the latching/reset linkages are quite complex (compare FIGS. 5 / 6 ), also being gravity dependent and operable only in the mode depicted.
Estrella U.S. Pat. No. 5,324,043 (1994) is another target resetting system, involving a racheting system and gears, requiring the target mounting shaft to be rotated with the assistance of lever arms (compare FIGS. 2 / 4 ), it is depicted as in extreme complexity of the ratcheting and reset devices.
It is therefore a principal object of the present invention to provide a portable target resetting device in which the array of targets, including the reset target, are substantially located on the same plane, and which device can also operate in the inverted position, as well, for safety purposes.
Another object of the present invention is to provide a target array in which the effecting projectile force and/or target distance can be varied, to one which is adequate for target deflection, allowing a range of projectile sizes usable with a single target array.
Still another object of the present invention is to provide a resettable target array with a uncomplicated linkage means, which latches a hit target and sets one or all of them upon striking of the single reset control target means.
Yet another object of the invention is to provide a resettable target array in which any number of targets can be deflected, permitting a reset action to be triggered, should a shooter have expended his clip without deflecting all his targets.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic front (display side) elevation view of how the resettable target array of the present invention appears to an approaching practice shooter;
FIG. 2 is an above angle, perspective view of the target array system depicting their underlying elongate support and action shafts, and their associated helical spring rotational biasing mechanisms;
FIG. 3 is a schematic illustration depicting the use of the target array at the point where the shooter is now striking the reset target to bring the entire array target upright;
FIG. 4 is a top plan view of the present system depicting the targets array, all being upright and of the associated pair of torsion-biased elongate bars and their interconnecting levers;
FIG. 5 is a vertical sectional view of typical target plate depicting its pivoted target support means and the associated deflecting and latching mechanism;
FIG. 6 is a vertical sectional view of the resetting target plate depicting the pivotable target support and the associated transient deflection and array resetting mechanism;
FIG. 7 is a broken out, reverse side, perspective view of the one of the intermediate targets, depicting its deflection and latching mechanism, which corresponds to the view FIG. 5;
FIG. 8 is a broken away, perspective view of the reverse view of the present array, depicting two of the targets in the deflected mode, but capable of reset; and,
FIG. 9 is a broken out, reverse side, perspective view of the one terminal end of the device frame which supports the reset target, along with its discrete deflection, and array reset linkage, and corresponds to view of FIG. 6; and
FIG. 10 is a broken away, enlarged top side view of a segment of the rearward mechanism of FIG. 5 (rotated 180 degrees) depicting the lever return arresting device for targets 1 - 5 .
SUMMARY OF THE INVENTION
According to the invention, there is provided a multiple target apparatus having: an array of discrete target plates arrayed linearly on and mounted pivotally upon a horizontal elongate rigid first rod; a plurality of first torsion-providing means encasing the first rod substantially along its length, and which first means is adapted to bias a first target to rotate in a first arcuate direction that normally maintains the associated target in an upright mode; a spaced-apart, horizontal elongate second rod, being substantially parallel with the first elongate rod, has a second torsion-providing means, encasing the second rod substantially along its length, and which second torsion means is adapted to bias rotation of said second rod in the opposing arcuate direction to that of the first rod; at least one target deflection and arrest means is functionally interconnecting the first and second rods, which said arrest means comprising a depending first arm tied to the pivotal axis of the first target plate; a rigid first lever spanning the space between the second elongate rod and the depending first arm, and with lever end being slightly offset from that first arm at the depending first longitudinal end thereof; a first detent means secured proximal to the free longitudinal end of the first lever means and adapted to contact and arrest the counter-rotation of the depending end of the first arm of the first target plate; the first lever means also being tied at the other longitudinal end thereof to the second rod; a single target deflection and array reset means functionally associated with a second target plate, comprising: a second lever means spanning the space between the second elongate rod and the depending second arm; a second detent means secured flush with the free longitudinal end of the second lever means; the second arm, which is adapted to make transient contact with the somewhat longer, second arm of the second target reset means, such that when the second target plate of the array reset means is deflected backwardly by a projectile impact, then the second arm rotates clockwise and depresses both the second lever means and its associated second rod, and thus concurrently depresses the remote, first lever means, inter alia, thereby spacing apart the first detent means and the associated depending first arm, allowing the first torsion means of the first rod to rotate both the associated first target from an arrested deflection position back to the upright position, as well as rotation to the upright of the second target. In a preferred embodiment, the first arcuate direction of the first rod is the one that rotates an associated target means such that the unlatched first target rotates in a first arcuate direction from an inclined deflection mode to an upright mode, whereby the second torsion-providing means rotates the second rod reciprocally in the opposite arcuate direction, returning each of the first and second lever means to a non-arrest mode for the associated depending arms thereof of each.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawing, and to FIG. 1 in particular, there is seen a schematic view of the display facade of a resettable target array of the present invention, comprising an elongate rectangular frame, generally 20 , with paired sets of stilt-like support legs, 22 L/M/R, and an exemplary, substantially linear, array of six targets, 26 A-F, with each face plate numbered 1 to 5 , all being independently deflectable by a bullet, and each retainable in that back deflection mode (FIG. 2 ). However, the sixth end target, 26 F (letter R inscribed), provides a single deflectable and array reset means for the depicted array in a manner to be described.
In the downward angle, perspective view of FIG. 2, it will be seen that each target bottom arcuate edge (periphery), is mounted upon an elongate first support rod 28 , which rod is supported at its opposing longitudinal ends upon the transverse elements, 30 L/R, within the lower end brackets, 32 L/R, of rectangular frame 20 , with the targets themselves being rotatable upon a discrete collar encasing the rod segments.
First rod 28 is encased through most of its linear length by a set of like helical springs, 34 A/F, each of which are operatively connected to one of the plate-like targets, 26 A/F, themselves. For example, left end, coiled spring 34 A is linked to left hand target 26 A (# 1 ), and will then serve to continuously bias that specific target to be in the erect mode, as is depicted, until a projectile (not seen) provides the kinetic energy needed to deflect target 26 A arcuately backward (See FIG. 3 ). An associated mechanism, to be described, then arrests the deflected target 26 A in the “knock-down mode” so it is mostly out of line of sight until a later event, also to be described, which event will reset target 26 A, and any, or all, of the other numbered deflected targets 26 A/E, deflected by hitting target “R”, the reset target.
Behind each of the targets is a separate rigid means, such as lever 36 A, the free end, 37 A, of which (FIG. 5) functionally contacts the opposing targets in a manner, to be described. Each of transverse levers, 36 A/F, are pinned at their rearward longitudinal ends to a second elongate rod 38 , which is spaced apart from, and parallel to, the first rod 28 , which is also similarly mounted at its longitudinal ends, rotatably to members 30 L/R frame 20 . As with first rod, a plurality of helical springs, 40 A/F, encase rearward rod 38 , and they serve to bias that rod, and its attached levers, 36 A/E, to rotate in an upward (clockwise) direction, whereby the lever free ends, 37 A/E, will make contact with the arms, 46 A/E, depending from target support collar, 44 A/E (FIG. 5 ).
FIG. 3 depicts schematically a target user directing a bullet, at the reset target, 26 F, after the first five targets have been deflected and arrested in the deflected position. The transient deflection of target 26 F will serve to reset the entire array by means, to be described.
In the top plan view of FIG. 4, the interconnection of each of the upright targets 26 A to 26 F, to the spaced apart, torsionally-biased rotatable elongate bars, 28 and 38 , and the spanning levers, 36 A to 36 F, which are each pinned spaced apart to the rearward rod 38 , are better seen.
Aligned along second rod 38 , on the upper perimeter thereof, and a spaced apart set of arrest elements 39 A/E located proximal to each lever 36 A/E. They serve to arrest the rotation upwardly of each lever, while it is subjected to the second set of torsional bearing means 40 A/F.
Averting to the vertical cross sectional view of FIG. 5, there is depicted how any single one, or all, of the deflectable targets, 1 to 5 , appear after their deflection by a projectile (not 20 seen). Each target support collar, generally 44 A, is provided with a depending rigid arm 46 A. Detent 52 A is mounted proximal to, but spaced apart from, the opposing free longitudinal end of spanning lever 36 A. The upward bias of lever arm 36 A (induced by associated rearward helical spring 40 A) has been interrupted by the clockwise rotation (a projectile impact on target 26 A), which then engages detent 52 A located on spanning lever end 37 A, to prevent the return of target 26 A to the vertically erect position of FIG. 1 . This depicted deflection for the target 26 A will remain in the arrest mode, until some later event (like a FIG. 3 firing), which breaks the seating contact, at least momentarily, such would then permit the torsion-induced bias of helix 34 A on the target support assembly 44 A to rotate target 26 A back to the upright position (seen in phantom).
When the “knockdown” of reset target 26 F occurs (FIG. 3 ), the downward deflection of ganged lever 36 F rolls up on 52 F, and rotates shaft 38 counter-clockwise. The shaft 38 rotation concurrently rotates ganged levers 36 A/E, releasing them, so that each of the deflected targets 26 A/E, will rotate back to the erect mode. At this moment, helical spring 34 F rotates also resets target 26 F back to the erect mode.
In the vertical cross sectional view of FIG. 6, the differing free end configuration, namely of edge-mounted detent, 52 F, on spanning lever 36 F is depicted. Only depending arm 46 F has on its terminal end, a cylindrical bar 54 F, so that the depending end 52 F of depending arm 46 F is not arrested by the arcuate movement bias inherent in lever 36 F. Depending arm 46 F itself, being somewhat longer than all of the other arms, like 46 A, such that when target 26 F is deflected backwardly, spanning lever 36 F is depressed more steeply than any of the similar arrayed levers, like adjacent lever 36 E (FIG. 7 ), would be. A transient gap, 53 A, (FIG. 5) is created briefly by the projectile-driven downward rotation of rearward ganged support rod 38 (FIG. 5 ), which breaks the seating of dependent contact arm 46 A and lever detent 52 A (and of all other targets), thus permitting associated target 26 A to return to the erect mode. Similarly, as the rearward deflection of reset target 52 F is a transient one, since lacking any arrest effect by detent 52 F on arm 36 F, then that target concurrently returns to the erect mode, as shown in phantom. All six targets are now reset for another of shooting round.
With respect to the broken out perspective view of FIG. 7, the option of varying the resistance of a target, like 26 E, to projectile impact, will now be described. Helical spring 34 F provides an upright bias to target 26 E at its inner end, 351 , while the outer spring end, 35 O, is pinned to rotatable collar 41 . Collar 41 is locked upon shaft 28 via a set screw 41 S. By temporary release of set screw 41 S, and rotation of associated shaft of collar 41 , the biasing tension imposed upon target 26 E can be varied. Then, the set screw 41 S is tightened down to hold the new position for collar 41 . The purpose of this adjustment is to accommodate the variable projectile momentum of different bullets, from small caliber to higher powered rifles.
The reverse side, perspective view of FIG. 7 corresponds to the vertical sectional view of FIG. 5, and somewhat better depicts how each of deflected targets, 26 A/E, are arrested by the associated spanning lever means 36 A/E. This arrest mode exists until the target array reset sequence, just described above, is activated by firing upon adjacent reset target 26 F only. It is noteworthy that the force of the torsional bias provided by helical spring 40 F approximates the sum of forces provided by the bias of springs 40 A to 40 E.
The perspective view of the observe side of FIG. 8 is complemental of the display side (legs omitted), perspective view of FIG. 2 . Note that only targets 26 A and 26 D are deflected, and thus are held in the arrest position. The other three targets, 26 B, C, and E, are still upright as is, of course, reset target 26 F. At this juncture, if the shooter has expended all but one of his ammo clip of bullets, he can use his last shell to strike reset target 26 F, and thus to reset the entire target array. This is done either for starting his next clip of bullets or, as a courtesy, by resetting same for the next user of the target array. The entire target array, 26 A/F, will again display upright as in the schematic view of FIG. 1 .
In the reverse side of perspective view of FIG. 9, such corresponds to the sectional view of FIG. 1, and is the different configuration for the free end of lever 36 F, here being depicted in the stage of its maximum downward deflection by depending arm 26 F, which transient stage effects a gap (FIG. 5) between the depending arm and the detent-bearing lever, for each of targets 26 A/E. As noted, this transient gap permits each of the five targets to arcuately rotate to the vertical mode of FIG. 1, along with the reset target (R) itself. After reset, the several detents ( 52 ) mounted on spanning levers ( 36 ) are spaced apart from the lower ends of the depending target arms 46 . This target array deflection obtains until an induced deflection permits such a depending end arm ( 46 A) to pass over its associated offset detent, and then arrest the target in the position depicted in FIG. 5 .
In the broken out view of FIG. 10, the rod biasing assembly 40 A which regulates the rotatable action of spanning lever 36 A, via rearward elongate rod 38 is seen. As noted, lever 36 A, which extends transversely of elongate rods 28 and 38 , serves to cooperate with a depending lever arm 46 A (FIG. 5) and is pinned to rearward rod 38 , as are all other spanning levers, 36 A/F. Associated torsional spring 40 A provides the upward (clockwise) bias for lever 36 A, when the latter is freed to rotate arcuately. Erect post 41 A is mounted fixedly upon the 20 collar 36 T, which is pinned to elongate shaft 38 itself. Angle-shaped, linear detent component, 39 A, is aligned axially along rod 38 so as to provide an arrest element for the moving vertical post 41 A. As described in relation to correlated FIGS. 5 and 7, when lever 36 A rotates upwardly, post 41 A on collar 36 T makes contact with detent 39 A, which limits the arcuate rotation of free lever end 37 A to the arrest position depicted in FIG. 5 . This arrest feature obtains for each of levers 36 A/E. As to the target reset assembly 40 F of FIG. 6, such a detent component and associated post arrest device are unnecessary, for the reasons discussed previously. | A multiple target apparatus having an array of target plates arrayed linearly and pivotally on a first elongate shaft; a plurality of torsion providing components located on the first shaft are adapted to bias the targets in an upright mode; each target has a depending arm pinned to rotate upon the imposed deflection of a target by a speeding projectile to a latching position. Arrayed upon a spaced apart, second shaft are a like number of rigid levers spanning the lateral space between the first and second shafts. A detent on the one end of each of the depending arms is adapted to be contacted and arrested by the opposing lever until such are dislodged by a descrete target deflection and array reset, which are located at one end of the device, such that upon imposed rotation of the reset means, it also releases the latching position of the other targets. | 5 |
RELATED APPLICATIONS
[0001] This application is the national stage entry under 35 USC 371 of PCT/EP2014/000817, filed on Mar. 26, 2014, which claims the benefit of the Apr. 3, 2013 priority date of German application DE 102013103310.5, the contents of which are herein incorporated by reference.
FIELD OF DISCLOSURE
[0002] The invention relates to a conveyor system for container-processing machines.
BACKGROUND
[0003] Conveyor systems for delivering containers to and/or removing containers from container machines are known. Known conveyor systems have a rotating conveyor element that has many container holders arranged around a circumference thereof. These container holders move containers from one position to another in the course of delivering containers that are to be processed to a container processing station on the container-processing machine.
[0004] Known conveyor systems have a substructure by means of which a conveyor element stands opposite an installation surface that forms part of the structure. Such a substructure can house all sorts of devices, such as the drive for the conveyor element, further functional elements, controllers, and sensors.
[0005] A substructure as described above completely or substantially completely fills an installation space between the conveyor element and the installation surface. As a result, the installation space can no longer be used for any other purpose.
SUMMARY
[0006] Among the objects of the invention is a conveyor system that guarantees a more flexible use of the installation space underneath the conveyor element.
[0007] In one aspect, a securing installation that stands on an installation surface suspends a conveyor element. As a result of this suspended arrangement, a substructure-free space forms under the conveyor element. This space can be used for many things. The result is a more flexible conveyor system.
[0008] In one embodiment, a rack spans at least part of the conveyor element. This rack forms the securing installation. The rack can have one or more floor-standing and/or floor-anchored columns that are tall enough so that the top free ends of the columns are above the conveyor element. When there are multiple columns, a connecting element connects the free ends to each other. In some embodiments, this connecting element is a plate.
[0009] In one embodiment, the securing installation has a structural element that forms a vertical machine axis. The conveyor element surrounds the circumference of this structural element. The structural element is preferably a rod or cylinder connected at its top free end at least indirectly to at least one column. The connection is preferably one that resists rotation. The structural element thus forms a connection between the part of the securing installation provided on the top and the functional elements to be mounted underneath, under the conveyor element.
[0010] In one embodiment, the structural element projects beyond an underside of the conveyor element. In this embodiment, further guide or transfer installations that interact with the conveyor element are held on the projecting section of the structural element. Examples of guide or transfer installations of this kind include guide panels and external guides. In this way, further installations are held underneath the conveyor element supported by the securing installation without any substructure needing to be provided. This allows for a light structure with just a few components and thus a reduction in components in, for example, a sterile area of a container-processing machine.
[0011] In some embodiments, a conveyor delivers containers to a conveyor element and/or removes containers from the conveyor element. The securing installation on which the conveyor element is mounted also supports the conveyor. The conveyor can be a linear conveyor, such as a conveyor belt or a conveyor chain. Because this conveyor is mounted on the securing installation, no corresponding substructure in the area of the conveyor element is needed.
[0012] In some embodiments, a single conveyor delivers containers to and removes containers from the conveyor element. The conveyor element is preferably designed to both deliver a container to be processed to a container-processing machine and to also remove an already-processed container from the container-processing machine. This occurs when a container holder that has become free as a result of having delivered a container is filled in the next process step by an already-processed container so that a further rotation of the conveyor element removes the already-processed container and delivers it to the conveyor. In this way, a single conveyor running in the area of the conveyor element can be used to both deliver containers to be processed and to remove containers already processed.
[0013] In some embodiments, the conveyor runs under the conveyor element. This can be done because the absence of substructure frees installation space.
[0014] In other embodiments, the conveyor is fed in a straight line under the conveyor element. In this case, the conveying direction for delivering containers to be processed is the same as the conveying direction for removing already-processed containers.
[0015] In some embodiments, the conveyor runs through the center of the conveyor element so that the machine axis runs through the conveyor. This causes optimum delivery of the containers in the direction of the center point of the substantially annular-shaped conveyor element.
[0016] Other embodiments include a direct drive or a torque motor as the drive for the conveyor element. This allows a further saving of installation space. The drive is arranged above the conveyor element between the conveyor element and a top structural element of the securing installation arranged in a rotation-proof manner. In some embodiments, the drive is designed on the circumferential side around the structural element that forms the axis of rotation for the conveyor element. Embodiments include those in which the drive drives the conveyor element in a phased or intermittent manner to deliver the containers to the container-processing machine step by step.
[0017] In some embodiments, the drive is arranged between a first drive element that is held stationary on the securing installation and a second drive element mounted on the structural element so that it can rotate. The first drive element and the second drive element are preferably sleeves, with one being inside the other and forming an annular gap. The first drive element has a larger diameter than the second drive element. The drive elements are arranged concentric with each other and are aligned with the first machine axis. A pivot bearing between the first and second drive element can be turned relative to the first drive element or relative to the structural element arranged in a rotation-proof manner and that forms the first machine axis. The second drive element forms the drive shaft of the drive.
[0018] In some embodiments, the second drive element extends by a first end into either the drive itself or into the first drive element. The second drive element is then connected at a second end to the conveyor element. In these embodiments, the second end of the second drive element protrudes beyond the underside relative to the first drive element. This creates a projecting free end on which the conveyor element can be secured.
[0019] In some embodiments, the conveyor element is a transfer star. In other embodiments, the conveyor element comprises a circular disc. In yet other embodiments, the conveyor element is separate from the recesses that form the container holders on the circumference on the conveyor element. As a result of any of the foregoing features, the containers can be moved on a circular path through the conveyor element. The container inlet, the transfer position onto the container-processing machine, and the container outlet are all on this circular path.
[0020] In one aspect, the invention features an apparatus for at least one of delivering containers to a container-processing machine and removing containers from the container-processing machine. Such an apparatus includes a conveyor system that has a conveyor element that rotates about a vertical machine axis and that has container holders distributed around a circumference thereof. A securing installation suspends the conveyor element. The conveyor element moves containers from a first position to a second position. The securing installation includes a structural element that is arranged circumferentially around the conveyor element. This structural element forms the vertical machine axis about which the conveyor element rotates. The structural element comprises a projecting portion that protrudes beyond an underside of the conveyor element. A functional element is held at this projecting portion. The functional element, which is either a guide element or a transfer element, is one that interacts with the conveyor element.
[0021] In some embodiments, the securing installation comprises a rack that at least partially spans a top of the conveyor element.
[0022] In other embodiments, the structural element is held on the securing installation in a manner that prevents rotation thereof.
[0023] In yet other embodiments, the conveyor element surrounds a circumference of the structural element.
[0024] Certain embodiments include a conveyor, at least a section of which is supported by the securing installation. This conveyor conveys containers. Among these embodiments are those in which the conveyor either delivers containers to the conveyor element or removes containers from the conveyor element, and those in which it both delivers containers to the conveyor element and removes containers from the conveyor element. Also among these embodiments are those in which the conveyor runs under the conveyor element. These embodiments include those in which the conveyor runs along a path that intersects the vertical machine axis of the conveyor element and that is centered around the vertical machine axis.
[0025] Other embodiments include a drive that drives the conveyor element. The drive is either a direct drive or a torque motor. Some of these embodiments also include first and second drive elements. In these embodiments, the drive is arranged between the first drive element and the second drive element. The first drive element is held stationary on the securing installation. The second drive element surrounds the structural element around a circumference thereof. In some of these embodiments, the second drive element comprises a hollow shaft having first and second ends. The hollow shaft extends by the first end into the drive. The second end connects and wherein the hollow shaft is connected on the second end to the conveyor element.
[0026] Embodiments also include those in which the conveyor element comprises a transfer star.
[0027] Also among the embodiments are those in which the functional element is a guide element that guides bottles along a path, those in which the functional element is a transfer element that permits bottles to be slid along a path, and those in which there is more than one kind of functional element.
[0028] Another aspect of the invention features a conveyor system that includes a rotating conveyor element with container holders arranged around a circumference thereof for moving containers between container positions, and a securing installation that suspends the conveyor element. The securing installation includes a structural element that forms an axis of rotation. A projecting portion of the structural element projects beyond the conveyor element's underside. An element, which is either a transfer element or a guiding element is held at this projecting portion so that it can interact with the conveyor element.
[0029] As used herein, the expressions “substantially” or “approximately” mean deviations from exact values in each case by ±10%, and preferably by ±5% and/or deviations in the form of changes that are not significant for functioning.
[0030] Further developments, benefits, and applications of the invention arise also from the following description of examples of embodiments and from the figures. Moreover, all characteristics described and/or illustrated individually or in any combination are categorically the subject of the invention, regardless of their inclusion in the claims or reference to them. The content of the claims is also an integral part of the description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] These and other features of the invention will be apparent from the following detailed description and the accompanying figures, in which:
[0032] FIG. 1 shows a top view of a first embodiment of a conveyor system;
[0033] FIG. 2 shows a lateral cross-section of the conveyor system of FIG. 1 along the line A-A;
[0034] FIG. 3 shows a lateral section of a second embodiment of a conveyor system; and
[0035] FIG. 4 shows a lateral section of details of a conveyor element having an assigned drive.
DETAILED DESCRIPTION
[0036] FIGS. 1 and 2 show a conveyor system 1 that is used to deliver containers 2 to a container-processing machine 10 and to remove already-processed containers 2 from the container-processing machine 10 .
[0037] The conveyor system 1 comprises a conveyor element 3 that is driven to rotate about a vertical machine axis MA 1 and that conveys containers 2 on an at least partially circular path. The conveyor element 3 has container holders 3 . 1 distributed around the circumference thereof and spaced apart at fixed angular distances. In some embodiments, the conveyor element 3 is a transfer star. In other embodiments, the conveyor element 3 is a substantially disc-like structure in which recesses formed in a circumference thereof form the container holders 3 . 1 . The recesses are adapted to the containers 2 or container holders 2 a to be conveyed.
[0038] In the illustrated embodiment, container holders 2 a , also called “pucks,” secure containers during delivery and removal thereof. Such container holders 2 a are particularly useful for containers 2 that tend to topple over or containers that have no independent floor-standing area. An example of such a container is a PET keg. These are large-volume plastic containers volumes such as 10 liters, 20 liters, or 30 liters. However, it is also possible to use the conveyor system to convey containers 2 directly, without having to use a container holder 2 a . To simplify the exposition that follows, any reference to a container 2 is to be regarded as a reference to either a container 2 or a container holder 2 a.
[0039] As shown in FIG. 1 , a conveyor 6 delivers upright containers 2 to a stopper element 8 . The stopper element 8 temporarily stops the container 2 so that it cannot reach the conveyor element 3 . At an appropriate time, the stopping element 8 releases the container 2 so that it can continue to the conveyor element 3 .
[0040] Recesses around the circumference form container holders 3 . 1 that carry the containers 2 through the conveyor element 3 . Each recess holds a container 2 at least partially around a circumference thereof. The stopper element 8 releases a stopped container 2 in a time-phased manner so that the conveyor 6 can take it to a container holder 3 . 1 of the conveyor element 3 .
[0041] Starting from an inlet P 1 , the conveyor element 3 moves the container 2 clockwise to the transfer position UP at which the transfer of the container 2 to the container-processing machine 10 takes place. An outer guide 9 prevents the container 2 from swerving laterally or radially. The outer guide 9 runs at least in a partial circular path around the conveyor element 3 at a radial distance from the conveyor element 3 .
[0042] A drive 7 , such as a servo motor, drives the conveyor element 3 in a phased manner. This results in intermittent motion of the conveyor element 3 , and thus intermittent delivery of containers 2 located in the container holders 3 . 1 to the transfer position UP.
[0043] The conveyor element 3 delivers containers 2 still to be processed to the container-processing machine 10 and also removes already-processed containers 2 from the container-processing machine 10 . In particular, the conveyor element 3 delivers a container to be processed to the transfer position UP for delivery to a processing station 10 a of the container-processing machine 10 .
[0044] In some embodiments, the container-processing machine 10 is a rotating machine having a rotor 11 . On the circumference of this rotor 11 are processing stations 10 a spaced at fixed angular distances from each other. The rotor 11 is driven to rotate intermittently or in a phased manner around a second machine axis MA 2 that is parallel to the first machine axis MA 1 .
[0045] Once a container 2 has been transferred to a processing station 10 a , the container holder 3 . 1 becomes free. This means it is ready to accept another container. To take advantage of this, the rotor 11 turns while the conveyor element 3 remains stationary. This means that the container holder 3 . 1 , which has just been freed, also remains stationary. As a result, a container that has already been processed can be loaded from the processing station 10 a into the recently-freed container holder 3 . 1 .
[0046] A phased further rotation of the conveyor element 3 , then delivers the already-processed container 2 to an outlet P 2 to be conveyed away by a conveyor 6 . Alternatively, it is possible to deliver the already-processed container 2 to a further container-processing machine. Meanwhile, the same phased further rotation of the conveyor element 3 delivers the next container to be processed to the transfer position UP.
[0047] As can be seen in particular in FIG. 1 , the same conveyor 6 handles both delivery of the containers 2 to the inlet P 1 of the conveyor element 3 and the removal of the containers 2 from the outlet P 2 of the conveyor element 3 . In the illustrated embodiment, this single conveyor 6 is a linear conveyor. A suitable linear conveyor is a conveyor belt or conveyor chain.
[0048] After reaching the inlet P 1 , the conveyor 6 dips underneath the conveyor element 3 as shown in FIG. 2 and by the dashed lines in FIG. 1 . The conveyor 6 runs underneath and passes through the point at the center of the conveyor element 3 so that it is pierced by the first machine axis MA 1 . By routing the conveyor 6 under the conveyor element 3 , it is possible to effect delivery and removal by a single continuous conveyor 6 .
[0049] The conveyor element 3 is designed without a substructure to allow the conveyor 6 to be routed underneath the conveyor element 3 . This substructure-free design is achieved by suspending the conveyor element 3 from a securing installation 5 standing on an installation surface 4 , as shown in FIG. 2 .
[0050] In the embodiment shown, the securing installation 5 is a rack supported above the installation surface 4 by four columns 5 . 2 . The columns 5 . 2 are tall enough so that their top free ends are above the height level H 1 of the conveyor element 3 . As shown in FIG. 1 , two of the four columns 5 . 2 stand on either side of the inlet P 1 and the remaining two of the four columns 5 . 2 stand on either side of the outlet P 2 .
[0051] A connector 5 . 3 , shown in FIG. 2 , connects the top free ends of the columns 5 . 2 . In one embodiment, the connector 5 . 3 is a plate that suspends the conveyor element 3 .
[0052] A cylinder 5 . 1 on the underside of the connector 5 . 3 facilitates the suspension of the conveyor element 3 . The cylinder 5 . 1 runs vertically along the first machine axis MA 1 . The cylinder 5 . 1 , which is solid or hollow, forms an axis about which the conveyor element 3 rotates.
[0053] The cylinder 5 . 1 connects to the connector 5 . 3 in a way that prevents the cylinder 5 . 1 from rotating. The length of the cylinder 5 . 1 is selected such that it either ends flush with the underside of the conveyor element 3 or such that it projects slightly beyond the conveyor element 3 . As a result, it is possible to pass the conveyor 6 underneath the cylinder 5 . 1 .
[0054] The securing installation 5 , which is partially built over the conveyor element 3 , provides a place to mount further functional elements that are involved in the delivery of containers 2 to the container-processing machine 10 or removal of containers 2 from the container-processing machine 10 .
[0055] The conveyor 6 runs between the columns 5 . 2 of the securing installation 5 . Brackets of the conveyor 6 are connected to the columns 5 . 2 . In some embodiments, slide panels 12 and/or an outer guide 9 are arranged on the securing installation 5 , for example on its columns 5 . 2 . The slide panels 12 , which can be seen in FIG. 2 , allow surfaces of containers 2 to slide as they move through the conveyor element. The outer guide 9 prevents radial swerving of containers as they move through the transport element 3 .
[0056] FIG. 3 shows a further embodiment of the conveyor system 1 in which the securing installation 5 has a column 5 . 2 that stands on an installation surface 4 . The column 5 . 2 has an arm 5 . 2 . 1 that at least partially spans the conveyor element 3 . The arm 5 . 2 . 1 extends horizontally above the conveyor element 3 . A cylinder 5 . 1 secured to the arm 5 . 2 . 1 extends downward and forms the first machine axis MA 1 of the conveyor element 3 .
[0057] In the illustrated embodiment, a projecting free end of the cylinder 5 . 1 projects beyond an underside of the conveyor element 3 . Functional elements that interact with the conveyor element 3 are secured on this projecting free end. Examples of such functional elements include, for example, the slide panel 12 on which containers 2 are moved by sliding when the conveyor element 3 is rotated. In the embodiment shown, an outer guide 9 is indirectly held on the cylinder 5 . 1 .
[0058] In the illustrated embodiment, the conveyor 6 is fed under the conveyor element 3 so that it follows a path that is off to one side of the first machine axis MA 1 . In particular, the conveyor 6 follows a path that is on the side of the first machine axis MA 1 that is furthest from the container-processing machine 10 . In the illustrated embodiment, the conveyor 6 is held on an independent installation device. However, in other embodiments, the conveyor 6 is held on the securing installation 5 of the conveyor element 3 .
[0059] FIG. 4 shows a drive 7 for imposing a torque on the conveyor element 3 . In some embodiments, the drive 7 is a direct drive. In other embodiments, the drive 7 is a torque motor. The drive 7 is between a plate 5 . 4 that is firmly connected to the securing installation 5 and the conveyor element 3 . Alternatively, the drive can be connected to the connector 5 . 3 .
[0060] A first outer drive element 7 . 1 of the drive 7 extends from an underside of the plate 5 . 4 and ends just short of the conveyor element 3 . The first outer drive element 7 . 1 is shaped like a cylindrical sleeve having a circular cross-section. In one embodiment, the outer drive element 7 . 1 has a flange secured on the plate 5 . 4 and extending radially outward.
[0061] The first drive element 7 . 1 surrounds the cylinder 5 . 1 . The radius of the first drive element 7 . 1 is large enough so that a gap separates it from the cylinder 5 . 1 .
[0062] A rotatable second drive element 7 . 2 also extends down from the plate 5 . 4 concentric with the first drive element 7 . 1 thus forming an annular intermediate space between itself and the first drive element 7 . 1 . The second drive element is also a cylindrical sleeve having a circular cross section, but with a radius smaller than that of the first drive element 7 . 1 . Bearing points hold the second drive element 7 . 2 along part of its length within the annular intermediate space in a suspended and rotatable manner relative to the first drive element 7 . 1 .
[0063] A protruding free end of the second drive element 7 . 2 projects past the end of the first drive element 7 . 1 and attaches to the conveyor element 3 . In some embodiments, the second drive element 7 . 2 passes through a hole in the middle of the conveyor element 3 . A radially outward flange on the end of the second drive element 7 . 2 secures the conveyor element 3 to the second drive element 7 . 2 .
[0064] Bearing points in the intermediate space between the first drive element 7 . 1 and the second drive element 7 . 2 , enable the second drive element 7 . 2 to be turned. This turns the conveyor element 3 relative to the first drive element 7 . 1 or the cylinder 5 . 1 .
[0065] In addition to accommodating the bearing points, the intermediate space also accommodates windings of the drive 7 . The first drive element 7 . 1 thus forms the stator and the second drive element 7 . 2 forms the rotor of the drive 7 . The intermediate space between the plate 5 . 4 and the conveyor element 3 is thus optimally used for accommodating the drive 7 .
[0066] The invention has been described above using several exemplary embodiments. However, modifications and variations are possible without thereby departing from the inventive idea underlying the invention. | A conveyor system includes a rotating conveyor element with container holders arranged around a circumference thereof for moving containers between container positions, and a securing installation that suspends the conveyor element. The securing installation includes a structural element that forms an axis of rotation. A projecting portion of the structural element projects beyond the conveyor element's underside. A functional element, which is either a transfer installation or a guiding element is held at this projecting portion so that it can interact with the conveyor element. | 1 |
BACKGROUND OF THE INVENTION
The present invention is directed to a purification process for the removal of N-vinylcarbazole from polyvinylcarbazole. Polyvinylcarbazole has uses as an electrical insulating material, a dielectric in capacitors, and a photoconductive film in the xerographic reproduction process. Polyvinylcarbazole is typically prepared by the free radical polymerization of N-vinylcarbazole. Commercial grade polyvinylcarbazole contains up to six percent residual N-vinylcarbazole. N-vinylcarbazole is a mutagen and suspected carcinogen. Clay has been used to decrease the level of N-vinylcarbazole in the polyvinylcarbazole to below 25 ppm. The use of clay is disadvantageous due to the presence of large amounts of fine particulate matter. The fine particulate matter creates significant backpressure in purification columns and is difficult to remove from the final product.
SUMMARY OF THE INVENTION
We have now found that by dissolving polyvinylcarbazole in a suitable solvent and treating with certain acids or cationic resins, preferably sulfonic acids and sulfonated resins, the residual N-vinylcarbazole is reduced to below 25 ppm without the disadvantages of earlier methods. By recovery of the polymer by precipitation , filtration and drying, the polymer is obtained in pure form.
DETAILED DESCRIPTION OF THE INVENTION
Certain acids and cationic resins were found to react with N-vinylcarbazole to form carbazole, thereby removing the N-vinylcarbazole from the system. These acids can be used to remove N-vinylcarbazole from polyvinylcarbazole. Commercial grade polyvinylcarbazole, which typically contains from two to six percent N-vinylcarbazole, is dissolved in a suitable solvent at an elevated temperature. The preferred solvent is toluene. The preferred temperature range is 80°-90° C. An elevated temperature is not required to convert N-vinylcarbazole to carbazole, however by increasing the temperature the solubility of the polyvinylcarbazole is improved.
When treatment with acid is used, the acid is dissolved in a small amount of isopropanol then added slowly to the polyvinylcarbazole solution. The preferred acids are sulfonic acids. The preferred sulfonic acids are methane sulfonic acid and p-toluene sulfonic acid. The polyvinylcarbazole solution is agitated at an elevated temperature for several hours. The preferred temperature range is 50°-90° C.
When treatment with cationic resin is used, the resin is slurried with the solvent of choice used for dissolving the polyvinylcarbazole and placed in a column. The preferred resins are strongly acidic sulfonated resins. The preferred sulfonated resin is Amberlyst 15 Cationic Exchange Resin, made by Rohm & Haas Co. The polyvinylcarbazole solution is passed through the column at an elevated temperature. The preferred temperature range is 80°-90° C.
After the polyvinylcarbazole solution has been treated with the acid, the polyvinylcarbazole may be separated by any of the known methods such as freeze-drying, or precipitation by a non-solvent, preferably methanol. The precipitated polyvinylcarbazole is filtered, washed with methanol, filtered, then dried under vacuum at a maximum temperature of 60° C.
The following examples are meant to further illustrate, but not to limit the invention.
EXAMPLE I
In a 250 ml round bottom flask, 7.9 g of commercial grade polyvinylcarbazole (Luvican M-170, by BASF) was dissolved in 92.1 g of toluene by agitating for four hours at 90° C. The polyvinylcarbazole solution was cooled to 50° C. and maintained at that temperature during the remainder of the : process. Next, 0.2 g of p-toluene sulfonic acid was dissolved in 2 g of isopropanol, then added dropwise to the polyvinylcarbazole solution. The solution was agitated for two hours. The polyvinylcarbazole solution was added to a commercial blender containing 1 liter of methanol and agitated at high speed for 1 minute. The precipitated polyvinylcarbazole was vacuum filtered, then placed in a flask with 200 ml of methanol and agitated for 10 minutes. The polyvinylcarbazole was then vacuum filtered and dried under vacuum at 60° C. for four hours. A white powder was obtained.
Analysis by gas chromatography showed the untreated polymer to contain 2.2% N-vinlycarbazole and 0.09% carbazole. The treated polymer contained less than 25 ppm N-vinylcarbazole and 0.026% carbazole.
EXAMPLE II
In a 2 liter round bottom flask, 79 g of commercial grade polyvinylcarbazole (Luvican M-170, BASF) was dissolved in 921 g of toluene by agitating for 6 hours at 90° C. A slurry of 60.8 g of Amberlyst 15 Cationic Exchange Resin and 200 ml of toluene was transferred into a jacketed glass column (ID 3.12 cm, bed length 13 cm, bed volume 100 ml). A jacketed 500 ml addition funnel was mounted on the top of the column. The column and addition funnel were maintained at 80°-90° C. throughout the process. The excess toluene was drained from the column. The polyvinylcarbazole solution was transferred to the addition funnel and passed through the column at a rate of one bed volume per 10 minutes. The polyvinylcarbazole solution was collected and precipitated by adding 500 ml of polyvinylcarbazole solution to a commercial blender containing 3 liters of methanol and agitating at high speed for one minute. The precipitate was vacuum filtered then placed in a flask with one liter of methanol and agitated for 10 minutes. The polyvinylcarbazole was then vacuum filtered and dried under vacuum at 60° C. for four hours. A white powder was obtained.
Analysis by gas chromatography showed the untreated polymer to contain 2.2% N-vinylcarbazole and 0.09% carbazole. The treated polymer before precipitation contained 1.4% carbazole and no detectable N-vinylcarbazole (<25 ppm). The treated polymer after precipitation contained 0.08% carbazole and no detectable N-vinylcarbazole (<25 ppm). | The residual level of N-vinylcarbazole in polyvinylcarbazole has been reduced to an amount less than 25 ppm by treatment of a solution of the polyvinylcarbazole with a strong acid. The polymer can be recovered in pure form by precipitation of the polymer from solution with a non-solvent. | 2 |
BACKGROUND OF THE INVENTION
The present patent has as its subject improvements applied to composite structures.
The composite structures comprise, sub-assemblies which can be associated to form volumes, made starting from profiles of a single type without especially fine tolerance more generally the shape of C-U omegas .
The volumes are thus formed of supporting and connecting structures, and of walls which themselves are supporting and connecting, using bracing bridges capable of making rigid and compact the sub-assemblies and assemblies which are rendered associative with one another.
The present patent constitutes a notable advance on all the earlier patents and in particular on French Pat. Nos. 2109129 - 2138289 - 2188786 - 2196056, by the applicant.
SUMMARY OF THE INVENTION
According to the invention the bridges are characterized: by a greater effectiveness in compression as a result of a capability for orientation of their compressive diaphragms in a number of directions. Compressive diaphragms in earlier bridges have been realised either by crenels and slides, or crenels and tenons etc., the profiles forming the secondary structure and the C-section sleeves.
A secondary structure is generally a principal beam, the bridges of which constitute visible bracing frames capable of being transversely braced and squared by another secondary structure or by one of these constituent elements. Conversely, a double face wall is formed of two principal beams which in the present case are longitudinal, engaged and held on two other principal beams oriented perpendicularly to the first two and disposed at a spacing equal to that between the retaining flanges of the C-sections forming walls.
The wall C-sections are in the present case connected to one another by supporting and interconnecting principal beams which, when used in this manner, are designated secondary beams.
These secondary beams transversely braced by similar ones constitute, by means of their bracing bridges, the internal structure of the wall C-sections.
It follows that the new method and its means enable chains of walls to be realised which are characterized, amongst other things, by wall C-sections: these may be plane or curved depending upon the form of the bracing members, which may be
straight, curved or angulate, as a result also of the procedure of folding of the C-sleeves comprising a single retaining flange on at least two opposite sides,
self-supporting of great length, as a result of their internal structure and of the transverse folding, which forms at each of their two ends and perpendicularly to the two opposite retaining flanges, at least one retaining flange co-operating with the retaining flanges of the sleeve bridges belonging to the secondary structures,
acoustically insulating, as a result of the fact that, not being welded, the internal structure enables any insulating material or material having other properties such as asbestos for example to be blocked against the internal portion of the wall.
The secondary structures form frames, capable of crimping together omegas, for example, and thus of forming I.P.E. structures capable of being extended indefinitely, while the frame structures are, for their part, straight, angulate or curved.
These various aspects of the new composite structures demonstrate the flexibility in use, which is further accentuated by the fact that, there being no welding, it is possible to use the most varied material, and that two or three thin C-sleeves may be superimposed over the whole or a portion of their length.
Moreover, although the method dispenses entirely with welding or gluing, the bridges constitute a perfect means for maintaining compressed together various profiles, which enables gluing to be utilised as an auxiliary means of connection, the bridges ensuring safety and security and fulfilling the function, in this case, of a gluing press.
The bridges interconnect and also square of the components which they join together, as a result of the area and spacing of their compressing and opposed bearing faces.
Finally, as a result of the compression diaphragms which can be oriented to a certain variable, progressive and adjustable extent, the bridges will accept slight tolerances when they are relatively large.
The economic advantage results from the overall aspect of this novel technique applied to assemblies of profiles of a simple type by being braced, interconnected and rendered rigid by a novel connecting means, that is the bridges. This technique is of the class known as "soft technology" by reason of the simplicity of the transformation means utilised. In developed countries, it provides a very important economy in the quantities of materials used: a rigid wall has a weight of 6 kg 700per square metre, inclusive of bridges, while a I.P.E. beam weighs from 15 to 20% less than a steel structure of the same type, and its strength being associated with a deflection coefficient of approximately 18 millimetres, is from 15 to 20% better than that of a traditional steel structure.
The sectorial bridges permit the acoustic and thermal interconnections between two walls to be limited, which walls can be completely isolated from the bridges.
The frames of the bridges enable completely plane surfaces to be obtained, and a certain amount of curvature in the metal sheets to be taken up. The elimination of welding imparts to the assemblies a complete protection against corrosion and enables the whole structure to be made lighter.
The elimination of welding and of surface treatment enables considerable economy to be effected in heat consumption and the polution caused by these treatments to be overcome, and avoid the unhealthy operating conditions for human beings which arise when applying paint coatings.
To summarise, the invention provides an economy in materials, labour, investment and energy.
It enables man and the machine to be reconciled, and production line work to be eliminated as an economic factor.
BRIEF DESCRIPTION OF THE DRAWINGS
A description will be given below, purely as illustrative examples which are in no way limiting, of various forms of embodiment of the invention with reference to the attached sheets of drawings.
In these drawings:
FIG. 1 shows diagrammatically a cross-section of a primary subassembly of the new composite structure.
FIG. 2 similarly shows a cross-sectional view of two subassemblies of the new structure.
FIG. 3 shows a sectional view of a modification of FIG. 1.
FIG. 4 shows a sectional view of a first embodiment of the invention.
FIG. 5a illustrates in perspective a modified composite structure forming part of the invention.
FIG. 5b is a modified detail of FIG. 5a .
FIG. 6 shows in perspective, a detail of a composite structure according to the invention.
FIG. 7 shows in perspective a modification of FIG. 6.
FIG. 8 shows, in a partial front view, a further modification of FIG. 6,
FIG. 9 shows, in a partial perspective view, a further modified composite structure according to the invention,
FIG. 11 is a detail from FIG. 17.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The improvements applied by the present invention relate more especially to the technology of compressive stiffening bridges which brace composite structures comprising assembled, primary and secondary subassemblies, from the smallest to the largest size, and the modular character of which permits all the combinations of connections to straight or angulate profiles.
FIG. 1 schematically shows a primary sub-assembly or principal beams C-sleeves 10, and walls 33. Each sleeve 10 comprises a sleeve 101, bordered longitudinally on each of two opposite sides by a retaining sleeve flange 110 bent towards the most central region of the sleeve and at an acute angle of approximately 45°, as can be seen from FIG. 1. The two sleeves 10 have their generally C-shaped cross-sectional shapes open against one another, and have their flanges 110 slidably edgewise engaging mutually opposite wall flanges 136 of two walls or mutually elementary profiles or walls 33, which block into the corner 115 of the sleeve web 101 and sleeve flanges 110, the walls possess substantially the sectional shape of a U. The blocking of the two elementary profiles 33 inside the sleeves 110 placed face to face is effected by means of bracing bridges not shown in this figure but provided in the shaded area and forming rigid supports which act in the directions A and B, while at the same time forming bearings against each wall; these bridges as provided in accordance with the invention, will be described hereinafter. The principal P.S. forms a subassembly which is compact and rigid. It is capable of resisting the most varied stresses, as a result of the connecting and stiffening bracing bridges. In addition, the retaining flanges 110 constitute effective means for interconnection of P.S. with other beams as each of these flanges constitutes a longitudinal connecting means and forms substantially a jaw. One of the advances achieved here is a combination of bridges, C-section sleeves 10, and elementary profiles 33, permitting extensive composite structure or, true chains of walls to be formed, from primary subassembly P.S. and similar, secondary subassemblies. The composite structures, which can be utilized either for a decorative purpose or for a functional purpose.
FIG. 2 shows a primary subassembly P.S. located opposite a generally similar secondary sub-assembly SS but not yet connected therewith. Each subassembly has a pair of sleeves 10 and a pair of walls 33, generally as in FIG. 1, and also has a bracing bridge 20 - a rigid member between walls 33 and wall-tying sleeve flange members 110, bracing the subassembly against compressing loads, as will be seen from the illustration. As further shown in FIG. 2, each subassembly has one of its sleeves 116, formed with corrugations or undulations 117 intended for imparting to this section of sleeve a certain degree of elasticity. This C-sleeve 116 comprises two retaining sleeve flanges 110, which engage over retaining wall flanges 131 of the elementary profiles or walls 33 and which are shorter than the wall flanges 136 opposite to them, thus imparting to this sleeve 10 a larger free access, the face-to-face position of the retaining flanges 110 being set back in the lower part of this FIG. 2. The lower C-sleeve 10 barries on its internal face, a cardboard sheet 390, longitudinal edges of which are bent over, 390 bis, and blocked into the internal corner 115 by the wall flange 136 of each of the two elementary profiles 33, themselves blocked by framework bridge 20, which itself thus indirectly blocks two C-sleeves 10 and 390. The sleeves can be made of different materials, but possessing properties complementary one to the other, such as could be the case with a grillage for example, which could constitute, where applicable, a third thickness and form a sandwich. FIG. 3 shows another principal beam, in which the to face walls 33 are blocked by combined C-sleeve bridges carrying orientable compressive diaphragms 50 which constitute retaining and connecting means, the compressive diaphragms forming brackets, as a result of being folded manually or with the assistance of a lever.
The flanges 110 of the C-sleeves 11 also 110 retain a timber board bridge 21 which, at the right side of the figure, is retained through the intermediary of an angle member 10 GP comprising two flanges 10CP angled at approximately 95°. This angle member serves both for decoration and as a connecting means, being retained by one of its two flanges in the internal corner 115 of the C-sleeve.
FIG. 4 shows a wall chain or composite structure, comprising from left to right, secondary subcombinations SS2, SS1, principal subcombination PS, and secondary subcombination SS3. As shown, the subcombination SS2 has sleeves 10", 117"; correspondingly, the secondary subcombination SS-1 has sleeves 10 GP. The primary subcombinations PS is equipped with resilient sleeves 117, which enable the walls or elementary profile S-33 thereof to constitute a hinge facilitating the engagement and disengagement of the opposite sleeve 10, by the sleeve flange 110, with a bridge 10 G.P. of subcombination SS1; the adjacent wall flange 136 of wall 331 of subassembly SS1 constituting, over the entirety of its length, a support means, and the framework bridge 20 in SS1 constituting a reinforcement preventing the C-sleeve 10" of SS-2 from vibrating, enabling it to be completely plane and to take up, if necessary, the defects in appearance in the curvature of the composite structure.
The two beams providing the principal and secondary subassemblies P.S., SS1 of FIG. 4 constitute two opposite wall faces: one face (left portion) in which the sleeve 106P with its bridge diaphragms 50 is fastened to walls 331 of SS-1, thus constituting an external cladding for a building. In the right part, the principal beam P.S., is equipped internally with a resilient sleeve 117, which enables the diphragms 50 to be locked before engagement; the elasticity of these sleeves permits functioning of the engagement hinge 110, 115, 131 (lower left center of FIG. 4, while constituting a satisfactory support for an internal wall 331, the planeity of which is also assisted by this construction; the sectorial retention constituted by the retaining sleeve flanges 110 engaging in effect the bridges 50 of sleeve 10 G.P. co-operates effectively in the mutual engagement of the subassemblies or principal beams PS SS-1, SS-2, by permitting the engagement pressure to be localised on each of the retaining flanges of short length. The sleeve 10 of principal subcombination PS interconnect the corresponding walls 331, whereby the bridges 20 are blocked after engagement. As shown at the right end of the figure, the composite structure may comprise still further secondary subassemblies SS-3 having walls 33'" connected with the primary subassembly PS by further C-sleeves 10. As still further shown in the lower left part of the figure, the wall flanges 136 on wall web 134 of subcombination SS-1 extend transversely of this wall web to strengthen the wall and to cooperate with wall 33 of the primary subassembly PS. (and also with wall 33" of the secondary subassembly SS-2) in assembling the entire composite structure, with the help of the respective sleeve flanges 110.
The wide ranging use of the invention is also demonstrated in FIG. 5, which shows a composite structure formed of two subassemblies PS and SS which are formed to constitute a corner at the lower part of PS. An internal part of this corner is produced suitably cutting the wall flanges 136, and the external part bending the wall 33 to constitute a 90° angle, as shown external of the corner produced by a suitably curved wall 134' with correspondingly curved wall flanges 135. This presentation has been given to demonstrate one of several possible methods of constructing the subassemblies and the resulting composite structure. As shown in FIG. 5b, it is also possible to mutually overlap walls 33 of primary and secondary subassemblies. It will be understood that these walls are held together by sleeve flanges 110 (FIGS. 1-5) engaging their wall flanges 136, thereby further assisting the assembling of the entire composite structure. It will also be understood that these walls (FIG. 5b) are blocked by bridges 20 (FIGS. 2, 4, 5), which make it possible to impart to the whole assembly a rigid permanent square-bracing of such a nature as to withstand all the stresses associated with their dimensions and thickness of material employed.
In the upper part of FIG. 5, the structure as shown comprises a C-sleeve 10, against the web of which there is slid, or depending upon the dimensions engaged by pivoting, a bridge P.L. 10, the width of which permits it to bear against several mm of the external portion of the wall flanges 136 and to be retained by the external C-sleeve 10, which may, if necessary, extend over the entirety of the length of this structure. Several bridges P.L. 10 are generally provided, although only one of them is shown. They can be disposed at a variable spacing, and can be blocked by means of folding substantially perpendicular to the web of the C-sleeve 10, as will be described. The bridges permit the web 134 of each elementary profile or wall 33 to be transversely square braced. In the secondary structure SS, there are shown bridges 10 G.P., which are held with the aid of additional sleeves 10, not shown, and which comprises first and second change stiffening compressive diaphragms 50.
Symmetrical central perforations 56, the central axis of which is situated on a central line parallel to the retaining flanges 110 and between which the diaphragm 50, 50' are interconnected. Additional perforations 57 are situated adjacent of diaphragm 50, defining an arris 60 each parallel to flanges 110 and an arris 61 which is situated opposite to the arris 60, and makes an angle of approximately 30° with it and rejoins an arris 62 coinciding with the free edge of the diaphragm, this arris 62 continuing at 90° to join the central perforation 56, by an arris 63.
Three stiffening ribs 12 (FIG. 6), desirably swaged in the body of bridge PL 10 or 10 GP are disposed perpendicularly to the retaining flanges 110. It will be noted that the bridge diaphragm 50' of FIG. 6 is more elongate than the diaphragm 50 of FIG. 5, and that it has flange members, designated here by numeral 42, whereby the entire bridge is approximately Omega-shaped in cross-section. A perforation 55, spaced from the arris 63 and 62, permits the introduction of a lever for compressing the web 134 of the elementary profile 33 by forming a loop illustrated in FIG. 8, the diaphragm 50 tending to form its fold along a line joining the perforations 56 and 57. Finally, as shown in FIG. 5, a square perforation 65 is formed astride in one of the wall webs 134, and permitting, if necessary, the retaining flange 136 to be deformed relative to flange 110 to constitute a complementary fixing without adversely affecting the rigidity of this flange, which is firmly held by this bridge.
The compressive diaphragms of the illustrated bridges illustrate a notable advance, which makes them into a connecting means each portion of which constitutes a retaining and blocking means, each compressive diaphragm being applicable to any of the constituent elements of the composite structures in order to co-operate in the stiffening an interconnection of the subassemblies and assemblies.
Partly at two sides by a first perpendicular flange 104, itself extended perpendicularly towards the central portion of the sleve by a flange 105, forming the last retaining flange for an elementary profile or wall 33, one flange 131 of which is in contact with the interior of the flange 105, while its other flange 136 is disposed adjacent sleeve web 109. The sleeve is equipped with a crenel bridge 40 comprising a web 41 extended longitudinally at 90° by a flange 42 of a height substantially equal to that of the two elementary profiles 33 blocked by this bridge. The bridge grips these profiles 33 means of its last flange 43, also continued at 90° towards the exterior from each flange 42, and is blocked beneath the flange 136 of each elementary profile 33 by the compression of web 41 of diaphragm 50 permitted mainly by and adjacent the perforations 56 and 57.
FIG. 9 shows a part of a composite structure comprising an angularly folded C-sleeve 10, permitting the presence of two elementary profiles blocked in the lower angle by an angle section having four opposite diaphragms, at the top a plate incorporated into the fold and having four opposite diaphragms, and at the first floor a framework bridge blocking an angle member acting as bearing and fixing for a plate.
Each of the two opposite flanges 136 of the two elementary profiles 33 encases a retaining cavity opposite to a flange 110 of the C-sleeve 10, one of these flanges being shown.
This king of beam is useful for the creation of a very large number of types of composite structures, including a simple wall shelf or a cupboard, or a table-top, or a box; these are just some examples amongst others, which make use of parallel folds perpendicular to the flanges 110, whereas numerous applications make use of angle folds, enabling sleeve web areas 109 of trapezoidal shape for example to be produced.
The rigidity and compact character of these assemblies are also obtained by means of bridges known as framework bridges, capable of bracing wide sleeves 10 which require stiffening means extending that of the compressive diaphrams.
FIG. 9 shows a framework bridge 20' comprising two cut brackets 70, 71, each comprising a deep flange portion 70 extended longitudinally at 90° approximately by a bearing flange portion 71, the length of which exceeds that between the wall webs 331 of two elementary profiles 33 which it braces, by projecting at each of its two ends in such a manner as to be capable, as a result of a cut-out of the flange 70, 90 of being slid between the flange 131 of the elementary profile 33 and the web 109 opposite to it; each of the two ends being cut back to the shape of a compressive diaphragm 50, the arris 61 of which, along a fold indicated at the broken line A, compresses the elementary profile 33 in contact, forming a stiffening and compressive square arrangement. The cutting of this arris 61 from the end 73 forms an angle which varies according to the bearing width desired. The deep flange 70 is cut from its top to the folding corner at an angle which here is 90° but which can vary according to the shape and angle of the elementary profiles 33; the distance between the two opposite arrises 77 which mark this cutting is slightly less than that between the two webs 331 of the two elementary profiles 33 facing one another, and in addition at the base of this arris 77 a corridor 78 is formed on the flange 70 so as to facilitate the possible passage of a connecting piece, not shown. Two framework bridge brackets 20 ' are coupled together one against another by their flanges 70, the flanges 71 being towards the outside.
These two brackets are connected to each other by a clip 80, which is a small U of metal co-operating with symmetrical perforations or by a bearing diaphragm bestriding and forking into the corridor 78. These two frameworks connected to each other, comprise here an angle piece 85 of semi-hard steel designed to form a sectorised support on the web of the C-sleeve and to accentuate the curved shape if necessary.
The shape indicated by broken line 90 designates a cut of the flange 70 as an arc in such a way as to impart, where applicable, to this bracing framework 20', a permanent elasticity which is combined if necessary with the angle pieces 85.
In a corner portion, formed by the plane of sleeve P 1 continuing the C-sleeve 10 at 90°, a framework 21 braces the internal angle of this C-sleeve 10 and, as a result of a diaphragm 50 cut at each of its four ends, enables the two mutually facing elementary profiles 33 to be compressed.
This framework 21 is formed of a bracket, the two flanges of which angled at 90° are here of equal depth and the length of which, like that of the bridge 20', slightly exceeds that between the elementary profiles 33 after they have been blocked. In the upper portion P 2 which continues the plane P 1, the bracing process is substantially the same; the framework 22 in this case is of a length equal to that of the internal portion of the web 109 from one internal corner 115 to the other, and it is folded with the C-sleeves 10. This framework comprises, like the preceding one, four compressive diaphragms 50. The U-shape of the broken line 95 symbolises a U-section of adequate dimensions, which may be inserted, having one of its two flanges encased between the web 109 and the flange of the bracket 22, while the other flange is encased between the web 109 and the flange of the framework 21.
More specifically, FIGS. 24 and 25 show, respectively, a side view of an internal, secondary beam for a display stand according to the invention, and an external, perspective view of this stand. Profiles 33 are more fully shown in FIGS. 5 and 21, and with a modification in FIG. 22. The profiles are interconnected by bridges 10 GP to provide an angulate composition structure, insertable between or behind walls 10.
FIGS. 26, 27 similarly show, in perspective and side views respectively, a hollow, angulate wall structure comprising similar bridges and profiles.
FIGS. 28, 29 are perspective views, showing respectively, a four-sided frame structure P1--P1 insertable in one of the walls 10 of FIG. 25 or 26 as a joist, and another hollow, angulate wall structure comprising such frame-joists. | A composite structure, formed of construction elements capable of various uses. The elements are associated with one another for the construction of buildings and of fixed and movable fittings, also for use in maintenance, and for other purposes, for example in public works. The composite structure comprises; a primary subassembly which in turn comprises C-section sleeves each having angulate flanges; a supporting and connecting principal beam, having wall faces with longitudinal, mutually opposed retaining cavities, and, to insure the required rigidity of the sub-assembly, transversely bracing and connecting bridges, slid into and engaged with the sleeves and beams at variable spacing between the bridges. Each bridge acts on at least two beams; which have substantially the shape of C, U or omega profiles. The bridges are placed opposite to one another on at least a portion of the length of the internal corners of the retaining flanges of the C-section sleeves. The composite structure also includes a secondary subassembly generally similar to the primary one and connected to the principal beam thereof, by the C-section sleeves. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to bandgap voltage reference circuits, and more particularly to such circuits in which an attempt is made to correct for a Tln(T) deviation from linearity in the output voltage.
2. Description of the Prior Art
Bandgap reference circuits have been developed to provide a stable voltage supply that is insensitive to temperature variations over a wide temperature range. These circuits operate on the principle of compensating the negative temperature drift of a bipolar transistor's base-emitter voltage (V be ) with the positive temperature coefficient of the thermal voltage V T , which is equal to kT/q, where k is Boltzmann's constant, T is the absolute temperature in degrees Kelvin and q is the electronic charge. A known negative temperature drift due to V be is first generated. A positive temperature drift due to the thermal voltage is then produced, and is scaled and subtracted from the negative temperature drift to obtain a nominally zero temperature dependence. Numerous variations in the bandgap reference circuitry have been designed, and are discussed for example in Grebene, Bipolar and MOS Analog Integrated Circuit Design, John Wiley & Sons, 1984, pages 206-209.
Although the output of a bandgap voltage cell is ideally independent of temperature, or at least varies linearally with temperature, the outputs of prior cells have been found to include a term that varies with Tln(T), where 1n is the natural logarithm function. Such an output deviation is shown in FIG. 1, in which the bandgap voltage output (V bg ) increases from a value of about 1.2408 volts at -50° C. to about 1.2444 volts at about 45° C., and then returns back to about 1.2408 volts at 150° C. This output deviation is not symmetrical; its peak is skewed about 5° C. below the midpoint of the temperature range.
It is difficult to precisely compensate for the Tln(T) deviation electronically, so simpler approximations have been used. One such circuit is shown in FIG. 2, and is described in U.S. Pat. No. 4,808,908 to Lewis et al., assigned to Analog Devices, Inc., the assignee of the present invention. The circuit includes bipolar npn transistors Q1 and Q2, with the emitter area of Q2 scaled larger than that of Q1 by a factor A. The emitters of Q1 and Q2 are connected together through a resistor R1 that has a relatively low temperature coefficient of resistance (TCR). A second relatively low TCR resistor R2 is connected in series with a relatively high TCR resistor R3 between the R1/Q1 emitter junction and a negative (or ground) voltage bus V-. Q1 and Q2 are provided with collector currents with a constant ratio between the current magnitudes, such as by connecting their collectors respectively to the inverting and non-inverting inputs of an operational amplifier. R1 and R2 are preferably implemented as thin film resistors, with TCRs on the order of 30 ppm (parts per million)/°C.; such low TCRs may be considered to be negligibly small for purposes of the invention. R3 is preferably a diffused resistor having a TCR of typically 1,500-2,000 ppm/°C.
The output voltage V bg is equal to the sum of V be for Q1 and the voltage drops across R2 and R3. In the absence of R3, the voltage across R2 can be determined by considering the voltage across R1. This is equal to the difference in V be for Q1 and Q2; since the emitter of Q2 is larger than the emitter of Q1 but both transistors may carry equal currents, the emitter current density of Q2 will be less than for Q1 and Q2 will accordingly exhibit a smaller V be . The V be differential between Q1 and Q2 will have the form V T ln (Id1/Id2)=V T ln(A), where I1 and I2 are the absolute emitter currents, and Id1 and Id2 are the emitter current densities of Q1 and Q2, respectively. Since I1 is preferably equal to I2, the current through R2 will be twice the current through R1, so that the voltage across R2 will have the form (2R1/R2)V T ln(A). Still ignoring R3, the described circuit will exhibit the Tln(T) output deviation mentioned above.
The addition of high TCR resistor R3 approximates a Tln(T) output voltage compensation by producing a square law (T 2 ) term that is added to V bg . Since the tail current through R2 is proportional to temperature anyway, adding a significant temperature coefficient by means of the high TCR tail resistor R3 yields a voltage across this resistance that is proportional to T 2 . Combining this square law voltage with the voltage across R2 and V be for Q1 approximately cancels the effect of the Tln(T) deviation.
R3 is preferably a diffused resistor, which is not subject to trimming. However, the resistance values of thin film resistors R1 and R2 can be conveniently adjusted by laser trimming to minimize the first and second derivatives of the bandgap cell output as a function of temperature.
Unfortunately, the square law voltage compensation produced by the FIG. 2 circuit is perfectly symmetrical, as opposed to the skewed parabolic shape of the Tln(T) deviation that actually characterizes the bandgap cell. Thus, the voltage correction that can be achieved with the FIG. 2 circuit is limited. FIG. 3 compares the Tln(T) and T 2 functions, scaled to a normalized value of the correction voltage V corr . The resulting variation in the net V bg , plotted on a normalized scale in which zero is the nominal V bg , is illustrated in FIG. 4. This is a sideways S-shaped curve that exhibits a significant residual temperature coefficient in both the upper and lower portions of the temperature range.
SUMMARY OF THE INVENTION
The present invention seeks to provide a precise compensation for the Tln(T) deviation of a bandgap reference cell, without unduly complicating the circuitry or adding process steps, and with a compensation mechanism that is adjustable to account for manufacturing tolerances.
These goals are achieved by adding a relatively low TCR resistor in parallel with the high TCR tail resistor of a bandgap voltage reference as described in FIG. 2. This produces a resistance circuit that is non-linear with respect to temperature, such that when a proportional-to-absolute-temperature (PTAT) current is passed through it the voltage across the resistor circuit is very similar to the Tln(T) function. The ratio of resistance values between the two parallel resistors is selected so that, as a function of temperature, the rate of change in the cell's output voltage both with and without the parallel resistors is substantially zero at approximately the same temperature. This establishes a shape for the compensation voltage-temperature characteristic that closely matches the Tln(T) deviation. The absolute resistance values of the parallel resistors are selected so that the compensation scale matches to the deviation scale. The correction resistor is preferably implemented as a laser trimmable thin film resistor, formed from the same type of material as the other low TCR resistors in the circuit. The result is a highly accurate output correction that can be implemented with a minimum of additional elements and processing.
These and other features and advantages of the invention will be apparent to those skilled in the art from the following detailed description, taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph of a typical Tln(T) deviation, described above, for a known bandgap voltage reference circuit;
FIG. 2 is a schematic diagram of a known bandgap voltage reference circuit, described above, that partially compensates for the output deviation shown in FIG. 1;
FIG. 3 is a graph, described above, comparing the Tln(T) deviation of a standard bandgap voltage reference circuit with the compensation provided by the circuit of FIG. 2.
FIG. 4 is a graph, described above, illustrating the voltage output obtained with the circuit of FIG. 2;
FIG. 5 is a schematic diagram of a bandgap voltage reference circuit that incorporates the present invention;
FIG. 6 is a graph illustrating the non-linearity, as a function of temperature, of the parallel resistor combination of FIG. 5;
FIG. 7 is a graph illustrating a family of correction voltage-temperature curves achievable with the invention for different ratios between the low TCR correction resistor and the high TCR tail resistor;
FIG. 8 is a graph plotting the slopes of the various curves in FIG. 7 at a temperature corresponding to the peak Tln(T) deviation temperature;
FIG. 9 is a graph illustrating the voltage output achievable with the invention;
FIG. 10 is a graph comparing the bandgap voltage outputs with and without the correction provided by the invention; and
FIG. 11 is a family of curves similar to FIG. 8, showing the effects upon the ideal resistor ratio of varying the TCR of the high TCR tail resistor.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A bandgap voltage reference circuit that compensates for the Tln(T) deviation to achieve an essentially temperature-invariant output is shown in FIG. 5. Circuit elements that correspond to those of the prior bandgap reference cell shown in FIG. 2 are indicated by the same reference numerals.
Various known schemes are possible to establish a constant ratio of currents through Q1 and Q2 that does not vary significantly with temperature. One such technique, illustrated in the figure, is to connect low TCR load resistors RL1 and RL2 between the collectors of bandgap transistors Q1 and Q2, respectively, and a positive voltage bus V+. The voltages at the opposite sides of RL1 and RL2 from V+ are maintained at the same constant voltage levels by connecting these points respectively to the non-inverting and inverting inputs of an operational amplifier 2, the output of which is connected to the cell's output terminal 4. The operational amplifier 2 forces the voltages at its inputs to equal values, thus establishing currents through the load resistors RL1 and RL2 that are inversely proportional to their resistance values; the load resistor currents continue on as the collector currents of Q1 and Q2.
In accordance with the invention, an additional low TCR resistor R4 is connected in parallel with the relatively high TCR resistor R3. By a careful selection of the ratio of resistance values between R4 and R3, a voltage-temperature compensation can be achieved that has essentially the same shape as the Tln(T) output deviation of the circuit without R3 and R4, but with an inverted polarity. The absolute resistor values are then selected to equalize the scalings of the compensation and deviation voltages, so that the output deviation is essentially cancelled by the compensation voltage.
The low TCR resistors R1, R2 and R4 can all be formed in the same process step, and are preferably thin film resistors. Such resistors have a TCR on the order of 30 ppm, which is negligible for purposes of the invention. The high TCR resistor R3 can be implemented in various ways, such as by a diffused resistor with a TCR of about 1500 ppm/°C., a polysilicon resistor that also has a TCR of about 1500 ppm/°C., a p-well resistor with a TCR of about 8,000 ppm/°C. or a pinch resistor with a TCR of about 10,000 ppm/°C. An advantage of forming the low TCR correction resistor R4 as a thin film device is that such resistors are easily laser trimmable. As described below, R4 can be trimmed to compensate for fairly large fabrication tolerances without greatly disturbing the output voltage compensation.
FIG. 6 illustrates the non-linearity in the resistance of the R3/R4 parallel circuit as a function of temperature. Normalized resistance values and a unity resistance ratio were assumed for simplification. As described below, the invention takes advantage of this non-linearity to shape and scale a correction factor for the cell's Tln(T) output deviation.
It has been found that, as a function of temperature, the correction voltage (V corr ) across the R3/R4 parallel combination varies considerably with the ratio of the resistance value of R4 to R3. Computed traces of the correction voltage as a function of temperature for different resistance ratios are given in FIG. 7, with the resistance ratio increasing in increments of 0.5 from zero to eight. With a zero (short circuit) resistance for R4, the correction voltage is similarly zero. With a 0.5 ratio the correction voltage is slightly positive, but thereafter becomes increasingly negative as the ratio progressively increases. In addition to obtaining a larger scale, the shape of the correction voltage curve also shifts as the resistance ratio increases; the temperature at which the peak correction voltage occurs becomes progressively higher with an increasing resistance ratio. This phenomenon is utilized by the invention to select the particular resistor ratio for the most accurate output voltage correction.
It should be noted, from an inspection of the family of voltage-temperature curves in FIG. 7, that a first order effect of varying the resistance ratio is to change the absolute scale or size of the curvature correction, while the shift in the temperature at which the peak correction voltage is achieved is only a second order effect. Accordingly, so long as the resistance ratio is set at approximately the correct value to obtain a curvature correction curve with the proper shape, the resistance ratio can later be trimmed (by trimming the correction resistor R4) to maintain the output voltage correction without having a significant effect on the shape of the curvature correction. Such trimming may be called for if the desired resistance values for R3 and R4 are not obtained due to manufacturing tolerances. The high TCR resistor R3 will generally be implemented as a diffuse resistor, which is not subject to trimming. On the other hand, the use of thin film for the low TCR correction resistor R4 makes that device easily laser trimmable, as indicated by the trimming laser beam 6 indicated in FIG. 5. This is a valuable feature, since it allows the curvature correction to be trimmed by varying the value of R4 slightly, rather than having to trim the entire bandgap cell current.
A precise output curvature correction is obtained by selecting the particular voltage correction curve that reaches a peak correction voltage at the same temperature at which the peak Tln(T) deviation occurs. For the deviation curve of FIG. 1, the peak deviation occurs at approximately 44.7° C. (FIG. 1 corresponds to a bandgap cell with R1 equal to 21.4 kohms, R2 equal to 121 kohms, transistor collector currents of 3 microamps, a transistor emitter area ratio of 10:1 and a transistor V be of 0.51773 volts.) The slopes of each of the curvature correction curves in FIG. 7 at 44.7° C. are plotted as a continuous curve in FIG. 8. It can be seen that zero slope values, which correspond to a peak correction voltage at 44.7° C., occur at R4/R3 ratios of 0, 0.7 and 5.0. A zero ratio can be ignored, since it corresponds to a short circuit, while a 0.7 ratio is undesirable because it is in the positive compensation portion of FIG. 7 and the compensation scale is very low. A resistor ration of about 5:1 is thus the preferred ratio for achieving an accurate output correction.
Now that the proper resistor ratio for the desired curvature correction curve shape has been determined, the absolute resistance values are computed by computing the curvature correction peak size as the differential between the values of the output deviation voltage at the ends of the temperature range and at the peak deviation temperature. The overall PTAT voltage produced by the high TCR resistor R3 is also computed, and the value of R2 is reduced to compensate for this PTAT voltage. The resulting output deviation, for the resistance parameters described above, is shown in FIG. 9. The voltage scale of this figure is greatly magnified, with each vertical division corresponding to only a single microvolt; the peak-to-peak output voltage deviation has been substantially reduced down to about 5 microvolts.
The output characteristic in FIG. 9 has a pair of humps 8 and 10 that represent a third order correction, as compared the S-shaped output of a second order (square law) curvature correction illustrated in FIG. 4 for the circuit without the correction resistor R4. Also note that the absolute value of the output deviation in FIG. 9 is on the order of 10 4 times less than the deviation in FIG. 4.
FIG. 9 represents an optimized output that is theoretically obtainable if there are no other sources of output deviation. However, a hysterisis in the transistor operation as the temperature increases to the upper end of the desired range and then cools back down to room temperature typically introduces a greater output randomness, on the order of perhaps 100 microvolts, than the degree of accuracy indicated by FIG. 9. The presence of transistor hysterisis mitigates the effect upon absolute output temperature linearity that would otherwise result from trimming the correction resistor R4 and thus changing the R4/R3 resistor ratio. Any loss in output accuracy from trimming R4 would tend to be masked by the hysterisis effect, but the hysterisis deviation is still several orders of magnitude less than the residual deviation that can be expected with a square law output correction.
A comparison of the bandgap cell's output, with and without the curvature correction provided by the invention, is illustrated in FIG. 10 for a circuit with parameters as described above. Curve 12 represents the uncorrected output, while curve 14 represents the output after the addition of the curvature correction. Due to the voltage scale employed, the corrected output appears to be perfectly flat as a function of temperature, while the uncorrected output has a distinct bow.
The particular R4/R3 resistance ratio at which accurate curvature correction is obtained will depend upon the parameters of the particular circuit being considered. For example, the curve of FIG. 8 was obtained with an assumed TCR for R3 of 6,880 ppm/°C. FIG. 11 presents modified curves of the correction voltage-temperature slope, as a function of the resistor ratio, for different values of R3 TCR. Curves 16, 18, 20, 22 and 24 correspond respectively to TCRs of 4,000, 5,000, 6,000, 7,000 and 8,000 ppm/°C. for R3. It can be seen from these curves that the optimum resistor ratio increases progressively from a value of about 3.2 for curve 16 to a value of about 5.7 for curve 24.
While particular embodiments of the invention have been shown and described, numerous variations and alternate embodiments that employ a relatively low TCR correction resistor in parallel with a relatively high TCR tail resistor will occur to those skilled in the art. Accordingly, it is intended that the invention be limited only in terms of the appended claims. | A bandgap voltage reference circuit includes a low temperature coefficient of resistance (TCR) tail resistor connected in series with a high TCR tail resistor, and a low TCR correction resistor connected in parallel with the high TCR resistor. The ratio of resistance values for the parallel resistors is selected to produce a correction voltage that essentially cancels a Tln(T) output deviation from temperature linearity, where T is absolute temperature. Matching voltage-temperature characteristics are obtained by selecting a resistor ratio at which the rate of change in the circuit's output voltage, both with and without the parallel resistors, is substantially zero at approximately the same temperature. While the shape of the compensation voltage-temperature curve is determined by the resistor ratio, it is scaled to the magnitude of the Tln(T) deviation by an appropriate selection of absolute resistor values. The correction resistor is preferably a trimmable thin film element. | 8 |
TECHNICAL FIELD
[0001] The invention relates to a Fabry-Perot interferometer and a method for producing a Fabry-Perot interferometer. More specifically, the invention relates to electrically tunable Fabry-Perot interferometers which are produced with micro-opto-electromechanical systems (MOEMS) technology. The technical field of the invention is specified in the preamble of the independent claim.
BACKGROUND TECHNOLOGY
[0002] Fabry-Perot interferometers are used as optical filters and in spectroscopic sensors, for example. A Fabry-Perot interferometer is based on parallel mirrors, such as quarter wave Bragg reflectors, wherein a Fabry-Perot cavity is formed between the mirrors. The pass band wavelength of a Fabry-Perot interferometer can be controlled by adjusting the distance between the mirrors i.e. the width of the cavity. It is common to use micromechanical technology for producing Fabry-Perot interferometers. Such a solution is described e.g. in patent document F195838.
[0003] FIG. 1 a illustrates a prior art micromechanical Fabry-Perot interferometer produced on a substrate 130 . Mirrors of a micromechanical interferometer usually include several layers 102 , 104 , 106 , 112 , 114 , 116 , wherein materials of adjacent layers have a different refractive index. The micromechanical interferometers used in short wavelength ranges of visible light and near-infrared radiation generally have solid mirror layers, such as a silicon dioxide or silicon nitride layer 104 , 114 between silicon layers 102 , 106 , 112 , 116 . However, silicon oxide and silicon nitride have relatively high attenuation at long wavelengths, and therefore it is more preferable to use a layer of air between silicon layers in infrared range, especially in the wavelength range over 5 μm, i.e. thermal infrared radiation (TIR).
[0004] Movement of the mirror 112 , 114 , 116 is made possible by removing a sacrificial layer 111 from the optical area A and from a surrounding area around the optical area, whereby a cavity 123 is formed. The sacrificial layer may be e.g. silicon dioxide, which can be removed by etching with hydrofluoric acid (HF), for example. In order to allow the etching substance to reach the sacrificial layer, holes (not shown in FIG. 1 a ) are provided in the movable mirror. The remaining part of the sacrificial layer serves as a support for the movable mirror. The substrate has optionally been removed from the optical area 125 in order to avoid attenuation and reflection caused by the substrate.
[0005] The position of a moveable a mirror is controlled by applying voltage to electrodes, which are included in the mirror structures by making one layer 106 , 112 of both mirrors conductive by e.g. doping. There are electrodes 110 a and 110 b for connecting a voltage to the electrodes. When control voltage is applied between the electrodes of the fixed and movable mirrors this voltage causes a force which moves the movable mirror towards the fixed mirror. If the electrodes cover the whole mirror, the movable mirror will be bent throughout the cavity area. This causes the distance between the movable mirror and the fixed mirror to vary within the optical area A during electrical activation. This is illustrated in FIG. 1 b . The non-flatness of the movable mirror within the optical area causes the pass band frequency to vary within the optical area and the bandwidth to become wider. The quality factor of the filter, i.e. finesse, will therefore be reduced. As a result, the finesse of such an interferometer is not sufficiently high for several applications where high finesse is required.
[0006] The non-flatness of the movable mirror within the optical area can be avoided by providing the control voltage only outside the optical area of the mirrors. This solution is illustrated in FIG. 1 b . The layer 106 is only connected to control voltage at the area outside the optical area, and the voltage applied to the electrode is thus not effective at the optical area. However, there are some disadvantages in this approach as well.
[0007] Firstly, due to a smaller electrode area a higher voltage is required between the electrodes in order to achieve sufficient force between the mirrors. It is often difficult to provide high voltages in small-sized sensor circuits, and also energy consumption may increase due to energy losses in a required voltage conversion.
[0008] Secondly, even if deflecting voltage is not applied in the optical area it is still necessary to provide electrodes within this area. This is because the optical areas of the mirrors must be connected to a constant voltage potential in order to avoid coupling of static electricity in the optical area, which might cause errors in the mirror position. The movable mirror and the fixed mirror must be in the same electrical potential at the optical area in order to avoid a force between the mirrors in that area. Therefore, a conductive layer of the optical area must be electrically separated from the electrode outside the optical area, and these conductive areas of a mirror must be connected to different voltage potentials. Connecting the conductive areas into different potentials requires providing electrically conductive feed-throughs and leads into several mirror layers. To achieve the electrical feed-throughs and leads a layer, patterning and doping must be applied. As a result the number of micromechanical process phases is increased. This makes the production of the interferometers complicated and makes the production cost too high for cost sensitive applications.
[0009] One further disadvantage relates to the shape of the interferometer. The mirrors need to have circular shape because any other lateral shape could cause wrinkling of a tensile-stressed thin-film mirror when it is vertically displaced by the electro-static actuation. On the other hand, circular form of a component is usually not preferable in electronics because the density of the components on a substrate or on an electrical circuit is not optimal.
SUMMARY OF THE INVENTION
[0010] The purpose of the present invention is to avoid or reduce disadvantages of the prior art. The purpose of the invention is thus to provide an interferometer which has a good finesse and is not too complicated to produce.
[0011] The object of the invention is achieved with an electrically tunable Fabry-Perot interferometer, comprising
a substrate, a first mirror on the substrate, a second, movable mirror, the second mirror has a movable optical area and a movable area surrounding the optical area, a Fabry-Perot cavity between the first and second mirrors, the first mirror and the second mirror have electrodes for electrical control of the distance between the mirrors, at least the surrounding area of the second mirror has a gap between two layers of the mirror, and mirror layers at the opposite sides of the gap are connected with anchoring through the gap,
which is characterised in that
the electrodes of the first and second mirrors extend to the optical area, and the implementation of the anchoring is such that the stiffness of the second mirror at the surrounding area is lower than the stiffness of the second mirror at the optical area, whereby the second mirror is arranged to bend more at the surrounding area than at the optical area on activation of the electrodes with a control voltage.
[0021] The object of the invention is also achieved with a method for producing an electrically tunable Fabry-Perot interferometer, wherein
a substrate is provided, a first mirror is provided on the substrate, a second, movable mirror is provided, wherein the second mirror has a movable optical area and a further movable area surrounding the optical area, a Fabry-Perot cavity is provided between the first and second mirrors, electrodes are provided for the first and second mirrors for electrical control of the distance between the mirrors, a gap is provided between two layers of the mirror in at least the surrounding area of the second mirror, and anchoring is provided for connecting mirror layers at the opposite sides of the gap with the anchoring through the gap, which is characterised in that the electrodes of the first and second mirrors are formed to extend to the optical area, and the anchoring is such implemented that the stiffness of the surrounding area is lower than the stiffness of the optical area, whereby the movable mirror is arranged to bend more at the surrounding area than at the optical area on activation of the electrodes with a control voltage.
[0030] Significant advantages can be achieved with the present invention when compared to the prior known solutions. The invention makes it possible to achieve a movable mirror where the stiffness of the optical area is high compared to the area surrounding the optical area. It is therefore possible to achieve good flatness of the movable area even if the electrodes extend to the optical area of the mirrors. An interferometer with good finesse can thus be produced.
[0031] It is possible to extend the electrodes to the whole area of the movable area of the mirror. Therefore, it is not necessary to provide other, electrically separated conductive areas in the mirrors. The corresponding leads and feedthroughs of the mirror layers are thus avoided, and the production process is thus simple.
[0032] When control electrodes extend to the optical area of the mirrors the required movement of the movable mirror can be achieved with a lower control voltage. It is therefore possible to use the interferometers in devices where higher voltage is not available and without specific voltage up-converters.
[0033] The invention allows various geometries of electrodes, and the electrodes may cover smaller or larger portions of the optical area. According to one embodiment of the invention, the control electrodes extend over substantially whole optical area of the mirrors. With this embodiment it is possible to achieve minimal values of required control voltages.
[0034] In one embodiment of the invention the anchoring includes individual anchors through the gap, which have a shape of a beam or a cylinder, for example. Such anchors can be made of the same material as the layers at the opposite sides of the gap, and the anchors can be preferably deposited with the same, simultaneous process as the layer above the anchors. The width of the anchor are preferably smaller than or about the same size as the height of the anchor. The anchors are preferably perpendicular to the mirror planes.
[0035] The density of the anchors is preferably higher in the optical area of the movable mirror than at the surrounding area. This way a higher stiffness is achieved in the optical area compared to the surrounding area. Another alternative is providing different geometries in the distribution of the anchors, and/or providing different forms of the anchors and/or providing different widths of the anchors. It is further possible that the mirror stiffness between the optical area and the surrounding area of the movable mirror is based on the material properties of the anchors.
[0036] In one embodiment of the invention both mirrors of the interferometer have gaps which serve as layers of the mirror. Such a structure is preferable in long wavelength applications, such as TIR applications.
[0037] According to a further embodiment of the invention the movable mirror has gaps only outside the optical area, and the fixed mirror may be without a gap. While solid mirror layers are used in the optical area of the movable mirror, the surrounding area of the movable mirror is made more flexible by the gap/anchor structure.
[0038] The gap of a mirror preferably includes air, but it may also include other gas which is transparent at the operational wavelength range of the interferometer. The gap may also include a vacuum.
[0039] In one embodiment of the invention the form of the movable area of the second mirror is non-circular, preferably rectangular or square. The present invention makes it possible to use non-circular form of the movable area by using locally irregular distribution of anchoring. This way it is possible to compensate the irregular bending of the mirror in a non-circular geometry. It is possible to use same or different geometry in the forms of the optical area and the movable area of the mirror. For example, the movable area may be square, and the optical area may be circular.
[0040] If the movable area of the mirror is non-circular, preferably square, it is possible to include a higher number of interferometers in a given substrate area than if circular movable area is used. It is also possible to produce an interferometer component with a given optical area, which has a smaller component size than if circular movable area is used.
[0041] In one embodiment of the invention there are bumps extending from the mirror surface towards the other mirror for preventing touching of the even surfaces of the movable and fixed mirrors with each other. It is preferable to provide the bumps at locations of anchors at the surface area of the mirror.
[0042] Some further preferable embodiments of the invention are described in the dependent claims.
[0043] Since polycrystalline silicon and air both have low attenuation in the infrared range wavelengths it is possible to provide interferometers which have good performance even within long wavelength ranges, such as 5-30 μm. However, it is also possible to use the interferometers according to the invention within shorter wavelength ranges.
[0044] In this patent application the term “mirror” means a structure where there is a set of layers which reflects light in an optical area of the mirror. The “mirror” also includes areas of the layers that are outside the optical area.
[0045] In this patent application the terms “radiation” or “light” are used to mean any radiation in the optical range of wavelengths.
[0046] In this patent application “sacrificial layer” means a material layer which is at least partially removed in the final product.
[0047] In this patent application term “density of anchors” means the number of anchors in a given area of a mirror.
[0048] In this patent application terms “silicon oxide”, “silicon dioxide” and “SiO 2 ” comprise materials which may be formed by various alternative methods, such as PECVD, LPCVD, thermal oxidation, spin-on glass (SOG), and which may optionally be doped with various additives, such as phosphorus or boron, and which may be deposited from various alternative source materials such as silane, TEOS etc.
[0049] The material is thus not restricted to any single stoichiometric compound.
SHORT DESCRIPTION OF THE DRAWINGS
[0050] In the following part the preferable exemplary embodiments of the invention are described in more detail by referring to the enclosed drawings, in which:
[0051] FIG. 1 a illustrates a cross section of a prior art Fabry-Perot interferometer in a quiescent state;
[0052] FIG. 1 b illustrates a cross section of a prior art Fabry-Perot interferometer in an activated state;
[0053] FIG. 1 c illustrates a cross section of another prior art Fabry-Perot interferometer in an activated state;
[0054] FIG. 2 illustrates a cross section view of an exemplary electrically tunable Fabry-Perot interferometer according to the invention wherein both mirrors include an air gap in the optical area;
[0055] FIG. 3 illustrates a cross section view of another exemplary electrically tunable Fabry-Perot interferometer according to the invention wherein both mirrors include solid layers in the optical area;
[0056] FIG. 4 illustrates a top view of an exemplary electrically tunable Fabry-Perot interferometer according to the invention.
[0057] FIGS. 5 a - 5 e illustrate an exemplary process for producing an exemplary Fabry-Perot interferometer according to the invention.
[0058] FIG. 6 illustrates an enlarged view of a part of a movable mirror in production phases of an anchor.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0059] FIGS. 1 a , 1 b and 1 c were described in the prior art section of the description.
[0060] FIG. 2 illustrates a cross section of an exemplary Fabry-Perot interferometer according to the invention. The interferometer has a substrate 130 of e.g. monocrystalline silicon material, wherein there may be a hole 125 at the optical area of the interferometer, thus providing an optical aperture for the interferometer. If the substrate is heavily doped the substrate layer attenuates the radiation and prevents the transmission of radiation outside the optical aperture. However, an aperture may also be provided with a separate non-transparent layer, without removing the substrate.
[0061] The reflecting layers of the fixed mirror are provided by layers 102 , 104 , 106 , wherein layers 102 and 106 are of polycrystalline silicon, and layer 104 is a gap which includes vacuum, air or other gas which is transparent in the operating wavelength range. The gap has been formed by removing a sacrificial layer of silicon oxide 103 from the optical area. Layer 106 is made of doped polycrystalline silicon and serves as a control electrode of the fixed mirror.
[0062] The interferometer has a second, movable mirror which has reflecting layers 112 , 114 , 116 . Layers 112 and 116 are of polycrystalline silicon, and layer 114 is a gap which includes vacuum, air or other transparent gas. The gap has been formed by removing a sacrificial layer of silicon oxide 113 from the optical area. Layer 112 is made of doped polycrystalline silicon and serves as an electrically conducting control electrode of the movable mirror.
[0063] The electrode of the lower, fixed mirror is electrically connected to the connection 110 a , and the electrode 112 of the movable mirror is connected the connection 110 b . The electrical connections 110 a , 110 b are made of aluminium, for example. The electrodes cover substantially the whole area of the mirror. In this way the control voltage between the mirror electrodes produces a maximal force between the mirrors, and accordingly, a minimum force is required for obtaining a determined deflection of the movable mirror. By providing electrodes on the whole area of the mirror it is possible to avoid the electrostatic coupling of charges to the mirrors.
[0064] There are anchors 105 , 115 , in the gaps of mirror structures for keeping the width of the gap constant throughout the optical area. The anchors connect the layers at the opposite sides of the gap mechanically to each other. The anchors preferably cover only a small part, such as 1-10% of the optical area in order to avoid significant attenuation. The width of each anchor may be a few μm, for example. It should be noted that the sizes of the anchors and the holes are highly enlarged in the cross section Figures of this application in order to better illustrate the anchor structure. The anchors can be made of the same polycrystalline silicon material as the layers, for example. It is preferable to deposit the anchors with the same process as the layer above the anchoring.
[0065] According to the present invention, the stiffness of the movable mirror is made higher at the optical area than at the surrounding area. To achieve this, the density of anchors is preferably higher in the optical area than in the surrounding area. To achieve the required variation in the stiffness it is also possible to use different distribution geometry of the anchors. Further, it is possible to use an inhomogeneous distribution of anchors for compensating local variation of required stretching of the mirror in case the movable part of the mirror is non-circular.
[0066] The value of the gap width of the mirrors is preferably λ/4, wherein λ is the centre wavelength of the interferometer pass band. The optical thickness of the other mirror layers is preferably also λ/4. However, the gap width/optical thickness may alternatively be some multiple of λ/4.
[0067] The cavity of the interferometer is formed by the space 123 , from which sacrificial silicon oxide layer has been removed. The sacrificial layer is etched e.g. by liquid or vapour HF through holes 151 of the second mirror. The second mirror will thus become movable. The silicon oxide layer has been removed from the optical area of the interferometer but it is not removed from the edges 111 of the silicon oxide layer. The remaining silicon oxide layer between the edges of the movable upper mirror and the lower fixed mirror serves as a support for the movable upper mirror.
[0068] FIG. 3 illustrates an electrically controllable Fabry-Perot interferometer according to another embodiment of the invention. In this interferometer the all mirror layers are solid material at the optical area. This interferometer is thus usable in shorter wavelengths of radiation. The fixed mirror has e.g. a layer 104 of silicon oxide or silicon nitride between layers 102 and 106 of silicon. Layer 106 is doped in order to provide an electrically conducting electrode at the fixed mirror. In the optical area the movable mirror has e.g. a layer 114 of silicon oxide or silicon nitride between layers 112 and 116 of silicon. Outside the optical area there is an air gap 114 b between the layers 112 and 116 of silicon, which are coupled with anchors 115 . Layer 112 is doped in order to provide an electrically conducting electrode at the fixed mirror.
[0069] A movable mirror area including an air gap with anchoring is made more flexible than an area with solid material. Therefore, the stiffness of the movable mirror is higher at the optical area than at the surrounding area. As a result, the movable mirror bending of the movable mirror mainly takes place outside the optical area, while the mirror area at the optical area remains substantially flat.
[0070] FIG. 4 illustrates a top view of an exemplary electrically tunable Fabry-Perot interferometer according to the invention. The optical area 461 of the interferometer is circular, and around the optical area there is a further area 462 where the upper mirror is movable. The dots in the Figure illustrate anchors between the movable mirror and the fixed mirror. The density of the anchors is higher at the optical area 461 than at the area 462 outside the optical area. Thus, in accordance with the invention, the stiffness of the movable mirror is higher at the optical area than at the surrounding area. Therefore, the bending of the movable mirror takes place at the surrounding area 462 , and the movable mirror remains relatively flat at the optical area 461 .
[0071] The movable mirror is provided with small holes (not shown) which have been used for removing the sacrificial layer. The holes are preferably evenly distributed across the second mirror. The diameter of each hole may be e.g. 100 nm-5 μm. The holes may cover an area of 0.01%-5% of the optical area of the second mirror. Due to their small total area such holes do not have substantial effect on the performance of the interferometer.
[0072] FIG. 4 also illustrates the contacts 110 a and 110 b for the electrodes of the upper and lower mirrors. The contacts are located at corners of the interferometer.
[0073] FIGS. 5 a , 5 b , 5 c , 5 d and 5 e illustrate a flow diagram of an exemplary method according to the invention for producing an electrically tunable Fabry-Perot interferometer, such as an interferometer of FIGS. 2 and 4 . The production process is started by providing a wafer substrate, 51 . The substrate can be e.g. monocrystalline silicon. Next an isolating layer of silicon oxide is deposited on the substrate by LTO (Low temperature Oxidation) deposition, 52 . Then layers of a fixed mirror are deposited.
[0074] In phase 53 a layer of polycrystalline silicon is deposited. It is possible to provide holes in this layer for etching a sacrificial layer if required. It should be noted that in this embodiment of the invention it is not necessary to provide ion implantation for this layer because electrically conductive areas are not needed. After depositing polycrystalline silicon layers annealing is provided, but this will not be specifically mentioned in the following description of the further phases.
[0075] Next a sacrificial layer is deposited by e.g. LPCVD SiO 2 deposition, 54 , which is then patterned, 55 , for anchors. Then a polycrystalline silicon layer is deposited, 56 , and conductive areas are formed by ion implantation 57 . It should be noted that in this embodiment of the invention it is possible to have the whole layer electrically continuous because no isolating areas are required in the layer. The polysilicon is then patterned, 58 , in order to provide holes for etching the sacrificial layer. Thus the layers for the fixed mirror have been produced.
[0076] A sacrificial layer for forming a Fabry-Perot cavity is deposited by LPCVD SiO 2 deposition, 59 . It is not necessary to pattern the sacrificial layer. Next, the layers for the movable mirror are produced. A layer of polycrystalline silicon is deposited, 80 , and conductive area is formed by ion implantation, 81 . The layer is patterned, 82 , in order to provide holes for etching the sacrificial layer. Next a further sacrificial layer is made with LPCVD SiO 2 deposition, 83 , and the layer is patterned, 84 . With this patterning locations of anchors are determined for the movable mirror. The density of the anchors is preferably larger in the optical area than in the surrounding area. This way a higher value of stiffness is achieved in the optical area compared to the surrounding area. A layer of polycrystalline silicon is then formed with LPCVD deposition, 85 , and holes are etched, 86 . Thus the layers for the movable mirror have been produced.
[0077] Metallization with aluminium is performed for the connectors by sputtering and patterning, 87 . Next, the stack of oxide and poly-Si layers is patterned at the backside of the interferometer, 88 . By ICP etching of silicon a hole/recess can be made to the substrate, 89 , at the optical area. Finally, the interferometer chips are diced, and the sacrificial layer is etched, 90 .
[0078] FIG. 6 an enlarged view of a part of a movable mirror in production phases of an anchor. The FIG. 6 also shows a bump which is produced for preventing the mirrors from sticking to each other when their surfaces touch due to electrical activation. After the first, bottom layer 61 of the movable mirror has been deposited on a sacrificial layer 60 (phases 80 , 81 in FIGS. 5 b and 5 c ), the layer is patterned (phase 82 ) in order to provide holes 62 a for etching and for providing a hole 62 b for a bump 68 . A sacrificial layer 63 of the movable mirror is deposited (phase 83 ) and holes 64 for anchors are patterned (phase 84 ). The top layer 65 of the movable mirror is deposited (phase 85 ), whereby anchors 67 and a bump 68 are also formed. The anchor 67 illustrated in FIG. 6 has a cylindrical shape. The top layer of the mirror is patterned (phase 86 ) for forming holes 66 for etching. Finally the sacrificial layers 60 , 63 are removed by etching (phase 90 ) through the holes 66 and 62 a.
[0079] The invention has been described with the reference to the enclosed embodiments. It is, however, clear that the invention is not restricted only to those, but it comprises all embodiments which can be imagined within the inventive idea and the enclosed patent claims.
[0080] For example, some materials, dimensions and forms have been mentioned as examples for implementation of the invention. However, it is clear that dimensions, forms and materials as well as details of structure can be changed and optimised for each implementation according to the specific requirements.
[0081] The inventive interferometers have several preferable applications. They can be used as controllable filters in optical spectrometers, colour analyzers, imagers, optical data communications, and in various devices exploiting spectroscopy on organic compounds or polymers in gases or liquids. The invention is most preferably applied in infrared measurements, and particularly in the thermal infrared range. | Electrically tunable Fabry-Perot interferometers produced with micro-optical electromechanical (MOEMS) technology. Micromechanical interferometers of the prior art require high control voltage, their production includes complicated production phases, and the forms of the movable mirrors are restricted to circular geometries. In the inventive solution, there is a gap in the movable mirror, whereby mirror layers opposite to the gap are connected with anchoring. The anchoring is such that the stiffness of the mirror is higher at the optical area than at the surrounding area. This way it is possible keep the optical area of the mirror flat even if the control electrodes extend to the optical area. Due to large electrodes, lower control voltages are required. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is related to the copending U.S. patent application entitled, "A Solderless Printed Wiring Board Module And Multi-module Assembly", Ser. No. 07/350,862 filed May 11, 1989.
BACKGROUND OF THE INVENTION
This invention relates to connections in electronic assemblies and more particularly to a surface mounted integrated circuit chip carrier.
Surface mounted devices (SMDs) are electronic components that are designed to sit on the surface of a printed wiring board (PWB) or another compatible substrate. Components such as resistors, capacitors, diodes, transistors and integrated circuits (IC) may be designed as SMDs and, as such, have either no leads but flat interfacing surfaces or very short leads. The interfacing surfaces or the short leads of these components serve as contact pads which align with corresponding electrical connections on a PWB.
Typically the components are mounted or fabricated within a ceramic or plastic carrier to provide a desired configuration having contact pads on the external surface of the carrier which are electrically connected to the component contained therein.
The advantages of SMDs are numerous. The size of these devices may be 30 to 60% smaller than the traditional leaded components they replace. The holes within the PWBs which accept the leads of leaded components are no longer necessary when utilizing SMDs. For this reason, not only may SMDs be mounted closer together, but SMDs may also be mounted on each side of a PWB. Because of these factors, the overall size and weight of a populated PWB is less than that of a PWB using leaded components.
One specific type of an SMD is an IC chip carrier. Because of the frailty and the inherently small size of an IC chip, the IC chip is typically mounted in a chip carrier which provides structural reinforcement for the chip and also provides a means for making external electrical connections to the IC chip. A chip in a sealed ceramic carrier has the further advantage of providing to the chip hermetic isolation from the outside environment.
Utilizing current chip carrier designs, problems arise when the IC chip is a high power device which generates substantial amounts of heat. First of all SMD technology the size of the chip carrier may be reduced but the necessary heat transfer from the IC chip remains the same. For this reason a chip carrier design is required that is more conducive to transferring heat from the IC chip, thereby permitting heat transfer from an IC chip within a smaller chip carrier.
Secondly, in the past decoupling capacitors used in conjunction with the IC chip were mounted elsewhere on the PWB and electrically connected to the IC chip or a capacitor was mounted to the exterior of the chip carrier, thereby requiring external connections from the chip carrier to the decoupling capacitor even though the decoupling capacitor was electrically connected only to the IC chip.
Thirdly, ceramic materials are used in the fabrication of the chip carrier and associated with the use of ceramic is some degree of shrinkage during the chip carrier fabrication. This becomes critical with SMD chip carriers because the contact pads on the outside of the carrier must be in a precise pattern to align with mating pads on the PWB. As the size of the distance between contact pads is reduced, precise patterns become even more critical.
FIG. 1 shows a cavity-up chip carrier with a pad grid array 10. The chip carrier 10 is comprised of a body 15 having an upwardly facing cavity 20. An IC chip 25 is mounted at the base of the cavity 20. The body 15 configuration is such that within the cavity 20 are a series of ledges 30. From the surface of a ledge 30, electrical strips known as traces 31 extend through the body 15 to vias 32 which then extend downward and are distributed within the body 15 such that each via 32 emerges through the bottom of the body 15 to connect with electrical contact pads 35 of the chip carrier 10. Bonding wires 34 extend from connections on the IC chip 25 to corresponding traces 31 on the ledge 30 of the body 15. With this arrangement, each chip connection from the IC chip 25 is electrically connected to a pad 35 at the bottom of the body 15. As a protective measure, a package lid 40 is secured to the body 15 to fully enclose the cavity 20. The arrangement of the pads 35 at the bottom of the body 15 may form a grid array which extends over the entire area of the bottom of the body 15 or may form a pad arrangement limited to a single row of pads around the perimeter of the body 15. With the number of connections from an IC chip remaining approximately constant and the size of chip carriers steadily reducing, the arrangement of pads in a single row around the perimeter of the body 15 may become impossible because of the necessity for a minimum pad 35 size and therefore it becomes necessary to utilize pads in a grid array arrangement to take full advantage of the area at the bottom of the body 15.
The chip carrier 10 is secured to a PWB 45 which has on its surface electrical interconnect pads (not shown) to which the pads 35 on the chip carrier 10 are aligned. The pads 35 may be secured to the PWB 45 using solder at each carrier pad/PWB interconnect pad interface or may be secured utilizing an external mechanical means to secure the chip carrier 10 to the PWB 45. A decoupling capacitor 50 typically associated with IC chips is attached to the PWB 45 at a proximate location to the chip carrier 10 and electrical connections are made between the decoupling capacitor 50 and the chip carrier 10. In some instances the decoupling capacitor 15 is externally mounted upon the chip carrier 10. Note that an electronic component other than a decoupling capacitor may also be mounted relative to the chip carrier in the same manner as that just described.
The body 15 may be made ceramic and as such during fabrication experiences shrinkage. Because of the tolerance required to fabricate a chip carrier 10 with precisely located pads 35, great care must be taken in designing and fabricating the body 15 such that after shrinkage, the location of the pads will be known. While the shrinkage of the ceramic material used to construct the body is uniform and there is a predictable error range of shrinkage, accurate determination of the locations of the pads 35, after the base has been fabricated, is very difficult.
Furthermore, oftentimes the IC chip 25 will generate substantial amounts of heat that must be effectively removed in order to avoid damage to the chip 25. Typically, the PWB 45 has associated with it a heat sink 55 secured to the PWB 45 through an adhesive interface 60. Heat generated by the IC chip 25 is first conducted through the body 15 and then conducted through each of the pads 35 to the associated PWB interconnect pads at the PWB 45. From here, the heat passes through the PWB 45 past an adhesive interface 60 to a heat sink 55, as indicated by arrows 57, where the heat is removed. For high power IC chips, this heat transfer path may not be adequate to remove all of the generated heat.
It is an object of this invention to provide a chip carrier design that effectively removes heat from a high powered IC chip.
It is another object of this invention to provide a chip carrier design in which the decoupling capacitors may be located directly within the chip carrier body.
It is still another object of this invention to provide a chip carrier design in which the locations of the external electrical contact pads on the chip carrier are known with precision.
SUMMARY OF THE INVENTION
The invention is an improved chip carrier design comprised of an integrated circuit chip carrier package comprised of a body of an electrically insulating material having planar top and bottom surfaces with a thickness therebetween and a central cavity extending through the top surface to a distance above the bottom surface thereby defining a cavity floor upon which an integrated circuit chip having a plurality of chip connections extending therefrom is mounted, and a cavity wall and at least one bonding ledge having an outer surface and extending from the cavity floor along the cavity wall, a plurality of vias of electrically conductive material and with cross-sectional areas within the body, each with a first and a second end, the first ends of the vias terminating at and penetrating through the body top surface at approximate locations in a predetermined pattern and the second ends of the vias terminating at and penetrating through the bonding ledge outer surface, electrical connection means extending from each of the chip connections to the second end of a corresponding via such that an electrically conductive path is established between the chip connections and corresponding vias terminating at the body top surface and a cover plate, with an area approximately equal to the cavity area, secured at the body top surface such that the cavity is fully enclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is prior art and shows a cross-section of an existing cavity-up chip carrier with pad grid array;
FIG. 2 shows an isometric view of the cavity-down chip carrier with pad grid array;
FIG. 3 shows a plan view of the cavity-down chip carrier with pad grid array shown in FIG. 2;
FIG. 4 shows a cross sectional view of the cavity-down chip carrier with pad grid array shown in FIG. 2; and
FIG. 5 shows the cavity-down chip carrier situated between a PWB and a heat sink for optimal heat transfer.
FIG. 6 is an isometric view showing a detail of the compliant solderless interface used as an electrical interconnect between the PWB and a chip carrier.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the invention is illustrated in FIGS. 2 through 5. Just as in FIG. 1, FIG. 2 shows a chip carrier 100 having a body 115 with a planar top surface 120 and a planar bottom surface 125. Within the body 115 is a cavity 130 which defines a cavity floor 135 and cavity walls 140. A first bonding ledge 145 and a second bonding ledge 150 within the cavity 130 extend from the cavity floor 135 along the cavity walls 140. A plurality of electrical strips, or traces 153, extend from the surface of each bonding ledge 145 and 150 through the body 115 and intersect with vias 155 which extend upward and penetrate through the body top surface 120. An IC chip 160 is mounted on the cavity floor 135. From the IC chip 160 are a plurality of bonding wires 165 which electrically connect the IC chip 160 to corresponding traces 153 on the bonding ledges 145 and 150.
In order to minimize the length of the wires 165 from the IC chip 160 to the bonding ledge traces 153, the height of the first bonding ledge 145 from the cavity floor 135 is very close to that of the height of the IC chip 160 from the cavity floor 135. Furthermore, the distance between each bonding wire 165 coming from the IC chip 160 is defined as the pitch and for an IC chip, this distance may be of the order of magnitude of 0.004 inches. The bonding wires 165 are typically bonded to the traces 153 on the bonding ledges 145 and 150. Because the pitch between the bonding wires attached to a typical IC chip 160 is so small, using currently available wire bonding technology attaching the wires 165 to a single ledge such as 145 would be beyond the current fabrication technology. As a solution, the bonding wires 165 remain approximately parallel as they leave the chip 160 and are separated by a distance of the pitch but the wires are then attached to traces 153 which are staggered along a plurality of ledges. In this manner, assuming two ledges are used, then the distance between two consecutive bonding wires 165 on a single ledge is equal to a distance of twice the pitch at the IC chip connections which then permits bonding of the wires 165 to the traces 153 on the bonding ledge 145 and 150 surfaces. If an IC chip was utilized in which the pitch of the wires 165 coming from the IC chip 160 was greater, then it could be possible to utilize only a single bonding ledge 145.
Note the bonding ledges 145 and 150 do not extend the length of the entire cavity wall 140. This permits other components such as a decoupling capacitor 170 to be mounted within the cavity 130 along with the IC chip 160. Electrical connections, through bonding wires 175 may be made between the decoupling capacitor 170 and the traces 153 on the bonding ledges 145 and 150. Furthermore, when necessary, a portion or all of the cavity floor may be metallized and electrically connected to the capacitors 170, such that at one terminal on the capacitors 170 the bonding wires 175 would be attached and at the other terminal on the capacitor 170, which would rest on the cavity floor, a second attachment could be made. The metallized segment (not shown) would then be electrically attached using traces to vias within the body 115.
The width of a typical trace 153 is about 0.004 inches. While this is an acceptable size with which to attach a bonding wire 165, this width does not produce an area that would be practical for use in external connections to the chip carrier. Furthermore, as mentioned earlier, during the fabrication of the body 115, the ceramic material which the body is comprised of, tends to shrink. For this reason, the shrinkage of the body 115 at the location of the vias 155 on the planar top surface 120 is uniform. While the shrinkage of the ceramic material used to construct the body is uniform, and there is a predictable error range of shrinkage, accurate determination of the locations of the pads, after the base has been fabricated, is very difficult. It is critical to provide a chip carrier with the external contact points at known locations on the chip carrier.
The traces 153 and the vias 155 will be referred to for simplicity as electrical connectors. While the original design of the body 115 and the location of the vias 155 within the body may be calculated and placed such that the body 115 will shrink to locate the vias 155 in proper locations, this is a fairly complex procedure and a simpler solution is utilized in this invention. An alignment and electrical connecting means 200 is made up of a thin planar electrically insulating rectangular layer 205 with a central opening 210. The layer 205 has a plurality of contact pads 215 located such that when the alignment and connecting means 200 is overlaid upon the planar top surface 120 of the body 115, the contact pads 215 are approximately aligned with the vias 155 extending through the surface of the planar top surface 120 of the body 115. The radius of each contact pad 215 is uniform and intentionally larger than the radius of the vias 155.
The radius of each of the contact pads 215 will depend on a number of factors including the ceramic material used for the body, the radius of the vias and finally the desired overlap of the contact pads 215 with the corresponding vias 155.
Since the shrinkage is greatest at the edge of the body 115, the amount of shrinkage is calculated at the edge of the body 115 and this value is added to the radius of the via 155 along with a value representing the desired overlap between a pad 215 and a via 155. This sum is then used as the value for the minimum pad 215 radius, thereby providing a pad size that will ensure contact with the respective via and also provide at least the desired overlap. While a layer 205 which is located on the body 115 surface has been discussed for locating the pads 215 over the respective vias 155, it is entirely possible to place pads 215 directly onto the vias 155 without the need for layer 205, however the pad 215 size would remain the same. Note the ground pads 220 on the body 115. Just as the pads 215 are connected to vias 155, so to are the ground pads 220. Because of their larger size, one ground pad 220 may cover more than one via 155, or the via may be designed to conform with the shape of the ground pad 220. There may be an edge 225 around the inner perimeter of the body 115 such that a lid 230 may enclose the cavity 130 and seal the chip 160 within the cavity 130.
FIGS. 3 and 4 show a plan view and a section view respectively of the chip carrier shown in FIG. 2. Similar items of FIG. 2 have the same item number in FIGS. 3 and 4.
FIG. 5 shows an application for the chip carrier 100. The contact pads 215 of the chip carrier are aligned with mating pads not shown on the PWB 300.
The chip carrier 100 may be secured to the PWB 300 in a number of ways. The contact pads 215 may be directly soldered to the interconnect pads on the PWB 300. However, it is then difficult to inspect the solder joints between the chip carrier 100 and the PWB 300 to verify the integrity of the connection. Furthermore, in the event removal of the chip carrier 100 from the PWB 300 becomes necessary, it may be difficult to remove the chip carrier 100 from the PWB 300 since the inner most contact pads 215 on the chip carrier are inaccessible.
A second preferred method for securing the chip carrier 100 against the PWB 300 involves the utilization of a compliant solderless interface 240. The compliant solderless interface 240 illustrated in FIG. 6. An insulating planar frame 245 contains individual wads of finely woven electrically conductive wire inserted into holes in the frame 245 which form contact pads 250. The pads 250 are arranged to align with the PWB interconnect pads and the component contact pads. The component compliant interface 240 is manufactured under the tradename "CIN::APSE" by the Cinch company. Other types of compliant solderless interfaces are commercially available and may be utilized as long as electrical contact between the carrier interconnect pads and the component contact pads is provided.
The interface material is placed between the contact pads 215 and the contact pads on the PWB 300. The chip carrier 100 is then secured to the PWB 300 such that the compliant solderless interface 240 is slightly compressed between the contact pads 215 and the PWB 300 contact pads. One arrangement for securing chip carrier 100 to the PWB 300 could involve the use of an epoxy around the perimeter of the chip carrier 100 such that the chip carrier 100 is secured to the PWB 300. Another arrangement for securing the chip carrier 100 to the PWB 300 involves a flat plate 310 which in conjunction with the PWB 300 is used to compress the chip carrier 100 against the compliant solderless interface 240 which is then compressed against the PWB 300. The flat plate 310 is then independently secured to the PWB 300. This may be accomplished through mechanical means such as a bolt or by means of a spacer between the flat plate 310 and the PWB 300 to which both are secured through epoxy.
A feature of this invention involves the use of a thermally conductive material for the flat plate 310 such that the plate 310 may also substitute as a heat sink. This exploits an important aspect of the invention because it permits heat transfer from the IC chip 160 over an entirely different path than that previously described for cavity up chip carriers. The heat transfer path must no longer pas through the thickness of the body 115 and through the contact pads 215 to the PWB 300. There is now a much shorter more efficient path to induce heat transfer. With the IC chip 160 mounted to the cavity floor 135, the heat transfer path, indicated by arrows 315, now extends through the cavity floor directly to the flat plate 310 which is utilized as a heat sink. Thermal management is greatly affected by removing heat through the cavity floor since a heat sink applied directly to the chip carrier 100 provides a much shorter thermal path than does the conventional thermal management approach shown in FIG. 1.
The estimated thermal impedance for the path shown in FIG. 5 is approximately 0.46° C. per watt. This assumes the body 115 to be made of a ceramic of aluminum oxide with a cavity floor thickness of 0.015 inches. The cavity up chip carrier shown in FIG. 1 has an estimated thermal impedance of 3.64° C. per watt. As can be seen, the improved heat transfer between the chip carrier shown in FIG. 1 and that shown in FIG. 5 is substantial.
Finally note that the base 115 and the ledges 145 and 150 should be of the same material, which could be ceramic and be comprised of one of the materials of aluminum oxide, beryllia or aluminum nitride.
Although this invention has been described with reference to a specific embodiment thereof, numerous modifications are possible without departing from the invention, and it is desirable to cover all modifications falling within the spirit and scope of this invention. | The invention is an improved chip carrier assembly utilizing a cavity-down chip carrier with a pad grid array wherein the IC chip within the chip carrier is mounted against a surface opposite the PWB to which the chip carrier is attached such that heat transfer from the IC chip may occur along a short path to a heat sink such that a large heat transfer rate is possible. Furthermore, the apparatus utilizes an alignment and electrical connection means between the contact pads of the chip carrier and a PWB to which the chip carrier is attached to compensate for shrinkage variation which occurs during the chip carrier fabrication process. Furthermore, within the cavity of the chip carrier there is space for additional components such as a decoupling capacitors. This permits the design of an apparatus providing better heat transfer properties, more accurate contact pad locations and the option of including within the chip carrier components which in the past had been mounted outside of the chip carrier. | 7 |
[0001] This application claims the benefit of U.S. Provisional Application No. 60/754,620, filed Dec. 30, 2005, which is herein incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The invention relates generally to a power adapter, and more particularly, to linear AC/DC power adapters with power efficiencies.
[0004] 2. Background of the Invention
[0005] A conventional linear AC/DC power adapter that is commonly used in consumer electronics such as cordless telephones includes a diode bridge composed of four conventional diodes. The use of conventional diodes contributes in reducing the adapter power efficiency, which, along with other component power consumption, fails to comply with the Appliance Efficiency Regulations promulgated by California Energy Commission. To solve the problem, one available technical option is to use switching power adapters. Such adapters, however, are expensive and may add electrical side effects to the telephone. Known side effects include, for example, noise, radiated emissions, and poor isolation between an electricity main ground and a telephone line ground.
[0006] An improved linear adapter uses a better-quality core for a transformer to reduce core losses. This improvement results in AC/AC adapters passing the California regulation, but AC/DC adapters still do not comply the regulation. Accordingly, there is still a need for an AC/DC power adapter with higher power efficiency.
BRIEF SUMMARY OF THE INVENTION
[0007] Certain embodiments of the invention provide an AC/DC power adapter used in consumer electronics such as cordless telephones. The AC/DC power adapter replaces conventional diodes of a diode bridge with Schottky diodes. The use of Schottky diodes reduces the heat dissipation of the bridge to increase the power efficiency.
[0008] In some embodiments of the invention, an AC/DC power adapter includes a transformer for reducing the level of an input AC voltage, a rectifier bridge coupled to an output of the transformer for changing the AC voltage to DC voltage after reduced, and a filter capacitor for reducing the ripple of the voltage after rectified, wherein the rectifier bridge is composed of four Schotty diodes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a electrical circuitry of an AC/DC power adapter in accordance with the present invention.
[0010] FIGS. 2-6 are tables showing experimental results.
DETAILED DESCRIPTION OF THE INVENTION
[0011] As illustrated in FIG. 1 , a linear AC/DC power adapter 10 includes a linear transformer 11 , a rectifier bridge 12 , and a filter capacitor 13 . Linear transformer 11 is used to reduce and isolate an alternating current/voltage (AC) input voltage. Rectifier bridge 12 is used to convert AC to direct current/voltage (DC). Filter capacitor 13 is used to reduce the DC voltage variations or ripple. Conventionally, the rectifier bridge is composed of four conventional rectifier diodes. Ideally, there is no energy consumption in the adapter. The energy is just transferred from the adapter input to the output. However, real adapters dissipate energy in heat form at linear transformer 11 , rectifier bridge 12 , and filter capacitor 13 . Linear transformer 11 has energy losses due to its coil resistances and core. Rectifier bridge 12 consumes energy due to its voltage drop greater than zero. Filter capacitor 13 has contact and insulator resistance, which also dissipates heat.
[0012] Embodiments of the present invention use Schottky diodes to replace the conventional diodes of rectifier bridge 12 . Schottky diodes have smaller voltage drop than conventional diodes. For example, typical voltage drop values are 0.4V for Schottky diodes and 0.7V for conventional diodes. This voltage drop reduction causes less heat dissipation on rectifier bridge 12 .
[0013] The use of Schottky diodes instead of conventional diodes in Linear AC/DC power adapters improves power efficiency. It is a reliable, economic, and simple way to comply with Appliance Efficiency Regulations from California Energy Commission (CEC). Further, by using Schottky diodes, no electrical side effects occur in AC/DC power adapter 10 so that the reliability of linear adapters is maintained.
[0014] The use of Schottky is believed never been seen in linear AC/DC power adapters nor in any technical publication. Due to a smaller voltage drop of the Schottky rectifier diodes, rectifier bridge 12 composed of Schottky rectifier diodes potentially dissipates less energy than conventional rectifier diodes, as it is proved in FIGS. 2-6 .
[0015] FIG. 2 shows test results of three different adapters, rated at 9 VDC 600 mA, 9 VDC 400 mA, and 9 VDC 200 mA, respectively. All of the adapters include an improved transformer core and a conventional rectifier bridge. As shown, a full load efficiency of all of them is less than a CEC average efficiency.
[0016] FIG. 3 shows test results of the same adapter rated at 9 VDC 600 mA used in the test of FIG. 2 , but now with Schottky diodes in its rectifier bridge. The first row indicates the full load efficiency is 63.5% that is better than 60.9% with conventional diodes. Thus, the average efficiency is 71.4%, which is more than a required efficiency of 65.2%.
[0017] FIG. 4 shows test results of the same adapter rated at 9 VDC 400 mA used in the test of FIG. 2 , but now with Schottky diodes in its rectifier bridge. The first row indicates the full load efficiency is 59.4% instead of 57.5% with conventional diodes. Thus, the average efficiency is 65.6%, which is also more than a required efficiency of 61.5%.
[0018] FIG. 5 shows test results of the same adapter rated at 9 VDC 200 mA used in the test of FIG. 2 , but now with Schottky diodes in its rectifier bridge. The first row of the result indicates the full load efficiency is 56.8% instead of 53.4% with conventional diodes. Thus, the average efficiency is 59.0%, which is still more than a required efficiency of 55.3%.
[0019] FIG. 6 shows test results of a different adapter that is rated at 9 VDC 400 mA and has an improved transformer core. As shown, the power efficiency with conventional diodes is not enough to pass CEC requirement. However, the same adapter with Schottky diodes instead of conventional diodes passes the CEC requirement with margin.
[0020] According to the present invention, AC/DC power adapters 10 has at least the following advantages:
(1) No adapter dimension changes required; (2) Easy to manufacture; (3) Reduce heat dissipation of a whole telephone; and (4) No electric side effects, for example no noise added and high insulation between power main ground and telephone line ground.
[0025] Furthermore, although the rectifier bridge shown in FIG. 1 is composed of four Schottky diodes as a full wave rectifier, the number of the Schottky diodes is not limited to four. For example, the rectifier bridge can also be a half wave rectifier, in which only two Schottky is included in the rectified bridge.
[0026] The foregoing disclosure of the preferred embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein will be apparent to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims appended hereto, and by their equivalents.
[0027] Further, in describing representative embodiments of the present invention, the specification may have presented the method and/or process of the present invention as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to the method and/or process of the present invention should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the present invention. | An AC/DC power adapter comprising a transformer and a rectifier bridge. The rectifier bridge replaces the conventional diodes with Schottky diodes. Due to a low voltage drop, the heat dissipated by the rectifier bridge is decreased and the power efficiency of the rectifier bridge is significantly increased. | 7 |
RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 61/090,003, filed Aug. 19, 2008, entitled TENNIS RACKET WITH ADJUSTABLE BALANCE AND METHOD FOR USING THE SAME, by Cristina M. Cook, the entire disclosure of which is herein incorporated by reference.
FIELD OF THE INVENTION
This invention relates to a novel tennis racket design in general that may be utilized for training, demoing, as well as point play allowing players to adjust the balance of the racket between points or drills.
BACKGROUND OF THE INVENTION
Current tennis rackets come in a wide variety of designs with every racket having a predetermined balance. The performance of the racket is greatly affected by its balance—the weight distribution from head to butt cap. For the purpose of teaching/learning tennis (ranked in the top ten most difficult games to play), a head-heavy balance distribution is highly preferable for ground strokes, while a head-light distribution is preferable for volleys. To date, there is not a racket that allows the flexibility while learning the game to have both head-heavy and head-light in one racket.
With respect to demoing (the period of time before the purchase of a racket, when a player borrows several different rackets from a retail or other source to test before committing to a purchase), the ability to alter the balance of the racket allows the customer to borrow a single racket instead of many that they can adjust to their personal balance preference. A racket can then be finally selected based on the player's preferred balance selection. This narrows the purchasing field from several hundred distinct rackets and brands to just a few, thus drastically reducing the lag time before the purchase of a racket.
For general game play, different weight distributions in a racket accommodate different styles of play. For instance, someone who prefers playing from the baseline, a head-heavy (weight distribution toward the top or the head of the racket) balance might be most appropriate. Conversely, a head-light balance would be more suited to a serve and volley player. In regular game play a player often changes styles of play from point to point for various reasons including exploiting a particular opponent's weakness, or in response to an opponent exploiting their weakness, accommodating different court surfaces, weather conditions, or even personal temperament. The ability to alter the racket balance optimizes the racket for different styles of play from point to point. Creating a head-heavy balance shift can aid in countering headwinds or adding extra power to strokes that might not otherwise be generated. The different court surfaces—for example, clay courts slow down the ball and produce a high bounce, while grass courts are the fastest type of tennis court, and hard courts are considered “medium” surfaces—each favor different styles of play.
To address the singularity of balance within a racket several previous inventions have developed mechanisms, each of which has their own drawbacks. U.S. Pat. No. 6,432,004 B1, for example, proposes an add-on weight system that is pressure fit within the throat of the racket. This mechanism, while allowing for adjustability, interferes with the pre-established aerodynamics of the racket. It also places large amounts of pressure on the frame and provides extra pieces that can dislodge at high speed, and cause injury to a player or spectator. These same disadvantages are present in U.S. Pat. Nos. 4,179,121 and 4,427,195. An early concept for dynamically changing the racket balance during use is taught in U.S. Pat. No. 3,907,292. However, this concept is based on out-of-date racket technology that would not apply to modern constructions. Moreover, this approach is a violation of the ITF definition of a racket (due to the dynamically changing balance).
It is therefore desirable to provide a system that allows the balance of the racket to change while securely maintaining the chosen balance during play. The choice of the change becomes conscious and deliberate, thus educating the player [on the effects of balance] while improving their performance. The mechanism for allowing balance change should be easy to use, not compromise structural integrity of the racket, and maintain the original lines of the racket without protuberances or parts that can be accidentally dislodged. It should, more generally, allow the racket to comply with any applicable rules and regulations of the game.
SUMMARY OF THE INVENTION
This invention overcomes the disadvantages of the prior art by making the balance change a conscious decision made by the player between points, games, or exercises. The entirety of the mechanism is contained within the frame in the grip portion of the racket, thus eliminating undesirable stresses on the racket frame and the possible liability of loose parts. The mechanism replaces the current popular option of a static structure within the frame's grip for a different structural system, with a weight that can be adjusted according to the most desirable balance.
The mechanism may have different levels of complexity depending on the end purpose. For example, with a training device for learning purposes having 2 weight positions is sufficient (keeping the user interaction simple, while still allowing for both the head-heavy and the head-light positions), where as a mechanism for demo purposes and point play need more micro-adjustability. One variation is primarily a training device and has the ability for gross adjustments from head-heavy to head-light. An alternate mechanism allows for micro-adjustments along the entire length of the mechanism. The concept is easily altered for players at various levels of competition. The adjustment then becomes an additional control for the player when variables such as but not limited to, weather, court surface, opponent, personal play for that moment (ie switching weight distribution depending on the style of play desired for that particular point or micro-adjustments based on mistakes or weaknesses). The entirety of the mechanisms is contained within the racket (more specifically within the handle of the racket) so as to alleviate the problems encountered by previous art of altered aerodynamics and stray parts and safety. The racket itself adapts to its predecessors in appearance—thus generating an immediate understanding of its general use—while also providing a bit of extra customizability for optimized play.
An additional advantage to this system is that it affords a wider range of players the ability to play with the same racket. For families or clubs that have multiple players who may have differing styles of play, one racket can be purchased and adjusted to suit each individual when they are playing.
More particularly, this invention provides a racket that allows for the adjustability of balance within the structure of the racket. The racket's adjustment mechanism and its function are easy to use to use and optimize any player's game. The adjustment mechanism resides in the handle in a manner that does not substantially (or in any way) alter the aerodynamic profile of the racket or affect its usability by providing unwanted external structures. Rather a movable mass/weight is contained within a hollow space of the handle and can be moved upwardly and downwardly along the handle using a guide mechanism and fixing or locking structure that can be illustratively activated by rotating a knob at the lower end of the racket handle (or by another low-profile external trigger). This can comprise a shaft with a thread or key that engages a corresponding thread or key slot on the mass/weight. The knob can include an indexing mechanism that facilitates rotatable restraint and/or alignment of the knob when not in use.
In an illustrative embodiment, the racket handle includes a guide located within a hollow interior space of the handle. The guide extends between opposing ends of the hollow space. A weight or mass slides with respect to the guide between at least two opposing locations approximately adjacent to each of the opposing ends. A locking mechanism is constructed and arranged to selectively lock the weight in and unlock the weight from each of the opposing locations. The guide and the locking mechanism of the illustrative embodiment are each constructed and arranged to locate and lock the weight in at least one intermediate location along the handle between each of the opposing locations.
In one embodiment, the guide comprises a keyed shaft and the weight includes a corresponding key slot, the shaft being located between opposing locators within the handle that allow the shaft to rotate within a predetermined range to selectively lock and unlock the weight with respect to the shaft by moving the key out of and into alignment with the key slot, respectively. In another embodiment the guide comprises a threaded shaft and the weight includes a mating threaded hole, the shaft being located between opposing locators within the handle that allow the shaft to rotate to selectively move the weight along the handle to a predetermined adjustment location. In various embodiments requiring rotation of the shaft, the shaft extends externally to a butt end of the racket. The external portion of the shaft is operatively connected to a graspable knob attached to the shaft at the butt end that allows the shaft to be rotated thereby. An indexing mechanism can be provided to the knob to rotatably restrain and report alignment of the knob at a predetermined location with respect to the butt cap. In this manner, the user feels a “click” when the knob is appropriately aligned to lock or unlock the weight, and the knob is generally restrained from free movement in this position so that the adjustment remains fixed during racket use.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention description below refers to the accompanying drawings, of which:
FIG. 1 is a diagram showing the general shape of a typical, commercially available tennis racket according to the prior art;
FIG. 1A is a side cross section showing the current rigid internal structure of the racket handle of the typical commercially available tennis racket of FIG. 1 ;
FIG. 1B is a frontal cross section of the racket handle of FIG. 1 ;
FIG. 2 is frontal cross section of a tennis racket handle having an internal mechanism that allows for gross balance adjustments according to an illustrative embodiment of the invention;
FIG. 2A is a partial perspective view of the internal rod for the handle of FIG. 2 showing the uppermost portion where the rod transitions from a keyhole cross section to a round cross section and where the weight is locked in place;
FIG. 2B is a top view of the butt cap of the racket handle of FIG. 2 , showing the knob (user interface) which is used to rotate the rod, locking and unlocking the weight;
FIG. 2C is a top view of a weight used to effect a balance shift according to an illustrative embodiment of this invention, also showing the key hole that allows the weight to move along the shaft and be locked in place;
FIGS. 3A and 3B show partially exposed front views of the entire racket including a balance-adjustment mechanism in the handle according to the embodiment of FIG. 2 , depicting how orienting the racket allows the user to utilize gravity to change the weight position;
FIG. 3C shows a top view of the butt cap of the racket of FIGS. 3A and 3B in which the knob aligned (with indicator arrows askew) in the locked position;
FIG. 3D shows a top view of the butt cap of the racket of FIGS. 3A and 3B in which the knob is in the unlocked position (with indicator arrows aligned);
FIG. 4 is a frontal cross section front view of a threaded shaft and weight mechanism which allows for micro-adjustments of balance within the racket handle according to an illustrative embodiment;
FIG. 4A is a top view of a weight that moves along the threaded shaft within the racket handle; and
FIG. 4B is a top view of the racket handle's butt cap showing the knob (user interface) which allows for the manipulation (up and down the threaded shaft) of the weight with an optional external indicator to show the weight location.
DETAILED DESCRIPTION
FIG. 1 depicts a typical, modern, commercially available tennis racket 100 according to the prior art. The racket includes a strung head 110 with a frame 112 . The head 110 extends downwardly to a pair of base members 114 (the throat) that interconnect with the racket handle 120 . The handle 120 extends to a butt cap 122 . The handle 120 includes a covering that enhances the user's grip. Most modern tennis rackets are constructed from a lightweight and durable composite, such as carbon fiber composite. To reduce weight, the handle 120 is often hollow along the majority of its length LH, and/or are filled with a lightweight foam filler. In either case, the handle is constructed from a shell that can provide an interior that can receive an internal balancing mechanism, surrounded by an outer shell. Where the racket design is such that a structural foam or other internal material is replaced with the mechanism, the mechanism can itself act as a reinforcing structure in accordance with this invention.
The internal structure of the hollow racket handle 120 is shown in further detail in side and front cross section in FIGS. 1A and 1B , respectively. FIG. 1A shows a side view of the wavy carbon fiber weighting structure 130 that is generally contained within the walls 140 of the handle 120 . FIG. 1B shows a front view of the same weighting structure 130 , detailing the structure's 130 full width WW across the interior of the handle 120 . Fixed weights 150 and 160 , which can define pieces of lead, are distributed at predetermined locations along the length of the structure 130 to achieve a specific set balance for that particular racket 100 . In this example one weight 150 is located near the top of the racket handle and another is located at the bottom. The distribution of weights can be varied at the factory to customize the racket, but this requires careful placement of the weights in the structure 130 .
FIGS. 2-2C depict one the internal sliding mechanism contained within the handle 200 of the racket according to an embodiment of this invention. A central shaft 204 is contained within the material that makes up the shell walls 210 of hollow handle 200 between two locators 220 and 222 that are affixed at each of opposing ends of the interior of the handle 200 . The locators 220 , 222 can be inserted and adhered to the inner surface of the handle wall 210 using fasteners, adhesives or by molding techniques. The locators 220 , 222 center the shaft 204 within the handle 200 , and keep it stable and coaxially aligned with the handle. A pair of opposing through-holes in each of the respective locators 220 , 222 each receive the opposing ends 224 , 226 of the rod 204 and allow the rod 204 to freely rotate with respect to the locators. To axially retain the rod 204 , a circlip, or other removable fastener 228 can be positioned along at least one portion of the rod (e.g. adjacent to the top surface of the top locator 220 ).
In FIG. 2 the rotatable central rod 204 is attached through the butt cap 230 (or another structure that defines the handle's butt end) via a through-hole, and secured to an external knob 238 . When knob 238 is turned, (double curved arrow 240 ), it transmits rotation to the rod 204 itself. The knob can be relatively low in profile (axially) and fits within the perimeter of the butt cap 230 . In this embodiment, it includes a pair of concave reliefs 250 that are sized and arranged to receive the user's fingers and assist in rotation the knob with respect to the butt cap 230 . The surface of the knob 238 (or graspable portions thereof) is highly variable. It can be textured in an illustrative embodiment for greater gripping friction. Likewise, the knob 238 and other operatively connected components can be constructed from a variety of materials including, but not limited to, polymers, composites and/or metals.
A movable weight 260 can be constructed from lead, or another appropriate, high-density material, is provided within the handle interior. Its outer perimeter 261 is sized and arranged similarly, or approximately smaller than, the inner perimeter of the handle wall 210 . As shown the weight 260 and corresponding handle inner perimeter are each ovular. Thus, the weight 260 is restrained from free axial rotation with respect to the handle 210 . The weight 260 is slidable along the shaft 204 with a slot 262 that is sized similar to or greater than the diameter DS of the shaft 204 .
Notably the shaft 204 includes a key 270 that extends radially from the cylindrical surface of the shaft. The key 270 includes opposing upper and lower ends 272 and 274 , respectively, which are located so as to accommodate the height HW of the weight 260 when confronting either the upper locator 220 or lower locator 222 . That is the weight 260 resides beneath the respective end 272 , 274 of the key 270 in the uppermost (shown in phantom) and lowermost positions.
The weight defines a central hole 262 that includes a conforming key slot 280 . The key slot 280 is sized to be similar to, or slightly larger than, the key 270 so that when the key 270 is rotationally aligned with the slot 280 , the weight can pass over the shaft 204 and transition between the uppermost and lowermost positions. When not aligned the key ends 272 and 274 are interfered-with by the surface of the weight 260 , thus preventing a sliding motion. In this manner, rotating the shaft 204 allows the weight to be selectively locked in place in either the uppermost or lowermost position, or unlocked to be slidable along the shaft to one or the other position. In this manner, the position is adjustable to either a head-heavy (weight in uppermost position or head-light (weight in lowermost position). The shaft length SL, and thus the weight shift distance, is determined by the length of the handle within which it is contained which can vary from racket to racket but the length of the shaft is generally made to optimize the full length of the handle.
As shown in FIGS. 2 and 2B , the knob 238 facilitates rotation of the shaft 204 between the locked and unlocked positions. In this embodiment, to allow indexed positioning of the locked and unlocked states, the knob 238 and butt cap 230 include a spring-loaded ball assembly 290 and opposing detents 292 that allow the knob to be rotated into at least two perpendicular orientations wherein the knob is rotatably restrained in each position by a light-but-noticeable “click.” A variety of other indexing mechanisms that allow restraint in each of the locked and unlocked positions are expressly contemplated and should be clear to those of ordinary skill.
As demonstrated in FIG. 3A and FIG. 3B , a racket 300 having the novel, adjustable handle 200 allows the weight 260 to be moved between resting positions through the use of gravity. By orienting the racket and turning (curved arrow 326 ) the knob 238 to the unlocked position (as shown in FIG. 3D where an indication arrow 330 on the knob 238 is aligned with another arrow 332 on the butt cap 230 .), allowing the weight 260 to shift (arrows 328 ) to one end and then locking knob 238 (as shown in FIG. 3C wherein the knob arrow 330 is not aligned with an arrow 332 on the butt cap 230 ). This position indicates that the weight is locked in place, either in the head-heavy ( FIG. 3A ) or head-light ( FIG. 3B ) orientation.
FIGS. 4-4B depict an alternate embodiment of a racket handle 400 that can be part of an overall tennis racket as described herein. The handle 400 allows for micro-adjustment of the position of the internal weight 410 . The handle 400 , thus includes a pair of opposing upper and lower locators 420 and 422 that are affixed within the inner perimeter of the handle's hollow space 418 . A threaded shaft 404 runs down the central axis of the handle 400 , and through holes in each of the locators 420 422 . The shaft 404 rotates freely with respect to the locators 420 , 422 , as the opposing ends 424 and 426 of the shaft 404 are unthreaded and cylindrical. The shaft 404 can be secured to the upper locator 420 by a circlip or similar retaining structure 428 as shown. Again, the central shaft 404 is attached through the butt cap 430 to a knob 438 . Notably, the weight ( FIG. 4A ) includes a threaded central hole 462 . The size and pitch of the threaded hole 462 of the weight 410 matches the size and pitch of the threads 464 on the shaft 404 . By rotating the knob 438 , and hence the shaft 404 , the weight moves (double arrow 466 ) along the inner space 418 of the handle 400 between a lowermost (as shown) position adjacent to the lower locator 422 , a highly variable central position (an example being shown in phantom), and uppermost position, adjacent the upper locator 420 . The pitch of mating threads determines the distance weight 208 travels with each 360-degree rotation (double curved arrow 468 ) of knob 438 . A greater thread count along threaded shaft 404 allows for greater micro-adjustment. Each full rotation of knob 438 moves the weight a predetermined distance along threaded shaft 404 —depending upon the pitch of the threads. The internal geometry of the handle and weight or another anti-rotation component can prevent the rotation of the weight as the shaft rotates, thereby ensuring that rotational motion of the shaft is translated into axial movement for the weight.
The direction of the movement of weight 410 is determined by the direction of rotation of knob 438 and thus threaded shaft 404 . The rectangle labelled ‘indicator’ located below the lower locator 422 can contain a gear/cog system, digital meter, or any other mechanical or digital means of translating the movement of weight 410 to external readout/indicator 470 . The external readout 470 can be digital or mechanical or any other method that translates the movement of weight 410 into readable information for the user to see. The external readout 470 is represented in the illustrative embodiment by a series of circular cut-outs through butt cap 430 which progressively increasing in diameter, indicating their increasing closeness to the head heavy weight extreme at the top of handle 400 . As the weight 410 travels up threaded shaft 404 more of the circular cut-outs of external readout 470 are darkened—shown here with the smallest circle filled depicting weight 410 at the bottom of the handle 400 . The knob 438 can include grip structures 450 to assist in grasping the knob as it is rotated. It can also include an indexing structure that allows the knob 438 to be restrained against free rotation. In this example a ball and spring 490 assembly engages a detent 492 in the butt cap 430 . Rotation overcomes the engagement pressure. Each time the knob rotates 360 degrees (in this embodiment) the user feels a click. The knob can be restrained in the engaged position after a click is felt, and will remain in that position with the weight moved to the appropriate location within the handle.
It should again be noted that, in any of the embodiments herein the mechanism for indexing and/or locking/unlocking the knob with respect to the handle is highly variable. In alternate embodiments, the knob can be replaced with another component such as a hex-wrench socket provided within the butt cap. Likewise the knob can be secured to the shaft in any acceptable manner, using, for example pins, screws, splines, keys and the like. The shaft can, itself be mounted into the handle in a variety of manners. Also, while a shaft is used to move and lock/fix the weight, in alternate embodiments another structure that surrounds the outside of the weight (a rotatable, threaded cylinder provided within the handle for example) can be used to move and lock/unlock the weight.
It should be clear that the various embodiments herein define a novel racket, for use in a variety of sports. In general each racket defines a frame structure, generally conventional in size, shape, appearance and overall weight, but constructed and arranged to allow multiple weight distribution characteristics in response to a manipulation of an internal weight and external adjustment mechanism by the user. In this manner, the racket is readily adjustable to the user's specification without the need of external weights or other impractical, and non-regulation structural components.
The foregoing has been a detailed description of illustrative embodiments of the invention. Various modifications and additions can be made without departing from the spirit and scope if this invention. Each of the various embodiments described above may be combined with other described embodiments in order to provide multiple features within a single embodiment. Furthermore, while the foregoing describes a number of separate embodiments of the apparatus and method of the present invention, what has been described herein is merely illustrative of the application of the principles of the present invention. For example, the threaded rod and the keyhole rod are just two options on how to embody this concept. In alternate embodiments the movement and locking of the weight at different locations along the handle can be effected using external locking structures (for example screws or spring-loaded, trigger activated buttons located along the side of the handle. A ratchet mechanism can also be used to move and fix the weight at various locations along the handle. The weight may also be guided along the handle interior by a plurality of guide structures, such as channels. The weight assembly can in fact be provided to the hollow part of the handle as a separate insert assembly that is passed into the base during construction of the racket. Likewise, a rotatable key shaft can also be provided with intermediate areas that are non-keyed so that careful sliding of the weight can deposit the weight at such intermediate locations. In one embodiment, the key in each portion of the shaft (between non-keyed sections), can be located at a slight arcuate offset. In this manner, the weight stops at each intermediate location resting on the slightly misaligned key section's end, and requiring a slight twist of the shaft to align the next key section and thereby pass the weight onto that next key section. Finally, while the principles herein are applied to a tennis racket, the terms “tennis racket” and “handle” should be taken broadly to include other handheld sporting rackets and implements (for example, racquetball rackets, squash rackets, bats, etc.) that would benefit from the ability to adjust weighting over a predetermined range. Many other variations on style of the central rod and shape and dimension of the individual pieces can yield the same results. Likewise, the appearance of the indicator, if employed, can be highly variable. Accordingly, this description is meant to be taken only by way of example, and not to otherwise limit the scope of this invention. | This invention provides a racket that allows for the adjustability of balance within the structure of the racket. The racket's adjustment mechanism and its function are easy to use and optimize any player's game. The adjustment mechanism resides in the handle in a manner that does not substantially (or in any way) alter the aerodynamic profile of the racket or affect its usability by providing unwanted external structures. Rather a movable mass/weight is contained within a hollow space of the handle and can be moved upwardly and downwardly along the handle using a guide mechanism and fixing or locking structure that can be illustratively activated by rotating a knob at the lower end of the racket handle (or by another low-profile external trigger). This can comprise a shaft with a thread or key that engages a corresponding thread or key slot on the mass/weight. The knob can include an indexing mechanism that facilitates rotatable restraint and/or alignment of the knob when not in use. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to shoe soles and more particularly to a planarized ventilated insole including a plurality of conduits each having a triangular section so that fresh air can be introduced into the insole during walking for comforting and drying the footbed of a wearer.
[0003] 2. Description of Related Art
[0004] Sole of a shoe is provided for wear resistant and cushioning purposes during walking. Further, comfort, shock absorbing capability and ventilation are a shoe sole are needed to consider in the devising stage.
[0005] Ventilation of most typical ventilated insoles is achieved by cooperating with other layers of a sole or being integrally formed therewith. For example, Taiwan Utility model No. 180,846 entitled “Removable ventilated insole” discloses an internal bladder, a one-way entry valve, and a one-way exit valve. The entry and exit valves are removably provided at one side of the bladder for communicating air with the exterior of a shoe. The bladder and adjacent valves are removably disposed in a cavity at a front portion of the sole. Taiwan Utility model No. M312,209 entitled “Unitary ventilated insole” discloses a projection on a heel, the projection including a hollow cylinder having a central stem as support and a plurality of entry and exit troughs on a periphery communicating with the hollow cylinder. However, a wearer cannot replace the ventilated insole when it is worn due to its unitary characteristics. Further, it is useless when it is removed. This can adversely decrease the applicability of the ventilated insole and thus decrease consumer's selections.
[0006] For allowing consumers to replace a worn ventilated insole by themselves, a number of removable ventilated insoles have been devised. For example, Taiwan Publication No. 200624048, entitled “ventilated insole” discloses a main layer, a spacer layer, a first and a second one-way valve, and a bladder. The bladder communicates with the aperture. The first one-way valve is between the main layer and the spacer layer for introducing external air into the bladder. The second one-way valve is between the main layer and the spacer layer for exiting smell air from the aperture to the atmosphere. However, it is disadvantageous because the bladder is too large to sufficiently suck air or purge air. As a result, air in the bladder is still rather than being expelled or refreshed by external air. The ventilation effect is very poor.
[0007] Among prior art literature, a number of patents regarding ventilated insole which allow users to replace the worn insole and have conduits for purging air are disclosed. For example, Taiwan Utility Model No. 515,243, entitled “removable ventilated insole” discloses a pad, a bladder, at least one entry conduit, a first one-way valve in the entry conduit, at least one exit conduit, and a second one-way valve in the exit conduit. The bladder is in the heel of the pad and is comprised of internal elastic members of springs. Entry and exit are provided on the bladder and connected to the entry and exit conduits respectively. The footbed intermittently presses bladder during walking so as to introduce fresh air into the bladder through the entry conduit and exit smell air from the bladder to the atmosphere through the exit conduit. However, a number of drawbacks have been found in the removable ventilated insole having entry and exit conduits as detailed below.
[0008] 1. The entry and exit conduits are liable to block because if they are made of flexible material.
[0009] 2. A wearer may have a feeling of pain because something hard touches his/her footbed during walking if the entry and exit conduits are made of hard material.
[0010] 3. The exposed bladder is liable to wear and thus an uneven surface is formed on the outsole. To the worse, the wearer may slip during walking due to decreased friction.
[0011] 4. The single conduit arrangement can purge air to the front of the footbed, thereby limiting air flow in a single path between two specific toes.
[0012] 5. The exposed bladder can be blocked by foreign objects if it is worn. Further, the wearer may have a feeling of uncomfortable when the footbed touches the curved one-way valve.
[0013] 6. The elastic members of springs inside the bladder may hurt the foot during walking after aging. In view of above problems including being no provision of planarized ventilated insole and unsuccessful commercialization experienced by the prior art, the inventor thus devises a novel ventilated insole by eliminating the prior problems. The ventilated insole of the invention is thin, simple, easy to manufacture, durable, comfort during walking, and appropriate for mass production.
SUMMARY OF THE INVENTION
[0014] It is therefore one object of the invention to provide a planarized ventilated insole for carrying out forced ventilation through the shoe during walking. Further, the insole can be disposed in one of a variety of shoes and brings a degree of comfort and dryness to the foot of a wearer.
[0015] In a first aspect of the invention, there is provided a planarized ventilated insole comprising a pad comprising an upper member and a lower member secured to the upper member; a bladder disposed in the pad; an air entry disposed in the pad; an air exit disposed in the pad; an entry conduit disposed in the pad for interconnecting the air entry and the bladder; at least one exit conduit disposed in the pad for interconnecting the bladder and the air exit; and two one-way valves wherein one one-way valve is disposed at a joining portion of the bladder and the entry conduit and the other one-way valve is disposed at a joining portion of the bladder and the at least one exit conduit; wherein the lower member covers both the entry conduit and the at least one exit conduit from below; wherein the upper member comprises an upper opening with an upward arched upper half of the bladder fastened therein; wherein the lower member comprises a lower opening with a downward arched lower half of the bladder fastened therein; and wherein each of the entry conduit and the at least one exit conduit has a triangular section so as to increase resistance to external force, thereby facilitating air flow in the entry conduit and the at least one exit conduit and planarizing the pad.
[0016] Preferably, thickness of the pad externally of the bladder is in the range of about 2 cm to 5 cm.
[0017] Preferably, further comprises a plurality of equally spaced ribs radially extending from a center of the bladder to a periphery thereof wherein each of the ribs has a longitudinal section of half circle having an area gradually increased from a first end at the center of the bladder to a second end at the periphery of the bladder.
[0018] Preferably, further comprises a lengthwise arched ridge disposed in the entry conduit and a lengthwise arched ridge disposed in the exit conduit respectively.
[0019] Preferably, the air exit comprises a transverse exit groove under the pad and connecting to the exit conduit, and a plurality of exit apertures in the exit groove through the upper member, and wherein the air entry is concave on a rear end of the pad.
[0020] Preferably, each of the exit apertures comprises an arched top.
[0021] Preferably, the bladder comprises two channels at an edge, each channel having one of the one-way valves disposed therein and including a well; wherein each of the one-way valves comprises a divider plate including a through hole, and a flap including a hinge secured to the divider plate; and wherein the flap is vertical to close the through hole when no force is exerted on the bladder.
[0022] Preferably, the bladder comprises two tunnels each having an oval longitudinal section for disposing one of the one-way valves therein; wherein each of the one-way valves comprises an outer sleeve including a lengthwise slit on an outer surface and having a first end open to the bladder and a second end formed with a through hole, an inner sleeve of an oval longitudinal section, the inner sleeve including a lengthwise ridge on an outer surface, the ridge being inserted into the slit for assembling the outer and inner sleeves, and a flap pivotably secured to a first end of the inner sleeve, the flap being vertical to close the through hole when no force is exerted on the bladder.
[0023] In a second aspect of the invention, there is provided a planarized ventilated insole comprising a pad; an air entry disposed in the pad; and an air exit disposed in the pad; wherein the pad comprises an upper member, an upward arched upper element integrally formed with the upper member, a lower member secured to the upper member, and a downward arched lower element integrally formed with the lower member wherein the upper and lower elements are attached together to form a bladder.
[0024] Preferably, further comprises a plurality of spaced ribs radially extending from a center of the upper element to a periphery thereof, each of the ribs being of a longitudinal section of half circle and having an area gradually increased from a first end at the center of the upper element to a second other end at the periphery thereof; and a plurality of spaced ribs radially extending from a center of the lower element to a periphery thereof, each of the ribs being of a longitudinal section of half circle and having an area gradually increased from a first end at the center of the lower element to a second other end at the periphery thereof.
[0025] By utilizing the invention, the following advantages can be obtained:
[0026] 1. No conducts are required to mount in the insole. Thickness of the pad externally of the bladder is planarized to be in the range of about 2 cm to 5 cm. A wearer may not have a feeling of pain because something hard touches his/her footbed during walking. Wearer can feel a degree of comfort during walking.
[0027] 2. With the triangular sections of the entry conduit interconnecting the air entry and the bladder and the exit conduit interconnecting the bladder and the air exit rather than the typical circular section, pointed tops of the exit conduit and the entry conduit have are not liable to become flat or block when pressure is built thereon during walking. Further, the pad can be made thinner with decreased thickness. As a result, a wearer may feel a degree of comfort when wearing shoes incorporating the ventilated insoles during walking.
[0028] 3. A plurality of equally spaced ribs radially extend from a center of the bladder to a periphery thereof wherein each of the ribs has a longitudinal section of half circle having an area gradually increased from a first end at the center of the bladder to a second end at the periphery of the bladder. As a result, the bladder is capable of quickly returning to its original shape after releasing pressure exerted thereon.
[0029] 4. The one-way valves are easy to manufacture, install, and replace and are durable.
[0030] 5. The one-way valves having an oval longitudinal section can decrease height (i.e., thickness) of the bladder to a minimum. In addition to correct positioning, it is an error-proof design to prevent an erroneous installation from occurring.
[0031] 6. The one-way valves are disposed in the bladder and thus a wearer may not have a feeling of pain due to projections contacting his/her footbed during walking. Further, locations of air entry and air exit are not interfered. For example, the air entry can be disposed in a rear end of the pad. This eliminates the need of mounting a valve in an opening on an outer surface of outsole as experienced by the typical ventilated insole.
[0032] 7. The air exit is provided under the pad corresponding to the toes at the front of the footbed. Thus, the exit apertures correspond to the gaps between the toes and each exit aperture has an arched top. As a result, the exit apertures are not liable to be flattened or blocked by applying force thereon.
[0033] The above and other objects, features and advantages of the invention will become apparent from the following detailed description taken with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 is a perspective view of a ventilated insole according to a first preferred embodiment of the invention;
[0035] FIG. 1A is another perspective of the ventilated insole of FIG. 1 ;
[0036] FIG. 2 is an exploded view of the ventilated insole of FIG. 1 ;
[0037] FIG. 2X a detailed view of a circle X of FIG. 2 and FIG. 2Y a detailed view of a circle Y of FIG. 2 respectively;
[0038] FIG. 3 is a longitudinal sectional view of the air exit of FIG. 1 ;
[0039] FIG. 4 is a perspective view of the bladder of FIG. 1 ;
[0040] FIGS. 4A , 4 B and 4 C are broken away perspective views showing steps of mounting the one-way valve in the bladder;
[0041] FIG. 5 is a fragmentary perspective view of a ventilated insole according to a second preferred embodiment of the invention;
[0042] FIG. 5A is a detailed view of a circle of FIG. 5 ;
[0043] FIG. 6 is a longitudinal sectional view of FIG. 5 ;
[0044] FIG. 7 is a fragmentary view of FIG. 6 showing air being introduced into the bladder with the bladder being expanded;
[0045] FIG. 7A is a detailed view of a circle of FIG. 7 ;
[0046] FIG. 8 is a view similar to FIG. 7 showing air being expelled out of the bladder with the bladder being contracted after a result of pressing by the footbed;
[0047] FIG. 8A is a detailed view of a circle of FIG. 8 ;
[0048] FIG. 9 is an exploded view of the bladder of FIG. 5 ;
[0049] FIGS. 9A , 9 B and 9 C are views showing the construction of the one-way valve of FIG. 5A ;
[0050] FIG. 10 is an exploded view of a ventilated insole according to a third preferred embodiment of the invention;
[0051] FIG. 10A is a detailed view of the left circle of FIG. 10 showing entry conduit and
[0052] FIG. 10B is a detailed view of the right circle of FIG. 10 showing exit conduit respectively;
[0053] FIG. 11 is a fragmentary view of the heel portion of the ventilated insole of FIG. 10 but viewing from the bottom;
[0054] FIG. 11A is an enlarged broken away view of the air entry of FIG. 11 ;
[0055] FIG. 12 is a side elevation of a shoe showing the ventilated insole of FIG. 10 disposed therein;
[0056] FIG. 13 is a top view of the ventilated insole of FIG. 10 schematically showing the footbed thereon;
[0057] FIG. 14 is a longitudinal sectional view of the air entry and adjacent components of FIG. 11 ;
[0058] FIG. 14A is a view similar to FIG. 14 showing a depressing thereof during walking;
[0059] FIG. 15 is an exploded view of a ventilated insole according to a fourth preferred embodiment of the invention;
[0060] FIG. 15A is a fragmentary view of the left part of FIG. 15 and FIG. 15B is a fragmentary view of the right part of FIG. 15 respectively; and
[0061] FIG. 16 is a longitudinal sectional view of the assembled ventilated insole of FIG. 15 .
DETAILED DESCRIPTION OF THE INVENTION
[0062] Referring to FIGS. 1 to 4C , a ventilated insole in accordance with a first preferred embodiment of the invention is shown in which FIG. 1 is a perspective view of a ventilated insole according to the first preferred embodiment of the invention, FIG. 1A is another perspective of the ventilated insole of FIG. 1 and FIG. 2 is an exploded view of the ventilated insole of FIG. 1 . The ventilated insole comprises a pad 10 , a bladder 20 in the pad 10 proximate a heel portion, an air entry 30 on a rear end of the pad 10 , an air exit 40 in the pad 10 proximate a toe portion, an entry conduit 50 interconnecting the bladder 20 and the air entry 30 , and at least one exit conduit 60 (one being shown) interconnecting the bladder 20 and the air exit 40 .
[0063] The pad 10 comprises an upper member 11 and a lower member 12 secured to the upper member 11 . Each of the entry conduit 50 and the exit conduit 60 has a triangular section (see FIGS. 2X and 2Y ) and is disposed on the bottom of the upper member 11 . The lower member 12 is adapted to cover the entry conduit 50 and the exit conduit 60 from below. With the triangular sections of the entry conduit 50 and the exit conduit 60 , the entry conduit 50 and the exit conduit 60 have pointed tops which are not liable to become flat or block when pressure is built thereon during walking. Further, the pad 10 can be made thinner with decreased thickness. As a result, a wearer may feel a degree of comfort when wearing shoes incorporating the ventilated insoles during walking (see FIG. 10 ).
[0064] Thickness of the pad 10 externally of the bladder 20 is in the range of about 2 cm to 5 cm.
[0065] The upper member 11 comprises an upper opening 111 with an upward arched upper half of the bladder 20 fitted therein, and a plurality of projections 112 on a top, the projections 112 being for massaging the footbed. The upper member 11 further comprises a plurality of protrusions 113 on a bottom, the protrusions 113 being for pressing acupuncture points on the footbed (see FIG. 1A ). The lower member 12 comprises a lower opening 121 with a downward arched lower half of the bladder 20 fitted therein. The air entry 30 is on a rear end of the pad 10 .
[0066] Refer to FIG. 3 in conjunction with FIG. 2 in which FIG. 3 is a longitudinal sectional view of the air exit 40 of the first preferred embodiment of the invention. The air exit 40 comprises a transverse exit groove 41 connecting to the exit conduit 60 and being under the pad 10 , a plurality of exit apertures 42 in the exit groove 41 through the upper member 11 , each exit aperture 42 having an arched top 43 , and a plurality of half cylindrical pegs 44 on the edge of the exit groove 41 , the half cylindrical pegs 44 being projecting into the exit groove 41 for increasing the structural strength of the exit groove 41 . The exit conduit 60 is connected to the exit apertures 42 .
[0067] Refer to FIG. 4 and FIGS. 4A to 4C in conjunction with FIG. 2 according to the first preferred embodiment of the invention in which FIG. 4 is a perspective view of the bladder 20 of FIG. 1 , and FIGS. 4A , 4 B and 4 C are broken away perspective views showing steps of mounting the one-way valve 70 in the bladder 20 . The bladder 20 is shaped as a flying soccer. One one-way valve 70 is on an edge of the bladder 20 communicating with the entry conduit 50 , and the other one-way valve 70 is on the edge of the bladder 20 opposite to the first one-way valve 70 and communicating with the exit conduit 60 .
[0068] The bladder 20 comprises a channel 21 communicating with inside of the bladder 20 and the external thereof with each one-way valve 70 disposed therein, and a U-shape well 22 vertically disposed in the channel 21 . Each one-way valve 70 comprises a divider plate 71 and a flap 72 having a hinge 73 secured to the divider plate 71 .
[0069] The divider plate 71 has a central through hole 711 . Both sides and bottom of the divider plate 71 is sealingly fastened in the well 22 so that fresh air can only communicate from the entry conduit 50 to the bladder 20 through the through hole 711 of one one-way valve 70 and foul air can only communicate from the bladder 20 to the exit conduit 60 through the through hole 711 of the other one-way valve 70 . The divider plate 71 and the flap 72 of each one-way valve 70 are formed integrally from the same material with the hinge 73 of the same material made thinner.
[0070] The flap 72 is vertical to close one mouth of the through hole 711 due to gravity when the bladder 20 is not pressed. That is, fresh air can only communicate through the through hole 711 and the flap 72 of one one-way valve 70 to inside of the bladder 20 by pivotably pushing the flap 72 upward. In other words, air inside the bladder 20 is not allowed to exit by passing through the flap 72 and the through hole 711 of one one-way valve 70 . The divider plate 71 is shaped as trapezoid so as to prevent it from being incorrectly disposed in the complementarily shaped well 22 during installation.
[0071] Further, a plurality of equally spaced ribs 23 radially extend from a center of the bladder 20 to a periphery thereof. The rib 23 has a longitudinal section of half circle having an area gradually increased from one end at the center of the bladder 20 to the other end at the periphery of the bladder 20 . Thus, in response to being flexibly depressed, the bladder 20 can be quickly returned to its original shape after the depressing force is released.
[0072] The flap 72 of the other one-way valve 70 is at one end of the exit conduit 60 . Thus, air in the bladder 20 can only communicate through the through hole 711 and the flap 72 of the other one-way valve 70 to enter the exit conduit 60 . In other words, foul air in the bladder 20 can only communicate through the through hole 711 and the flap 72 of the other one-way valve 70 to enter the exit conduit 60 for exiting during walking.
[0073] The flap 72 of one one-way valve 70 is provided between the divider plate 71 and inside of the bladder 20 so that air is only allowed to enter the bladder 20 by pivotably upward pushing the flap 72 . A partial vacuum is created in the bladder 20 when a person wearing the shoe incorporating the ventilated insole lifts his/her foot. Thus, fresh air is introduced into the bladder 20 via the air entry 30 , the entry conduit 50 and one one-way valve 70 and next foul air is purged out of the bladder 20 by leaving the other one-way valve 70 , the exit conduit 60 and the air exit 40 in response to the footbed of the wearer pressing the bladder 20 .
[0074] Referring to FIGS. 5 to 9C , a ventilated insole in accordance with a second preferred embodiment of the invention is shown. The characteristics of the second preferred embodiment are substantially the same as that of the first preferred embodiment except the following: The bladder 20 comprises two tunnels 24 each having an oval longitudinal section for disposing either one-way valve 70 therein. Either one-way valve 70 comprises an outer sleeve 74 having one end open to the bladder 20 and the other end formed with a through hole 75 , a lengthwise slit 741 on an outer surface of the outer sleeve 74 , an inner sleeve 76 having an oval longitudinal section, a lengthwise ridge 761 on an outer surface of the inner sleeve 76 , the ridge 761 being adapted to insert into the slit 741 for assembling the outer and inner sleeves 74 , 76 in an error-proof manner. For facilitating manufacturing and quality control, a flap 77 is pivotably secured to the other end of the inner sleeve 76 . The flap 77 is vertical to close the through hole 75 . One end of the inner sleeve 76 is open to the bladder 20 .
[0075] Air introduction and air exit operations of the second preferred embodiment are the same as that of the first preferred embodiment. Air in the bladder 20 is only allowed to leave through the flap 77 of the other one-way valve 70 connected to the exit conduit 60 (see FIGS. 8 and 8A ). In short, air in the bladder 20 is expelled out to the atmosphere via the other one-way valve 70 and the exit conduit 60 in response to pressing the bladder 20 by the footbed of a wearer during walking. Fresh air is introduced into the bladder 20 via the entry conduit 50 and the flap 77 of one one-way valve 70 connected to the entry conduit 50 (see FIGS. 7 and 7A ). A partial vacuum is created in the flexibly expanding bladder 20 when a person wearing the shoe incorporating the ventilated insole lifts his/her foot. Thus, fresh air is introduced into the bladder 20 via the entry conduit 50 and one one-way valve 70 and next foul air is out of the bladder 20 by leaving the other one-way valve 70 , the exit conduit 60 and the air exit 40 in response to the footbed of the wearer pressing the bladder 20 .
[0076] Referring to FIGS. 10 to 14A , a ventilated insole in accordance with a third preferred embodiment of the invention is shown in which FIG. 10 is an exploded view of a ventilated insole according to the third preferred embodiment of the invention, and
[0077] FIG. 11 is a fragmentary view of the heel portion of the ventilated insole of FIG. 10 but viewing from the bottom. In FIG. 10 , the pad 10 is exploded in a sequence opposite to that of FIG. 2 in which the lower member 12 is correspondingly disposed on top of the upper member 11 .
[0078] In the third preferred embodiment, as shown in FIGS. 10A and 10B , for facilitating air flow a lengthwise arched ridge 51 is provided in the entry conduit 50 and a lengthwise arched ridge 61 is provided in the exit conduit 60 respectively. The provision of the ridges 51 , 61 thus can increase flexibility of the entry conduit 50 and the exit conduit 60 . In detail, force exerted from tops of the entry conduit 50 and the exit conduit 60 can be withstood by the ridges 51 , 61 so as to ensure a smooth air flow through the entry conduit 50 and the exit conduit 60 even when the entry conduit 50 and the exit conduit 60 are compressed to their minimums (see FIG. 14 ).
[0079] As shown in FIGS. 11 and 11A , on an upper portion of the air entry 30 , the upper member 11 comprises a thin piece 31 including a plurality of small apertures 311 for flowing air so that foreign objects are prevented from entering the triangular concave end of the entry conduit 50 to block same. It is desired that the foreign objects are prevented from entering the rear opening of the entry conduit 50 without interfering with air introduction.
[0080] Refer to FIGS. 12 and 13 in which FIG. 12 is a side elevation of a shoe 100 showing the ventilated insole of FIG. 10 disposed therein, and FIG. 13 is a top view of the ventilated insole of FIG. 10 schematically showing the footbed thereon. Preferably, for enabling a user to install the ventilated insole of the invention in the shoe 100 , the bladder 20 is provided at position at the heel 200 , the air entry 30 is provided on a rear end of the pad 10 corresponding to a rear end 201 of the heel 200 , and the air exit 40 is provided under the pad 10 corresponding to the toes 203 at the front of the footbed 202 . Thus, the exit apertures 42 correspond to the gaps 204 between the toes 203 . As a result, a maximum air introduction and expelling effect can be brought about to sufficiently dry the footbed and bring a degree of comfort thereto.
[0081] Referring to FIGS. 15 to 16 , a ventilated insole in accordance with a fourth preferred embodiment of the invention is shown in which FIG. 15 is an exploded view of a ventilated insole according to the fourth preferred embodiment of the invention, FIG. 15A is a fragmentary view of the left part of FIG. 15 , and FIG. 15B is a fragmentary view of the right part of FIG. 15 respectively. In the fourth preferred embodiment, the pad 10 A comprises an upper member 11 A, an upward arched upper element 111 A integrally formed with the upper member 11 A, a lower member 12 A secured to the upper member 11 A, and a downward arched lower element 121 A integrally formed with the lower member 12 A. The upper and lower elements 111 A and 121 A are attached together to form a bladder (see FIG. 16 ). This can simplify the assembly and the manufacturing processes.
[0082] A plurality of equally spaced ribs 13 A are radially extend from a center of the arched upper element 111 A to a periphery thereof. The rib 13 A has a longitudinal section of half circle having an area gradually increased from one end at the center of the arched upper element 111 A to the other end at the periphery of the arched upper element 111 A. A plurality of equally spaced ribs 14 A radially extend from a center of the arched lower element 121 A to a periphery thereof. The rib 14 A has a longitudinal section of half circle having an area gradually increased from one end at the center of the arched lower element 121 A to the other end at the periphery of the arched lower element 121 A. Thus, in response to being flexibly depressed, the arched upper and lower members 111 A and 121 A can be quickly returned to its original shape after the depressing force is released. This effect is the same as that described in the first preferred embodiment.
[0083] While the invention has been described in terms of preferred embodiments, those skilled in the art will recognize that the invention can be practiced with modifications within the spirit and scope of the appended claims. | A ventilated insole including a pad ( 10 ) having a bladder ( 20 ), an air entry ( 30 ), an air exit ( 40 ), an entry conduit ( 50 ) interconnecting the air entry ( 30 ) and the bladder ( 20 ), an exit conduit ( 60 ) interconnecting the bladder ( 20 ) and the air exit ( 40 ), and two one-way valves ( 70 ) wherein one one-way valve ( 70 ) is at a joining portion of the bladder ( 20 ) and the entry conduit ( 50 ) and the other one-way valve ( 70 ) is at a joining portion of the bladder ( 20 ) and the exit conduit ( 60 ). Each of the entry conduit ( 50 ) and the exit conduit ( 60 ) has a triangular section so as to increase resistance, thereby facilitating air flow in the entry conduit ( 50 ) and the exit conduit ( 60 ) and planarizing the pad ( 10 ). The insole can be disposed in one of a variety of shoes and brings a degree of comfort to wearer. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to building panels and methods and is more particularly concerned with wall-surface building panels with quick-assembly features and improved joint sealing, and method of installation thereof.
BACKGROUND OF THE INVENTION
[0002] It is well known in the art to use building panels to make wall or partition surface assemblies on structural building frames.
[0003] There are various requirements for such building panel assemblies. In particular the panels must be capable of quick, simple and reliable assembly. This will ensure that wall surfaces can be rapidly built, with minimal risk of damage to the wall panels during assembly.
[0004] In the case of an exterior wall, the joints should protect the building from the ingress of wind, moisture, and other environmental factors. In the case of an interior partition, the joints should be draftproof.
[0005] The problems encountered by existing panels are numerous. As the concept of panel modularity evolved, panels became larger in the interests of faster assembly time since obviously fewer large panels would be needed to complete a wall surface when compared to, for example, smaller panels or even bricks.
[0006] Large panels present various drawbacks, some of which are their increased weight and bulk, making it difficult to manoeuvre, position and attach the large panels to a building structure. Add to this the difficulty in sealing the edges of adjacent panels, such difficulty being accentuated the taller or more inaccessible the building structure becomes.
[0007] Furthermore, large panels, once installed, are not removable from the building structure without damages to the panels and/or the structure, thus preventing the re-installation of the panels on another structure or simply on the same building structure after relocation thereof.
[0008] Attempts have been made previously to seal the edges of adjacent panels with rubber sill garage doors sealing or windows rubber hoses sealing system but among the consistent drawbacks has been the frequent damage to sealing surfaces while the panels are handled, and during the building assembly activity. The damage to the sealing surfaces is often difficult to detect and repair during construction, resulting in drafty, leaky buildings that require repair as soon as they are placed in service.
[0009] Accordingly, there is a need for an improved building panel with modular, self-aligning, quick-assembly interfaces providing sealing and weatherproofing.
SUMMARY OF THE INVENTION
[0010] It is therefore a general object of the present invention to provide an improved wall surface building panel, and a method of installation thereof.
[0011] An advantage of the present invention is that the wall surface building panel provides for quick making of a wall surface with sealed weatherproof joints that are more damage-resistant.
[0012] An advantage of the present invention is that the wall surface building panel has self-aligning piloting features.
[0013] Another advantage of the present invention is that the wall surface building panel has improved joint sealing and weatherproofing, typically using of a stable (in the ways of being non-shrinkable, waterproof and always staying precisely fit for installation) and thermally non conductive (for insulation) material.
[0014] A further advantage of the present invention is that the wall surface building panel can be assembled and/or disassembled quickly.
[0015] Still another advantage of the present invention is that the wall surface building panel has joint sealing that is more resistant to installation damage.
[0016] According to an aspect of the present invention, there is provided a wall-surface building panel securable to a structural building frame having vertical connector strips connected thereto, said panel comprises: a generally planar panel body having elongate opposite upper and lower edge-defining structures, and elongate opposite first and second lateral edge-defining structures extending therebetween, said panel body having an outer width and an inner width; an elongate protuberant structure operatively associated with, and extending along, the upper edge-defining structure generally in a plane of the body; an elongate groove structure operatively associated with, and extending along, the lower edge-defining structure generally in the plane of the body, and being generally complementarily compatible with said protuberant structure; oblique vertical mating structures operatively associated with, and extending along, the first and second lateral edge-defining structures, complementarily compatible with the corresponding vertical connector strips, wherein the oblique vertical mating structures are arranged so that the outer width of the planar panel body is greater than the inner width thereof; wherein the elongate protuberant structure of a subjacent panel is shaped to releasably, pivotally and load-supportively interface with the elongate groove structure of said panel, said interfacing enabling a range of motion of said panel relative to the subjacent panel; wherein said range of motion ranges from a first position non-coplanar with the wall surface, to a second position generally coplanar with the wall surface; wherein said range of motion substantially reduces sliding contact between each said oblique vertical mating structures and corresponding said vertical connector strip.
[0017] In one embodiment, the elongate protuberant structure includes at least one aligning member extending upwardly therefrom away from said lower edge-defining structure and being tapered at a distal end thereof; and wherein said elongate groove structure includes at least one aligning cavity extending inwardly therein toward said upper edge-defining structure, said aligning cavity cooperating with said aligning member of the subjacent panel when positioned appropriately relative to the building frame, in a manner of pivoting interlock, to guide the panel in place over the subjacent panel, the aligning member and the aligning cavity making contact before said elongate groove structure contacts said elongate protuberant structure of the subjacent panel.
[0018] Typically, the aligning member has a height and said aligning cavity has a depth, said height and said depth being selected to provide a gap between the elongate groove structure and the elongate protuberant structure of the subjacent panel.
[0019] Alternatively, the aligning member includes a grasping feature. Typically, the grasping feature is a transverse through hole.
[0020] In one embodiment, the aligning member is a pin, and said aligning cavity is a pin hole. Typically, the pin is generally square, or round, in cross-section.
[0021] In one embodiment, the aligning member is a tenon, and said aligning cavity is a mortise.
[0022] In one embodiment, the elongate protuberant structure includes a plurality of coplanar and spaced-apart said aligning members, and wherein said elongate groove structure includes a plurality of coplanar and spaced-apart said aligning cavities, each said aligning cavities cooperating with a corresponding said aligning member of the subjacent panel when positioned appropriately relative to the building frame.
[0023] In one embodiment, the planar body further includes: at least one horizontal compliant sealing structure for interposing between the elongate groove structure and the elongate protuberant structure of the subjacent panel, and vertical compliant sealing structures for operatively interposing between the oblique vertical mating structures and the corresponding vertical connector strips.
[0024] Conveniently, the horizontal compliant sealing structure is attached to the protuberant structure, and each said vertical compliant sealing structure is attached to the corresponding vertical connector strip.
[0025] In one embodiment, the elongate protuberant structure and said generally complementarily compatible elongate groove structure have cross-sectional shapes that provide outer edges that are lower than inner edges.
[0026] In one embodiment, the oblique vertical mating structures comprise single planar surfaces.
[0027] In one embodiment, the oblique vertical mating structures comprise a plurality of surfaces.
[0028] In one embodiment, the oblique vertical mating structures comprise a plurality of oblique surfaces interconnected with reentrant surfaces.
[0029] According to another aspect of the present invention, there is provided a wall-surface building panel system securable to a structural building frame, the panel system comprises a plurality of building panels as hereinabove described interfacing with one another in a vertical direction and with a plurality of vertical connector strips in a horizontal direction, said connector strips being mountable on the building frame.
[0030] In one embodiment, the connector strips have an interpanel included angle selected from the group ranging from about ninety degrees to about three hundred and sixty degrees.
[0031] In one embodiment, the system further includes means for securing the planar panel body to the structural building frame.
[0032] Conveniently, the panel securing means includes a plurality of threaded fasteners or quick-connect fasteners.
[0033] According to a further aspect of the present invention, there is provided a method for applying a wall-surface building panel system securable to a structural building frame, the panel system comprising a plurality of building panels as claimed in claim 1 interfacing with one another in a vertical direction and with a plurality of vertical connector strips in a horizontal direction, said connector strips being connected to the building frame, said method comprises the steps of:
a) assembling said building panel releasably, pivotally and load-supportively over the subjacent panel in the first position with a non-coplanar, angle relationship with the wall surface; and b) moving said building panel from the first position non-coplanar with the wall surface, to the second position generally coplanar with the wall surface.
[0036] In one embodiment, the method further includes, before step a), the step of attaching the connector strips to the building frame.
[0037] In one embodiment, the method further includes the step of securing said building panel to the structural building frame.
[0038] Other objects and advantages of the present invention will become apparent from a careful reading of the detailed description provided herein, with appropriate reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] Further aspects and advantages of the present invention will become better understood with reference to the description in association with the following Figures, in which similar references used in different Figures denote similar components, wherein:
[0040] FIG. 1 is an isometric view of a building structure which is having surface panels installed in accordance with an embodiment of the present invention;
[0041] FIG. 2 is an enlarged exploded isometric view of the embodiment of FIG. 1 ;
[0042] FIG. 3 is a partially broken enlarged and exploded transverse vertical section view of the embodiment of FIG. 1 , particularly illustrating an aligning member and an aligning cavity;
[0043] FIG. 4 is a partially broken enlarged horizontal section view of the embodiment of FIG. 1 , particularly illustrating an internal corner assembly;
[0044] FIG. 4 a is an enlarged broken section view taken along line 4 a of FIG. 4 , with some parts being removed for clarity;
[0045] FIG. 5 is a partially broken enlarged horizontal section view of the embodiment of FIG. 1 , particularly illustrating a coplanar panel connection;
[0046] FIG. 6 is a partially broken enlarged horizontal section view of the embodiment of FIG. 1 , particularly illustrating an external corner assembly; and
[0047] FIG. 7 to 9 are partially broken enlarged vertical section views taken along line 7 - 7 of FIG. 1 , particularly illustrating a panel assembly sequence.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0048] With reference to the annexed drawings the preferred embodiments of the present invention will be herein described for indicative purpose and by no means as of limitation.
[0049] Referring to FIG. 1 , building panels 100 , 110 , 120 , 130 and 140 in accordance with the preferred embodiment of the present invention are shown in a building construction 10 . The building construction 10 includes a main structure 20 formed with upright columns, such as the columns shown at 30 , which columns are interconnected by horizontal beams 40 . The horizontal beams 40 further act to support the floor beams 50 , which are arranged in a generally parallel manner between the horizontal beams and are suitably spaced to support floor loads. In FIG. 1 it will be further observed that the upright columns 30 have connected to them vertical connector strips, such as for example vertical connector strips 60 and 70 .
[0050] In the particular structural arrangement which is pictured in FIG. 1 as an example, a simple three-cell structure is apparent. Appropriately mounted on the outside thereof are panels, generally shown at 100 , 110 , 120 , 130 and 140 , which are (a) modular in nature, (b) generally planar, and (c) rectilinear in perimetral outline. With respect to the panels illustrated in FIG. 1 , these panels lie in a substantially common plane and are disposed in a row-and-column arrangement. It is readily apparent that the structure comprises two stories, the lower story being partially enclosed by wall-surface panels 110 , 120 , 130 and 140 . It is further apparent that the first panel 100 of the second story wall surface is being positioned for assembly in a pivoting manner taking advantage of the improved characteristics of the invention.
[0051] In the particular structural arrangement which is pictured in FIG. 1 , as aforesaid, two stories 150 and 160 are illustrated, and it will be noted that each of the panels in FIG. 1 has a vertical dimension which is substantially the same as the story heights in building 10 . It should be understood that such a vertical dimension for the panels 100 of the invention is not a critical dimension. Stated otherwise, panels 100 can be made in accordance with the present invention which may have different, specific, vertical dimensions in relation to a single, building-story height.
[0052] Also, panels 100 in accordance with the present invention may be sectioned in order to initiate or finalize a columnar assembly of panels. Thus a sectioned start panel (not shown) would be positioned and connected at the bottom of the building structure to initiate a column of building panels, and a sectioned cap panel (not shown) would analogously be used at the top of the column to finalize the column. The skilled person will realize that the start panels and the cap panels can have irregular vertical dimensions in accordance with the building design.
[0053] Furthermore, in the particular structural arrangement which is pictured in FIG. 1 , it will also be noted that each of the panels are alike with respect to their lack of fenestration. It should be understood that existence or absence of fenestration on a particular panel is not critical to the present invention. Reiterating, fenestrated building panels may be made in accordance with the present invention, just as well as unfenestrated building panels.
[0054] The aforementioned vertical corner connector strips 60 and 70 are designed to interact complementarily with the lateral edges of the panel assembly. This will subsequently be described. It is important to understand vertical connector strips may be provided, in accordance with the present invention, integrally with or for attachment to the columns. As an example, with reference to FIGS. 4 , 5 , and 6 , attachable vertical connector strips 430 , 520 and 620 , are illustrated, as internal corner, flat corner and external corner strips, respectively.
[0055] With respect to the embodiment of the present invention which is specifically pictured in FIG. 5 , one will see that the vertical connector strip 520 is connected to the structural columns 530 by the use of a plurality of bolt-and-insert pairs 540 vertically spaced from one another for proper securing thereof (not illustrated in FIG. 1 for clarity purposes).
[0056] The skilled person will appreciate that other connector arrangements will be satisfactory for use in the present invention for connecting the vertical connector strips to the structural columns. Examples of other connector arrangements are welding, riveting, bonding and clips system with tie rods. Furthermore the vertical connector strips 430 , 520 , 620 can also be manufactured integrally with the structural columns 30 . Summarizing, the skilled person will appreciate that the vertical connector strips can be connected to the structural columns or manufactured integrally with the structural columns and still be within the scope and spirit of the present invention.
[0057] Referring more specifically to FIG. 2 , there is schematically shown an isometric exploded view of a building panel 200 embodying the present invention. As can be seen, the building panel has a generally planar shaped body. A peripheral frame sub-assembly 210 comprises upper and lower edge-defining structures 220 and 230 respectively, lateral edge-defining structures 240 and 250 , aligning members 260 , and aligning cavities 270 . An inner face sheet 280 , and an outer face sheet 290 are attached to the peripheral frame sub-assembly 210 , the internal defined space of which could be filed with heat insulating, fire retardant, and the like type materials whenever required. The specific constructions of the sub-components of the panel assembly do not form any part of the present invention.
[0058] On closer inspection, the upper and lower edge-defining structures 220 , 230 as well as the lateral edge-defining structures 240 , 250 are seen to have surfaces that are related to the present invention. FIG. 3 provides more detail and is now referred to.
[0059] In FIGS. 2 and 3 , the upper edge-defining structure 220 features along its length a protuberant structure 310 operatively associated therewith in the plane of the panel body and on which is typically affixed a compliant sealing structure 320 . In this preferred embodiment 120 of the invention, the outer edge 330 of the protuberant structure 310 is typically leveled with or lower than the inner edge 340 thereof, and the slope of the external side thereof (left hand side of FIG. 3 ) is typically steeper than the slope of the internal side, for reasons of allowing smooth insertion of a panel over a subjacent panel for easier assembly thereof and to prevent water infiltration when assembled. Furthermore, at least one, preferably two spaced-apart, aligning member 260 extends vertically upwardly from the upper edge-defining structure 220 . The distal end 360 of the aligning member is substantially tapered (or eventually rounded—not shown) and further features a convenient grasping feature such as a transverse through-hole 370 for lifting. The building panel 100 has at its lower extent and extending along the length of the lower edge-defining structure 230 a groove structure 390 operatively associated therewith in the plane of the panel body. Recessed into the groove structure 390 is at least one, preferably two spaced-apart, vertically-directed aligning cavity 270 .
[0060] The interactions of the aligning members 260 and cavities 270 will be described in subsequent paragraphs. In relation to the compliant sealing structures in FIGS. 3 and 9 , the aligning members 260 and cavities 270 , when fully engaged, define a fit dimension 930 between each corresponding protuberant and groove structures 310 , 390 both shaped to be in close cooperation and generally complimentarily compatible with each other. As is well known to the skilled person, a controlled fit dimension 930 is important for sealing integrity, since by this manner the correct squeeze or compression ratio within a required range can be achieved and thereby the desired functioning of a compliant sealing structure 320 can be obtained.
[0061] FIGS. 4 , 5 and 6 depict, among other features, the vertical mating interfaces. FIG. 4 illustrates two inventive building panels 100 , each juxtaposed with the corresponding vertical connector strip 430 , compliant sealing structures 420 being interposed between each building panel 100 and the corresponding vertical connector strip surface, to form an internal corner. That is, the included angle 410 between the building panels 100 is about ninety degrees. Next, FIG. 5 illustrates a vertical connector strip 520 for planar connections, that is, the included angle 510 between the building panels 100 is about one hundred and eighty degrees. Subsequently, FIG. 6 shows an external corner strip 620 , that is, the included angle 610 between the building panels 100 is about two hundred and seventy degrees.
[0062] It is important to understand that the invention is not limited to the three aforementioned configurations of generally ninety degrees, one hundred and eighty degrees, and two hundred and seventy degrees, respectively. Rather, the inventive building panels 100 may be used at any appropriate included angle, according to the building design, as will be apparent to the skilled person. The skilled person will appreciate that an included angle of about ninety degrees, especially less than ninety degrees, requires consideration of the design of the vertical connector strips. The vertical connector strips 430 , 520 , 620 are designed to provide a sufficient installation envelope for each building panel 100 . Without a sufficient installation envelope, particularly at included angles less than ninety degrees, building panels may contact adjacent building components, hindering assembly of the building panels 100 according to the present invention.
[0063] Returning now to the explanation of the vertical mating interfaces, and referring to FIGS. 4 and 4 a, a compliant sealing structure 420 is operatively interposed between the vertical connector strip 430 and the corresponding oblique vertical mating structure 440 . The compliant sealing structure 420 in this preferred embodiment is typically affixed to the vertical connector strip 430 . The compliant sealing structure 420 is disposed to contact the corresponding oblique vertical mating structure over a substantial surface area bounded, for example, by the inner extents of the face sheets 450 and 460 . Also, gap 470 is formed between each face sheet and the nearest vertical connector strip surface (or between two laterally adjacent panels as in FIG. 5 ), which may optionally be filled with a convenient caulking material or the like. The gap dimension, controlled by the panel aligning cavities 270 engaged by the respective aligning members 260 , and shape is adaptable to a particular building design. For example, the gap 470 may optionally have non-parallel, outwardly-divergent sides.
[0064] For use in the preferred embodiment, compliant sealing structures 320 and 420 in the form of gaskets made of rubber or the like have been found satisfactory. The skilled person will appreciate that other compliant sealing structure materials such as caulking and the like can be used to practice the invention and are understood to be represented by the term “compliant sealing structure”. The skilled person will further appreciate that compliant sealing structures such as sealing mastics and the like will still be within the scope and spirit of the present invention.
[0065] The assembly sequence involves the horizontal as well as the vertical mating surfaces. The assembly sequence as it pertains to the horizontal mating surfaces is now explained with reference to FIGS. 1 , 7 , 8 and 9 . The simultaneous interaction of the vertical mating surfaces will be handled in subsequent paragraphs.
[0066] The pivoting assembly activity as illustrated in FIGS. 1 and 7 is initially carried out, as aforesaid, by coarsely positioning the building panel 100 over the subjacent panel 120 in order to ensure proper engagement of the building panel's aligning cavities 270 with the aligning members 260 of the subjacent panel 120 . In such a manner the building panel 100 is suitably positioned in a first installation non-coplanar position within an initial out-of-plane relationship to the subjacent panel 120 , as indicated by angle 700 in FIG. 7 .
[0067] At this stage the weight of the building panel 100 is supported partially by the aligning members 260 of the subjacent panel 120 ; the rest of the panel's weight is supported by a lifting apparatus 180 engaged to the lifting holes 370 , as seen in FIG. 1 . At this point, contact has not yet been established with the horizontal compliant sealing structure 320 on the subjacent panel 120 .
[0068] Since in the manner of the preceding paragraph the horizontal compliant sealing structure 320 remains spaced away and substantially unaffected during the initial assembly process, the risk of sealing structure damage during assembly is reduced. As shown in FIG. 7 , the building panel 100 is then displaced in a combined lowering and generally pivoting motion, as schematically indicated by arrow 705 , while guided at its lower end by the partially coupled aligning member-aligning cavity pairs. Thus the building panel 100 passes through an intermediate position as depicted in FIG. 8 .
[0069] When the tapered distal ends 360 of the aligning members 260 have sufficiently engaged the respective aligning cavities 270 , the building panel 100 can achieve the in-plane orientation seen in FIG. 9 . The second installed in-plane or co-planar position of the building panel 100 is determined by the full engagement of the aligning cavity 270 on the subjacent respective aligning member 260 , and the aforesaid fit 930 exists in which is accommodated the compliant sealing structure 320 . In the installed position of the preferred embodiment, the adjacent face sheets 910 and 920 do not abut; the resulting transversal gap 940 can optionally be filled with a convenient caulking material or the like. The size, shape and proportions of the gap 940 are optional.
[0070] As aforementioned, towards the end of the assembly sequence the vertical mating surfaces will also engage, due to the panel motion generally described by arrow 805 in FIG. 8 . In this preferred embodiment, the vertical mating structure assemblies are seen in FIGS. 4 to 6 . The lateral edge-defining structures 480 , 485 on each building panel 100 are of a generally faceted nature, so that the outer width 490 of the outer face sheet 290 of the building panel is greater than the inner width 495 of the inner face sheet 280 of the building panel. The mating contour 415 of the vertical connector strip 430 is shaped to be in close cooperation and generally complimentarily compatible with the oblique vertical mating structure 440 of the lateral edge-defining structure 240 , 250 of the panel 100 . The compliant sealing structure 420 is typically and preferably attached to the vertical connector strip 430 . In this preferred embodiment, the oblique vertical mating structure 440 further features a reentrant section 405 which has been found to provide improved resistance to air leakage, drafts, and the like, as shown in FIG. 4 a.
[0071] It is further apparent that the vertical mating surfaces are shaped to engage in a direction vertically perpendicular to the plane of the wall surface formed by the building panels 100 , 120 , as schematically shown by arrows 505 in FIG. 5 . During the final phase of the aforesaid assembly sequence depicted in FIGS. 7 to 9 , the vertical mating surfaces seen in FIG. 4 engage in a manner that substantially reduces sliding contact between each oblique vertical mating structure 440 and the corresponding vertical connector strip 430 during assembly. Thus, according to the features of the present invention, the integrity of the vertical compliant sealing structures 420 is improved.
[0072] The aforementioned description of the vertical mating interfaces is equally applicable to the configurations in FIGS. 5 and 6 , as well as any other configuration according to the present invention.
[0073] The building panel once in the in-plane position is then connected to the building structure as seen in FIGS. 4 and 5 . The two building panels 100 depicted are typically bolted to the vertical connector strips 520 (see FIGS. 4 t 6 ) or eventually therethrough to the building structure (not shown) with bolt-and-insert pairs 550 (not illustrated in FIG. 1 for clarity purposes). In an alternative embodiment of the invention, quick-connect fasteners such as, for example, quarter-turn tightening fasteners, preferably with pre-selected compressive load springs, are used to connect the building panels 100 to the structural columns 530 . In such manner the building loads for example wind loads are transmitted from the building panels 100 through the connector strips 520 to the building structure 530 . The skilled person will appreciate that other types of connectors and load paths will be satisfactory for use in the present invention.
[0074] It must be emphasized that the choice of sealing technology does not form a part of the present invention. Furthermore the technology used to attach the compliant sealing structures 320 , 420 to the building panels 100 and the vertical connector strips 430 , 520 , 620 is not part of the present invention. In addition, the compliant sealing structure may be omitted from one or more of the mating surfaces between the building panels and the vertical connector strips; the skilled person will appreciate that such an arrangement will still be within the scope and spirit of the present invention.
[0075] In an embodiment of the present invention, compliant sealing structures 320 , 420 are present on all mating surfaces on the building panels as well as the vertical connector strips. That is, with respect to the building panels, compliant sealing structures are typically connected to each protuberant structure, to interface with each groove structure, and each oblique vertical mating structure. Furthermore, compliant sealing structures are connected to each vertical connector strip surface.
[0076] In a further embodiment of the present invention, the compliant sealing structures are absent from the building panel mating surfaces. Instead, the protuberant 310 and groove 390 structures are shaped in a tightly close-fitting manner. The vertical mating interfaces are similarly arranged in a tightly close-fitting manner, so that there is no space between the mating surface of the vertical connector strip and the corresponding mating surface 415 of the oblique vertical mating structures 440 . Thus, all the mating surfaces provide sealing through their precise, tight-fitting proximity. The other advantages and features of the present invention remain.
[0077] In yet another embodiment of the present invention, the upper 220 and lower 230 edge-defining structures and optionally the lateral edge-defining structures 240 , 250 are multi-lobed, corrugated interfaces, covered sealing membranes and the like.
[0078] An embodiment of a method of the present invention is now set forth. A building main structure is constructed having vertical connector strips. The building panels and the vertical connector strips have pre-affixed compliant sealing structures. A start panel comprising a protuberant structure and typically two spaced-apart aligning members is positioned and connected to the building structure at the lowest position of a planned column of building panels. Optionally, a plurality of start panels can be positioned and connected to the building structure in order to create the appropriate lateral spacing, involving the start panels and the vertical connector strips, for a plurality of the planned columns of building panels.
[0079] The first building panel is then lifted, making use of the convenient transverse through-holes 370 on the aligning members 260 , and hoisted to close proximity with the building structure. The first building panel is tilted so that its upper edge is farthest away from the building side, and the lower edge is coarsely positioned above and generally parallel to the upper edge of the start panel (or subjacent panel).
[0080] The first building panel's lower edge is brought closer to the start panel's upper edge so that the aligning cavities 270 are engaged by the respective aligning members 260 of the start panel. The first building panel is thus in an initial out-of-plane relationship to the building side, and the panel's weight is supported partially by the hoist and partially by the start panel's aligning members 260 .
[0081] The first building panel is then simultaneously lowered while its upper edge is brought closer to the building side. As shown in FIG. 7 , the aligning cavities 270 continue to be engaged by the aligning members 260 as seen by the insertion direction 705 . In such a manner the aligning cavities are generally vertically engaged by the aligning members in a sliding movement therealong as seen in FIG. 8 ; no substantial contact has yet been made between the lateral edge-defining surfaces and the vertical connector strips.
[0082] Since the majority of the vertical engagement has taken place at this stage, the final panel motion is then a pivoting motion 805 which shuts the panel's lateral edge-defining surfaces perpendicularly into the corresponding surfaces on the vertical connector strips (see arrows 505 of FIG. 5 ). At the end of the pivoting motion 805 the first building panel has reached the final position as seen in FIG. 9 and the vertical compliant sealing structures have made full surface contact without having experienced any substantial relative in-plane motion.
[0083] The first building panel is then connected by its vertical edges to the building structure using a structurally-suitable number of bolt-insert pairs 550 as seen in FIG. 5 . Using the aforementioned sequence, additional building panels are assembled upward columnarly as well as row-wise laterally until the building side is complete including the cap panels.
[0084] Although the present invention has been described with a certain degree of particularity, it is to be understood that the disclosure has been made by way of example only and that the present invention is not limited to the features of the embodiments described and illustrated herein, but includes all variations and modifications within the scope and spirit of the invention as hereinafter claimed. | An improved building panel is presented to make wall surface assemblies on structural building frames. The edge-sealed building panel includes with self-aligning features between adjacent horizontal edges for quick mating and assembly. The building panels have protuberant upper edges mate with grooves on the lower edges for improved sealing and weatherproofing, due to the interlocking shape and the use of compliant seals between the edges. The horizontal mating edge shapes enable pivoting assembly by engaging the building panel obliquely and swinging it onto the wall surface. Vertical mating surfaces with compliant seals are shaped to engage perpendicularly to the wall plane, so that the compliant seals clamp shut without in-plane relative motion, improving seal integrity. | 4 |
CLAIM OF PRIORITY
[0001] The present application claims priority from Japanese application serial no. 2005-216648, filed on Jul. 27, 2005, the content of which is hereby incorporated by reference into this application.
FIELD OF THE INVENTION
[0002] This invention relates generally to a motor drive device which drives a motor using a rechargeable battery as a power supply, and more particularly, to a motor drive device suitable for charge control of a rechargeable battery which is provided together.
BACKGROUND OF THE INVENTION
[0003] A motor drive device which drives a motor using a rechargeable battery as a power supply is equipped with a dedicated booster circuit and a rectification circuit to charge the rechargeable battery or uses an inverter device to drive a motor and windings of the motor to chop and boost without using a booster circuit dedicated for a charging circuit as disclosed in Japanese Patent Laid-open No. Hei07 (1995)-87616.
SUMMARY OF THE INVENTION
[0004] In Patent document 1 described above, the inverter has two operation modes: Motor Drive mode which does not connect an external AC power supply and Battery Charge mode which connects an external AC power supply and performs boosting to charge the rechargeable battery. The semiconductor switching devices of the inverter function differently in these modes and it is necessary to use any means to judge connection or disconnection of the external AC power supply. However, Patent document 1 does not describe it explicitly.
[0005] An object of this invention is to provide a motor drive device capable of doubling as a charge controller which detects the connecting status of an external charge power supply without using any mechanical switches and switches between Motor Drive mode and Battery Charge mode of the inverter.
[0006] A motor drive device that doubles as a charge controller in accordance with this invention is equipped with an AC motor, an inverter, a rechargeable battery, a charge power supply, and an inverter controller. The motor drive device contains a Motor Drive mode which converts a DC voltage of the rechargeable battery into an AC voltage by the inverter and supplies the AC voltage to the AC motor and a Battery Charge mode which detects connection of the charge power supply, applies the DC voltage from the rechargeable battery to the inverter through a winding of the AC motor and drives semiconductor switching devices to charge the rechargeable battery.
[0007] In accordance with this invention, switching between Motor Drive and Battery Charge modes can be reliably executed by the output of a means to detect connection or disconnection of a charge power supply.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a schematic diagram to explain the motor drive device of Embodiment 1 that combines a charge controller of a rechargeable battery.
[0009] FIG. 2 is a schematic diagram to explain the Motor Drive mode of Embodiment 1.
[0010] FIG. 3 is a schematic diagram to explain the Battery Charge mode of Embodiment 1.
[0011] FIG. 4 is a timing chart of the Battery Charge mode of Embodiment 1.
[0012] FIG. 5 is a timing chart to explain mode transition of the motor drive device of Embodiment 1 that combines a charge controller of a rechargeable battery between Motor Drive mode and Battery Charge mode.
[0013] FIG. 6 is a schematic diagram to explain another Battery Charge mode of Embodiment 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] This invention will now be described in detail with reference to the accompanying drawings.
[0015] FIG. 1 shows a motor drive device which doubles as a charge controller of a rechargeable battery in accordance with this embodiment. In FIG. 1 , the positive and negative ends of smoothing capacitor 4 are connected to voltage detector 5 . The positive pole of smoothing capacitor 4 is connected to the positive pole of rechargeable battery 1 and the negative pole of rechargeable battery 1 is connected to the negative pole of smoothing capacitor 4 via charge current detector 6 . The positive pole of smoothing capacitor 4 is connected to positive DC bus line P of inverter 2 . Negative DC bus line N 1 of inverter 2 is connected to the negative pole of smoothing capacitor 4 via current detector 7 which detects current passing through inverter 2 .
[0016] Inverter 2 is equipped with three upper arms and three lower arms. Each arm is made with a power semiconductor switching device (Tr 1 to Tr 6 ) such as IGBT or power MOSFET and a free wheeling diode (D 1 to D 6 ). 3-phase AC outputs of U, V, and W phases of inverter 2 are connected to AC motor 3 . Here, AC motor 3 can be a permanent magnet motor that uses a permanent magnet for the rotor.
[0017] Inverter driving circuit 15 controls power semiconductor switching devices (Tr 1 to Tr 6 ) of inverter 2 by gate driving signals corresponding to the operating mode of the inverter which is Motor Drive or Battery Charge mode. Further, inverter driving circuit 15 also determines whether to drive AC motor 3 actually by operation command 15 S in the Motor Drive mode. FIG. 1 shows position-sensor-less control by which inverter driving circuit 15 without a rotor position sensor inputs an inverter current waveform detected by current detector 7 , estimates the rotor position, and controls driving of the inverter thereby. However, it is possible that the inverter driving circuit uses position-sensing control by which inverter driving circuit 15 inputs the output of a rotor position sensor to inverter driving circuit 15 and controls driving of AC motor 3 .
[0018] In this embodiment as shown in FIG. 1 , the cathode of diode 10 is connected to the U-phase AC output of inverter 2 and charge voltage detector 11 is connected between the anode of diode 10 and negative end N of smoothing capacitor 4 . Further, removable charge power supply 14 is connected to connection terminal 12 which leads to the anode of diode 10 of FIG. 1 and connection terminal 13 which leads to negative end N of smoothing capacitor 4 . Here, it is possible to substitute diode 10 by a semiconductor having a small ON resistance such as power MOSFET, IGBT, thyristor, or GTO and turn on/off by the output of charge power supply connection judging circuit 16 or mode switching control circuit 17 .
[0019] The motor drive device that combines a rechargeable battery charge controller which is an embodiment of this invention is equipped with a charge-power-supply connection judging circuit 16 which inputs a detection voltage from charge voltage detector 11 and judges, by the magnitude of the detection voltage, whether charge power supply 14 is connected. Charge-power-supply connection judging circuit 16 outputs Charge-Power-Supply OFF signal 16 S 1 or Charge-Power-Supply ON signal 16 S 2 which is a judgment result signal to mode switching control circuit 17 . Upon receiving this judgment result signal, mode switching control circuit 17 outputs Motor Drive Mode control signal 17 S 1 or Battery Charge Mode control signal 17 S 2 to inverter driving circuit 15 as the operation mode of inverter 2 . Inverter driving circuit 15 receives the output from mode switching control circuit 17 and controls the operation of inverter 2 in Battery Charge mode or Motor Drive mode. It is possible to build up inverter driving circuit 15 , charge-power-supply connection judging circuit 16 , and mode switching control circuit 17 in individual logic IC chips. However, this embodiment accomplishes them by a microcomputer which is not shown in FIG. 1 .
[0020] Below will be explained the Motor Drive mode and the Battery Charge mode in detail. FIG. 2 shows only FIG. 1 sections related to the Motor Drive mode and does not show any other sections. In the Motor Drive mode, charge power supply 14 is not connected. Charge-power-supply connection judging circuit 16 outputs Charge-Power-Supply OFF signal 16 S 1 according to detection voltage information sent from charge voltage detector 11 . On receiving Charge-Power-Supply OFF signal 16 S 1 , mode switching control circuit 17 outputs Motor Drive Mode control signal 17 S 1 . By receiving Motor Drive Mode control signal 17 S 1 and operation command 15 S, inverter driving circuit 15 applies a drive signal which converts a DC voltage output of rechargeable battery 1 to an AC voltage to each gate of power semiconductor switching devices Tr 1 to Tr 6 of inverter 2 . With this, inverter 2 outputs an AC voltage and drives AC motor 3 . If operation command 15 S is a STOP signal, inverter driving circuit 15 leaves inverter 2 undriven and keeps AC motor 3 stopped.
[0021] The operation of the Battery Charge mode is explained below with reference to FIG. 3 . FIG. 3 shows only FIG. 1 sections related to the Battery Charge mode and does not show any other sections. In the Battery Charge mode, charge power supply 14 is connected. Charge power supply connection judging circuit 16 outputs Charge-Power-Supply ON signal 16 S 2 according to detection voltage information sent from charge voltage detector 11 . On receiving Charge-Power-Supply ON signal 16 S 2 , mode switching control circuit 17 outputs Battery Charge Mode control signal 17 S 2 . By receiving Battery Charge Mode control signal 17 S 2 , inverter driving circuit 15 turns off upper and lower arms of power semiconductor switching devices Tr 1 and Tr 2 which are 1-phase outputs of inverter 2 . The DC voltage output of charge power supply 14 connected to connection terminals 12 and 13 is applied to power semiconductor switching devices Tr 4 and Tr 6 of lower arms of the remaining 2 phases via windings of AC motor 3 , turns on and off power semiconductor switching devices Tr 4 and Tr 6 , and thus controls charging of rechargeable battery 1 .
[0022] Substantially, power semiconductor switching devices Tr 4 and Tr 6 of two phases (V and W phases in FIG. 3 ) of lower arms of inverter 2 are turned on to flow current to AC motor 3 and store electromagnetic energy in the windings of AC motor 3 . Then, while the lower arms of inverter 2 are off, current flows through free wheeling diodes D 3 and D 5 of upper arms by the stored electromagnetic energy and thus power is applied to rechargeable battery 1 to charge. It is possible to select arms of specific two phases such as V and W phases as arms of inverter 2 which are switched in the Battery Charge mode or to select any phases so that arms of three phases may have the same electric energy after charging of rechargeable battery 1 .
[0023] The current detected by charge current detector 6 is fed back to inverter driving circuit 15 and durations of switching pulses of power semiconductor switching devices Tr 4 and Tr 6 are controlled so that the charging current of rechargeable battery 1 may not exceed a constant current or permissible charging current.
[0024] Further, it is possible to charge rechargeable battery 1 by a synchronous rectification method which turns on the power semiconductor switching devices of upper arms when the power semiconductor switching devices of lower arms are off. In other words, as shown in FIG. 6 , power semiconductor switching devices Tr 3 and Tr 5 of the upper arms are turned on and off to charge rechargeable battery 1 synchronously as power semiconductor switching devices Tr 4 and Tr 6 of the lower arms are turned on and off.
[0025] FIG. 4 is a timing chart of a switching pulse command for ON/OFF control of power semiconductor switching devices Tr 4 and Tr 6 in the Battery Charge mode. When the switching pulse command of FIG. 4 goes to a high level, power semiconductor switching devices Tr 4 and Tr 6 and free wheeling diodes D 3 and D 5 are turned on and off. When the switching pulse command of FIG. 4 goes to a high level, power semiconductor switching devices Tr 4 and Tr 6 and free wheeling diodes D 3 and D 5 are turned on. When the switching pulse command goes to a low level, power semiconductor switching devices Tr 4 and Tr 6 and free wheeling diodes D 3 and D 5 are turned off. In time period t 1 of FIG. 4 , power semiconductor switching devices Tr 4 and Tr 6 of lower arms of inverter 2 are turned on and current flows through windings of AC motor 3 . As the result, electromagnetic energy is stored in the windings of AC motor 3 . In time period t 2 of FIG. 4 , power semiconductor switching devices Tr 4 and Tr 6 of lower arms of inverter 2 are turned off and free wheeling diodes D 3 and D 5 of upper arms are turned on. The electromagnetic energy stored in the windings of AC motor 3 is fed to rechargeable battery 1 through free wheeling diodes D 3 and D 5 of upper arms. With this, rechargeable battery 1 is charged.
[0026] Next a method will be explained in detail to switch between Motor Drive mode and Battery Charge mode in this embodiment. FIG. 5 is a timing chart which shows mode transitions between Battery Charge mode and Motor Drive mode when charge power supply 14 is connected and disconnected. Waveform ( 1 ) of FIG. 5 shows disconnection of charge power supply 14 by the low level of FIG. 5 and connection of charge power supply 14 by the high level. Waveform ( 2 ) shows how the detected charging voltage changes when charge power supply 14 is connected and disconnected. Further, waveforms ( 3 ) and ( 4 ) of FIG. 5 respectively show a change in Charge-Power-Supply OFF signal 16 S 1 and a change in Charge-Power-Supply ON signal 16 S 2 . Waveform ( 5 ) shows a transition between Motor Drive mode and Battery Charge mode.
[0027] In a status in which inverter driving circuit 15 is in the Motor Drive mode and charge power supply 14 is not connected, when charge power supply 14 is connected to connection terminals 12 and 13 at time t=a, the detection voltage output from charge voltage detector 11 starts to go up from time t=a and goes over preset voltage level VL for connection judgment at time t=b. When the detection voltage goes over voltage level VL, charge-power-supply connection judging circuit 16 judges that charge power supply 14 is connected, makes Charge-Power-Supply ON signal 16 S 2 high (to the High level) and Charge-Power-Supply OFF signal 16 S 1 low (to the Low level). When Charge-Power-Supply ON signal 16 S 2 goes high, mode switching control circuit 17 changes the level of Motor Drive Mode control signal 17 S 1 from High to Low and the level of Battery Charge Mode control signal 17 S 2 from Low to High as shown in FIG. 5 . With this, the mode of inverter 2 is switched from Motor Drive mode to Battery Charge mode. In this case, the Battery Charge mode is set at time t=c after mode transition period A as shown in FIG. 5 . This mode transition period A between time t=b and time t=c can assure a time period between interruption of operation of inverter 2 and stop of revolution of AC motor 3 even when AC motor 3 is actually running by operation command 15 S in the Motor Drive mode.
[0028] When charge power supply 14 is disconnected from connection terminals 12 and 13 at time t=d, the detection voltage output from charge voltage detector 11 starts to go down from time t=d and goes below preset voltage level VH for connection judgment at time t=e. When the detection voltage goes below voltage level VH, charge-power-supply connection judging circuit 16 judges that charge power supply 14 is disconnected, makes Charge-Power-Supply OFF signal 16 S 1 high (to the High level) and Charge-Power-Supply ON signal 16 S 2 low (to the Low level). When Charge-Power-Supply OFF signal 16 S 1 goes high, mode switching control circuit 17 changes the level of Motor Drive Mode control signal 17 S 1 from Low to High and the level of Battery Charge Mode control signal 17 S 2 from High to Low as shown in FIG. 5 . With this, the mode of inverter 2 is switched from Battery Charge mode to Motor Drive mode. In this case, the Motor Drive mode is set at time t=f after mode transition period B as shown in FIG. 5 .
[0029] The mode transition period B between time t=e and time t=f is used to initialize various kinds of data for motor control required to set the Motor Drive mode. In the new Motor Drive mode after time t=f, AC motor 3 is actually driven or left stopped by operation command 15 S at that time point.
[0030] As described above, in accordance with this invention, the Battery Charge mode can be held when a status indicating a connection of a charge power supply is output by a connection judging means which outputs a status indicating whether a charge power supply is connected or disconnected and the Motor Drive mode can be held when a status indicating a disconnection of a charge power supply is output. Therefore, the Motor Drive mode and the Battery Charge mode can be exclusively selected. In FIG. 5 , the voltage detection levels VL and VH are made different (e.g., VL<VH) to detect connection or disconnection of charge power supply 14 . However, the voltage detection levels VL and VH can be equal to each other.
[0031] In this embodiment, inverter 2 , inverter driving circuit 15 which is a control section of inverter 2 , charge-power-supply connection judging circuit 16 , and mode switching control circuit 17 can be built in separate packages. It is also possible to mount inverter 2 and the controller on the same package as an intelligent power module. The module which contains inverter 2 and the controller is compact, light-weight, and capable of stopping the motor without fail in the Battery Charge mode. Therefore, the module is suitable for a motor drive device that combines a charge controller of a rechargeable battery which is mounted on an electrically-powered car, motor-driven bike, or motor-assisted bicycle which drives wheels by AC motor 3 powered by rechargeable battery 1 . Further, since the module in which inverter 2 and the controller are mounted on the same package is compact and light-weight, it is also suitable for motor control of a cordless vacuum cleaner. | A voltage detector is connected to a connection terminal connected to one phase of an AC output of an inverter through a diode. A removable charge power supply is connected to said connection terminal and another connection terminal. A charge-power-supply connection judging circuit judges whether the charge power supply is or isn't connected, based on a charge power supply voltage detected by a voltage detector. A mode change control circuit outputs switch signal by the result of said judgment. By receiving this switch signal, the inverter controller switches the operation of the inverter between the Motor Drive mode or the Battery Charge mode. Thereby, a motor drive device detects a connecting status of an external charge power supply and steadily switches the operation of the inverter between the Motor Drive mode or the Battery Charge mode. | 7 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. provisional patent application No. 61/393,801 filed Oct. 15, 2010.
FIELD OF THE INVENTION
[0002] Embodiments of the invention relate to methods and apparatuses utilizing LED light sources however it is recognized that other directional sources could be used instead. Directional light sources are sources characterized by the ability of an optical system to groom the emitted light into a beam. For example a laser is a directional source. Another example is a waveguide that is coupled to a remote source. Yet another example of a LED light source that is used to make a beam is the arc lamp used in projectors.
BACKGROUND OF THE INVENTION
[0003] Definitions
[0004] CILF: Conventional Indirect Lighting Fixture as used in the prior art.
[0005] Coefficient of Utilization: The ratio of the integrated light power at the working plane to the total light power emitted by the fixtures.
[0006] IES: Illuminating Engineering Society.
[0007] LED: Light Emitting Diode.
[0008] Lumen: A photometric measure of light intensity.
[0009] Luminous Intensity: Lumen density in a particular direction.
[0010] OPDS: Optical Power Distribution System.
[0011] PCB: Printed Circuit Board.
[0012] Working plane: an imaginary plane at a specified distance from the floor (usually 28 inches) used as a reference to measure light intensity in a room.
[0013] Lighting fixtures are composed of lighting source(s) and an “optical power distribution system” or OPDS. Until recently the majority of the light sources used for indoor lighting has been either incandescent or fluorescent light sources. Over the years a number of OPDS have been created that work well with those sources. Over the past 5 years the performance of LEDs has dramatically improved while simultaneously reducing the cost per lumen. It is therefore generally recognized that LED sources will eventually replace the older incumbent lighting sources. Most of the current LED product development is focused on providing light fixtures that use the same OPDS but use LED based lighting sources of essentially the same form factors as the incandescent and fluorescent light sources. This allows the customer to take advantage of the lower operating costs and increased lifetime of LED based light sources.
[0014] What is needed is an improvement in indirect lighting performance using the special characteristics of LEDs or other small directional sources of low etendue, that allow the light fixture designer to more precisely direct a light beam to its target. For the most part indirect lighting is defined as lighting that comes from reflections from surfaces outside of the lighting fixture. The most common type of indirect lighting is from a hanging light fixture that has its optical power directed upwards towards the ceiling. Indirect lighting provides a superior quality of illumination because it is more uniform (less glare and hot spots) and is more isotropic (reduced shadows). It is generally acknowledged in the lighting industry that the reduction of hot spots and glare allows the user to achieve the same level of visual acuity at lower illumination levels. The key limitations of conventional indirect lighting are:
1. It requires significant space between the indirect lighting fixture and the ceiling and therefore only works well with rooms with higher ceilings and/or vaulted ceilings. 2. The lighting efficiency (coefficient of utilization) is reduced by the blockage of the lighting fixture since the fixture is often times in plain view between the ceiling and the working plane. 3. It interrupts the continuity of the architecture of the room because it is very visible to the room occupant. Direct lighting has the advantage in this aspect because there are many recessed fixtures that are flush with the ceiling.
BRIEF DESCRIPTION OF DRAWINGS
[0018] Embodiments of the invention will be understood more fully from the detailed description given below and from the accompanying drawings of various embodiments of the invention, which, however, should not be taken to limit the invention to the specific embodiments, but are for explanation and understanding only.
[0019] FIG. 1 is a perspective view defining the normal vector to a planar surface.
[0020] FIG. 2 is a perspective view of a room with a ceiling defining the normal vector to the ceiling of the room
[0021] FIG. 3 (PRIOR ART) is a cross sectional view of a room showing the angular distribution of a PRIOR ART indirect light fixture
[0022] FIG. 4 is a cross sectional view of a room showing the angular distribution of light from an indirect light fixture in accordance with an embodiment of the invention.
[0023] FIG. 5 is a cross sectional view of a room showing the resultant reflected light from an indirect light fixture where the ceiling has specular reflective characteristics in accordance with an embodiment of the invention.
[0024] FIG. 6 is a cross sectional view of a room showing the resultant reflected light from an indirect light fixture where the ceiling has diffuse reflective characteristics in accordance with an embodiment of the invention.
[0025] FIG. 7 is a cross sectional side view 700 and a front view 705 of LED secondary optics subassembly and defines the angles of the optical power vectors emitted by that subassembly.
[0026] FIG. 8 is a plot of the relative luminous intensity versus angle for a LED secondary optics subassembly with circularly symmetric emission.
[0027] FIG. 9 shows plots of the relative luminous intensity versus angle for a LED secondary optics subassembly with elliptically symmetric emission.
[0028] FIG. 10 is a cross sectional side view 1000 and a cross sectional front view 1050 or a LED secondary optics subassembly in a room illustrating the reference orientation of the LED secondary optics subassembly.
[0029] FIG. 11 is a top view of a linear array of LED secondary optic subassemblies illustrating the resultant superposition of beams from individual secondary optic subassemblies in two cases: Case A 1100 where the individual beams are narrow and Case B 1150 where the individual beams are wide.
[0030] FIG. 12 is a cross sectional side view of a room occupied by an observer illustrating the direct observation of stray emissions from a LED secondary optics subassembly.
[0031] FIG. 13 is a cross sectional side view of a room occupied by an observer illustrating an embodiment that includes a blocking structure that prevents the direct observation of stray emissions from a LED secondary optics subassembly.
[0032] FIG. 14 is a cross sectional view of an embodiment of the invention which has independent adjustments for orienting various elements of that embodiment.
[0033] FIG. 15 is a cross sectional view of an embodiment of the invention which has a fixed horizontal blocking shelf and a LED secondary optics subassembly that rotates.
[0034] FIG. 16 is a cross sectional view of an embodiment of the invention which has a blocking shelf and a LED secondary optics subassembly that rotate together.
[0035] FIG. 17 is a cross sectional view of an embodiment of the invention which has a blocking shelf and a LED secondary optics subassembly that rotate together.
[0036] FIG. 18 is a cross sectional view of an embodiment of the invention which has a blocking shelf and a LED secondary optics subassembly that rotate together.
[0037] FIG. 19 is a cross sectional view of an embodiment of the invention which has a blocking shelf and a LED secondary optics subassembly that rotate together. The blocking shelf is further characterized by the addition of an internal reflective plate to assist in projecting light into the room.
[0038] FIG. 20 is a cross sectional view of an embodiment of the invention which has a blocking shelf that includes an interior reflecting plate.
[0039] FIG. 21 is a cross sectional view of an embodiment of the invention that shows additional features on the upper and lower blocking structures to reduce self-illumination.
[0040] FIG. 22 is a top view of a room with a criss-cross arrangement of bi-directional linear array fixture in accordance with an embodiment of the invention.
[0041] FIG. 23 is a perspective view of a uni-directional linear array fixture in accordance with an embodiment of the invention.
[0042] FIG. 24 is a top view of a uni-directional linear array fixture in accordance with an embodiment of the invention.
[0043] FIG. 25 is a cross sectional side view of a unidirectional linear array fixture in accordance with an embodiment of the invention.
[0044] FIG. 26 is a top view of a bidirectional linear array fixture in accordance with an embodiment of the invention.
[0045] FIG. 27 is a top view of a reduced width bidirectional linear array fixture in accordance with an embodiment of the invention.
[0046] FIG. 28 is a top view of a curve linear array fixture in a circular configuration with no interior surface illumination in accordance with an embodiment of the invention.
[0047] FIG. 29 is a top view of a curve linear array fixture in a semi-circular configuration in accordance with an embodiment of the invention.
[0048] FIG. 30 is top view of a curve linear array in a circular configuration defining a cross section for FIGS. 31 and 32 in accordance with an embodiment of the invention.
[0049] FIG. 31 is the cross section side view defined in FIG. 30 for the case of annular blocking shelf areas per LED secondary optics subassemblies in accordance with an embodiment of the invention.
[0050] FIG. 32 is the cross section side view defined in FIG. 30 for cross firing LED secondary optics subassemblies with blocking walls of annular blocking shelf areas per LED secondary optics subassemblies in accordance with an embodiment of the invention.
[0051] FIG. 33 is a perspective view of a curve-linear array fixture with independent control of sub-arrays in accordance with an embodiment of the invention.
[0052] FIG. 34 is a top view of a 8 foot by 16 foot rectangular lighting fixture utilizing bidirectional linear array fixtures and an integral interior reflecting surface in accordance with an embodiment of the invention.
[0053] FIG. 35 is a perspective view of a multi-tier curve-linear array fixture in a circular configuration in accordance with an embodiment of the invention.
[0054] FIG. 36 is a top view of a room with wall mounted unidirectional linear array fixtures in accordance with an embodiment of the invention.
[0055] FIG. 37 is top view of a room utilizing a combination of types linear and curve-linear array fixtures in accordance with an embodiment of the invention.
SUMMARY OF THE INVENTION
[0056] Embodiments of the invention relate to distributing light on a flat ceiling parallel to the floor, however it is recognized that other shaped ceilings may be used. A ceiling is not always a simple plane parallel to the floor. It may be at an off angle or it may be made of several segmented planes. Furthermore it may be a curved surface. The apparatuses and methods taught here are also applicable to these situations.
[0057] Embodiments of the invention relate to “Optical Power Distribution Systems” (OPDS) which scatter light off the ceiling. It is possible to combine an embodiment of the invention with a conventional light fixture to yield a hybrid light fixture.
[0058] There are three sets of objectives for an embodiment of the invention. The first set of objectives address standard indirect lighting fixtures. The second set of objectives address the known problems with conventional indirect lighting. A third set of objectives expand the capabilities and features of indirect lighting.
[0059] The first set of objectives is:
1. Prevent the room occupant from seeing the light sources (LEDs and associated optics) directly. 2. Produce a more uniform distribution of light on the working plane. Mathematically this objective translates into minimizing Max/Min ratio (the ratio of maximum footcandles to minimum footcandles in the working plane). In the ideal case the Max/Min ratio is 1.0, however in reality a Max/Min ratio of less than 2.0 is considered excellent. This is important since a proper lighting design must provide adequate lighting for all of the room occupants. Therefore the minimum light level (in an area that is of significant size) must be above a specified design threshold. The Illuminating Engineering Society, IES, sets those standards for various applications. From a strictly energy conscious point of view, any illumination levels that are significantly above the minimum level are wasteful. Therefore the uniform distribution of light is not only important from an aesthetic perspective, it is also important from an energy conservation perspective. 3. Extend the field of illumination from the fixture such that the spacing between fixtures is large (and still maintaining uniformity in terms of distribution of light). Reducing the amount of fixtures in a given space reduces capital equipment costs, installation costs and maintenance costs. Traditional lighting practices for large office spaces assume that the linear fixtures are hanging from ceiling as pendants and are arranged in parallel linear arrays. Typically there is a tradeoff between meeting objective #2 and meeting objective #3. For example imagine a room designed with linear arrays of florescent lighting at 10 foot spacing with a Max/Min ratio of 2.5. If the spacing between the fixtures is increased to 16 feet then the Max/Min ratio may increase to 3 or more. If the field illumination is large enough compared to the dimensions of the room then it is possible to light the room by using only wall mounted fixtures, i.e. without using any pendant lighting. This is particularly useful in situations where there is no ready access to a source of electricity above the ceiling; for example most modern hotels do not have a crawl space between the ceiling and the floor directly above it.
[0063] The second set of objectives is:
1. Reduce the space requirements. As mentioned earlier the conventional means of implementing indirect lighting requires a significant space between the fixture and the ceiling. 2. Improve the efficiency. As mentioned earlier in the conventional means of implementing indirect lighting the lighting fixture partially blocks the reflected light from the ceiling.
[0066] The third set of objectives is:
1. Provide a means for reducing or eliminating the self-illumination of the fixture such that the light fixture appears to be dark even when it is on. 2. Provide a means of altering the distribution of light to accommodate the changing requirements of the user and to accommodate physical changes of the lighting fixture due to aging, vibration, temperature that may result in unwanted changes in the lighting distribution pattern. 3. Provide a means for changing the intensity of light either uniformly or by zone to accommodate the changing requirements of the user. 4. Provide a means for changing the color of light either uniformly or by zone to accommodate the changing requirements of the user. 5. Provide a means for hiding and or camouflaging the light fixture entirely.
DETAILED DESCRIPTION OF THE INVENTION
[0072] For the purposes of differentiating between conventional, or prior art, indirect lighting OPDS s and the indirect OPDSs contemplated in embodiments of the invention, the following features of OPDS s are highlighted: (1) the angular distribution of light from the light fixtures relative to the ceiling, and (2) the means for obscuring or blocking the direct view of those light sources or any interior fixture surfaces with high brightness.
[0073] Optical Angular Distribution
[0074] The ceiling's normal vector is defined as the vector that is perpendicular to all lines tangent to the plane. FIG. 1 illustrates the simplest case in which the ceiling surface is a plane 100 with a vector 105 normal to the surface of the plane. A planar surface is particularly important because most rooms 200 have a ceiling 205 which is a plane and an associated normal vector 210 , as shown in FIG. 2 . Now consider FIG. 3 showing the prior art where a conventional indirect light fixture 305 is hanging from the ceiling 315 in room 300 with a floor 320 and sidewalls 310 A and 310 B. Define θ as the angle between a given light ray from the light fixture and the normal vector 350 , where θ=0° when the normal vector and the light ray are parallel and in the same direction. The light rays from that fixture 305 intersect the plane of the ceiling 315 at various angles (e.g. θ 1 325 , θ 2 330 , θ 3 335 , θ 4 340 ) relative to the normal vector 350 of the ceiling. Conservatively speaking for conventional indirect lighting fixtures over 50% of the power incident on the ceiling has a value for θ such that θ<60°. FIG. 3 shows angles that are exemplary of this range where θ 1 325 is shown as 35°; θ 2 330 is shown as 20°; θ 3 335 is shown as 30°; and θ 4 340 is shown as 40°.
[0075] Now consider a light fixture 420 in accordance with an embodiment of the invention, as shown in FIG. 4 . It uses of a set of directional light sources, such as LED array 460 , whose optical output power is groomed into beams by OPDS's 455 A and 455 B directed towards the ceiling 405 . One of the salient features of a beam is the angular distribution of the light rays in those beams relative to the vector normal 450 to the ceiling, i.e. the distribution of the angles θ 1 425 , θ 2 430 , θ 3 435 , θ 4 440 , and θ 5 445 In one embodiment of the invention, the angular distribution of a beam is such that over 50% of the optical power emitted makes an angle θ with the normal vector 450 of the ceiling 405 such that 70°<θ<95°. FIG. 4 shows angles that are exemplary of this range where θ 1 425 is shown as 90°; θ 2 430 is shown as 80°; θ 3 435 is shown as 75°; θ 4 440 is shown as 75°; and θ 5 445 is shown as 90°. It should be noted that while FIG. 4 refers to an LED array as a directional light source, other types of light sources may also be used.
[0076] For example, a laser is a directional light source. Another example is a waveguide that is coupled to a remote light source. Yet another example of a LED light source that is used to make a beam is the arc lamp used in projectors. An arc lamp, or arc light, is the general term for a class of lamps that produce light by an electric arc (also called a voltaic arc). The lamp consists of two electrodes, typically made of tungsten, which are separated by a gas. The type of lamp is often named by the gas contained in the bulb, including neon, argon, xenon, krypton, sodium, metal halide, and mercury. The common fluorescent lamp is actually a low-pressure mercury arc lamp.
[0077] Most of the light will reflect from the ceiling, i.e. for θ such that 70°<θ<9 0 °. Optionally, in one embodiment, some portion of light may reflect off the top of the side walls. Consider the two embodiments for the light reflecting from the ceiling, as shown in FIG. 5 and FIG. 6 . FIG. 5 shows the specular reflection embodiment where a room 500 has a ceiling 505 that is minor-like. In this embodiment an incident light ray 540 from the light fixture 520 will reflect off the ceiling 505 in a reflected light ray 545 , such that angle γ 1 550 is equal to angle γ 2 555 . In this embodiment the vertical component of the light is small. If the ceiling 605 acts as a perfect light scatterer then the reflected light is represented by the embodiment shown in FIG. 6 . In this embodiment an incident light ray 635 from the light fixture 620 is reflected off the ceiling 605 into a diffuse set of reflected lights rays 640 , 645 , 650 , 655 and 660 . This is diffuse reflection; a special case of which is lambertian reflection. In this embodiment, a significant portion of the resultant reflected rays have a significant vertical component. If the light incident upon the ceiling is uniformly distributed then the effect is to make the ceiling appear to be a uniform light source to the occupant of the room. Most ceilings in homes and offices today have considerable texture and therefore are more closely approximated by the embodiment illustrated in FIG. 6 .
[0078] Blocking Structures
[0079] The LEDs and the LED secondary optics used to create the desired optical distribution pattern have significant secondary emissions, i.e. emissions outside the primary beam of light. The secondary optics is defined by an additional optics external to the LED assembly. It is termed secondary because the LED assembly may have its own embedded primary optics. The secondary optics input is generally coupled directly to the LED assembly output. Generally speaking at any interface where there is a change of direction of a light beam (either by reflection or by the refractive effect of changing of index of refraction in the transmission media) there is an opportunity to produce secondary emissions. Even in the exit of the primary beam from the secondary optics there is a portion of that optical power that is reflected back into the optics and subsequently re-emitted at angles outside of the primary beam. As a result the observer that is outside of the range of the primary beam can still see significant light being emitted by the LED secondary optics, often referred to and termed herein as stray emissions of light rays. It is therefore important that a blocking structure be used to block the direct view of the LEDs and its associated secondary optics. For CILFs the blocking is much less critical because the angle of the light distributions from the CILF is not close to the angle of view. However for embodiments of the invention the angular distribution of the primary beam, for example, from an LED assembly, can be within a few degrees of the viewing angle.
[0080] A blocking structure may take many forms, according to an embodiment of the invention. The functions of a blocking structure are: (a) block direct view of the LEDs and/or secondary optics, (b) not significantly obstruct the primary beam from its target, and (c) in the case that the primary beam is obstructed then redirect that portion of the primary beam that was obstructed back to the ceiling in an angular direction within the angle of the unimpeded primary beam. One aspect of a blocking structure is a blocking shelf.
[0081] Several aspects of the blocking structure in accordance with an embodiment of the invention are discussed below, including:
1) The size of the minimum blocking shelf necessary to prevent direct view of the LEDs and their associated optics is proportional to the size of the secondary optics. 2) The size of the blocking shelf is a contributing factor to the size of the light fixture using a blocking shelf, in one embodiment of the invention. 3) The size of the blocking shelf is related to distance that light can be projected from the fixture. Fixtures with larger blocking structures can project light further into the room. 4) As rooms become larger the depth of the blocking shelf in some embodiments becomes larger until it reaches an asymptote, where the vertical displacement of the blocking structure equals the size of the secondary optics.
Embodiments of the Invention
[0086] Embodiments of the invention implement a fully functional lighting system for a room or a set of rooms in a building. The entire system incorporates embodiments that are integrated into a light fixture design, and finally a room level solution integrates the light fixture functionality. Therefore the embodiments disclosed are vertically integrated into the final room lighting solution.
[0087] Achieving the Desired Angular Distribution
[0088] The optical output of an embodiment of the invention is ultimately the superposition of the individual beams from the LED+Optics combinations. For each LED there are beam shaping optics and beam directing mechanisms. In some embodiments the beam shaping optics and beam directing mechanisms are integrated. In some embodiments the beam shaping optics and beam directing mechanisms are shared by more than one LED.
[0089] As a starting point first consider that the LEDs are generally mounted on a PCB (printed circuit board). The beam shaping optics for the LED are composed of three parts: the primary optics, the secondary optics, and fixture optical constraints. The fixture optical constraints are for the most part the interior surface of the blocking structure, discussed further below. Most of the popular high brightness (HB) LEDS sold today are actually sub-assemblies that include miniature optics to precondition the emissions from the LED and to physically protect the LED. These optics are sometimes referred to as the primary optics. For example, the Luxeon Rebel and Cree Xlamp products include a small lens. It should be noted that some LEDs do not include primary optics, for example Nichia's 157A series does not include primary optics. At the other extreme are companies that integrate all the required optics into the LED, e.g. Illumitex, and don't require a secondary optics.
[0090] The choice of the secondary optics is a function of many factors including the LED array geometry, e.g. the number and the configuration of all the contributing LEDs and the room geometry. The secondary optics may be discrete, i.e. one secondary optic per LED, or multiple, i.e. one secondary optic structure serving multiple LEDs (for example a bar optics for a linear array of LEDs). Furthermore the secondary optics may be a custom solution or an off the shelf solution. Discrete secondary optics modules are readily available off the shelf from a number of vendors, e.g. Carclo, Ledil, Polymer Optics, and Dialight to name a few. Because off the shelf secondary optics are generally made to service several LED types, e.g. a Carclo secondary optics may be used with a Cree LED or Philips Lumiled LED, the performance will be inferior to a custom secondary optics solution. There are many parameters characterizing the performance of the secondary optics, e.g. angular distribution, throughput loss, and aperture size. As will be discussed below the aperture size is a consideration for embodiments of the invention because it is directly proportional to the size of the structure necessary to block the room occupant's view of the LEDs. The throughput loss is a consideration because it is part of the overall efficacy equation. A further consideration in connection with the beam shaping of the light emitted from the LED is the angular distribution. Some embodiments use secondary optics that have a circular symmetry or elliptical symmetry. FIG. 7 illustrates a general secondary optics 725 . The direction of the optical power vector 730 is determined by two angles: (1) the angle, φ 735 , with the central axis 715 of the secondary optics 725 , and (2) the angle, α 740 , of the projection 745 of the optical power vector on the plane transverse 750 to the central axis 715 of the secondary optics 725 with the reference line 755 (typically a line of symmetry passing through the central axis). The secondary optics is considered circularly symmetric if the power level incident on a plane perpendicular to the central axis of the beam is independent of α. The lines in this plane perpendicular to the central axis of the beam representing a constant power are circular in shape.
[0091] A typical angular distribution is shown in FIG. 8 , having its peak power at φ=0 and its half power at φ=φ 3 dB 810 B and φ=−φ 3 dB 810 A. For a secondary optics that has an elliptical symmetry, the lines tracing out constant power levels on any plane intercepting the beam perpendicular to its central axis are elliptical in shape. The angular distribution is shown in FIG. 9 which plots the Relative Luminous Intensity 905 as a function of φ 900 . There are two curves shown, i.e one curve 925 for power distribution as a function of φ 900 at α minor =angle of the minor axis of the ellipse, and one curve 920 for the power distribution as a function of φ 900 at α major =angle of the major axis of the ellipse. For convenience let's assume that α major =0 degrees and α minor =90 degrees. The elliptical shape is characterized by two 3 dB angles: (1) a 3 dB angle for the minor axis of the ellipse, φ 3 dB,minor 910 B and (2) a 3 dB angle for the major axis of the ellipse, φ 3 dB,major 915 B.
[0092] FIG. 10 shows the reference orientation of the secondary optics relative to the room features, i.e. ceiling 1010 and floors, from two views: a) the side view 1000 of the near wall and b) the front view 1050 of the far wall. Furthermore the reference orientation, i.e. orientation without any tilt, is defined as follows: (1) the central axis 1015 of the LED secondary optics subassembly 1025 is parallel to the plane of the ceiling 1010 , (2) the minor axis 1065 of the elliptical beam 1055 is perpendicular to the ceiling 1010 , and (3) the major axis 1060 of the elliptical beam 1055 is parallel to the floor.
[0093] The beams created by the LED secondary optics subassembly are then directed towards the ceiling by the fixture by tilting the LED secondary optics subassembly from its reference position to the ceiling of the room (the ceiling is assumed to be flat and parallel to the floor).
[0094] The specifics regarding the mechanism used to orient the LED secondary optics subassembly and any additional beam shaping accomplished by the fixture optical constraints are a function of the particular fixture design (see the discussion below regarding Embodiments of Fixtures). The orientation mechanism is generally field adjustable to some extent to account for variances in room geometries and construction variances, according to an embodiment of the invention.
[0095] Some embodiments of the invention use secondary optics that have an elliptical angular distribution where φ 3 dB,minor <<φ 3 dB,major . The reason becomes apparent if one considers a typical situation as illustrated in FIG. 4 , in conjunction with FIGS. 7 and 9 . Consider FIG. 7 which shows the definition of angles that are used to describe the angular distribution. Furthermore assume that the LED/secondary optics assembly is directed such that most of the light being emitted by the assembly is incident on the ceiling. More specifically, with reference to the right hand side of the fixture in FIG. 4 , let us assume that θ 4 440 is the angle for the closest intercept of the primary beam with the ceiling and that θ 5 445 is the angle of the farthest intercept of the primary beam with the ceiling. Furthermore let us assume that values for θ 4 and θ 5 respectively are 79° and 88° in one embodiment of the invention. If one further orients the angle of the central axis of the secondary optics such that it equally bisects the angle between θ 4 and θ 5 then the optical distribution of the LED/secondary optics assembly is constrained between −4.5° and +4.5°. If one assumes a reasonable power distribution where 80% or more of the power is captured in the range of −φ 3 dBm,minor <φ<φ 3 dB,minor , then one can use a LED secondary optics subassembly that has a φ 3 dB,minor approximately equal to 4.5°. This is representative of some embodiments in that φ 3 dB,minor is less than 5 degrees. On the other hand φ 3 dB,major is typically chosen to be greater than 20 degrees. The primary reason for this is illustrated in FIG. 11 . In case A the angular distribution of the beam from the LED/secondary optics array 1110 in the plane parallel to the ceiling is much smaller than in case B. As a result the optical power at point A 1105 , a distance x from the linear array, is only sourced by a single LED. However for case B 1150 consider point B 1155 at the same distance x from the linear array 1120 . In this case the optical power incident on the area around point B 1155 is contributed to by 5 LED/secondary optics beams. Choosing large angular distribution therefore will average out the variances in intensity and color of individual LEDs in the LED array.
[0096] Managing Stray Emissions
[0097] As shown in FIG. 12 nearly all of the optical power from the LED-Lens assembly 1215 within the primary beam 1220 , where the primary beam is defined as light that exits the light source 1215 , passes through the fixture exit port and is incident on the ceiling 1200 and the upper portion of the far wall 1205 . However a much smaller amount of power is emitted outside of the primary beam 1220 , defined as stray emissions 1230 . This results, in part, from the scattering that occurs at the various optical interfaces within the LED-Lens assembly 1215 . These stray emissions can reach the eye of the observer 1210 either directly or by reflection off the light fixture. Because the LEDs have high luminous intensity, then the stray emissions are of significant magnitude. Therefore direct observation of the stray emissions creates significant glare and degrades the effectiveness of the indirect lighting. It is therefore desirable that direct observation of stray emissions be significantly reduced or entirely eliminated, in one embodiment of the invention. Additionally the illumination of the light fixture by the stray emissions should be greatly reduced in order to achieve the effect of producing indirect lighting in a room without revealing the source, in one embodiment.
Preventing Direct Observation of Stray Emissions
[0098] FIG. 13 shows the blocking of the line of sight 1300 of the room occupant 1310 by a blocking structure 1340 . The aperture of the LED secondary optics assembly 1335 is blocked from the view of the observer 1310 by a shelf 1340 . The minimum depth 1360 of the shelf to completely block the view of the LED secondary optics 1335 is dependent on the relative orientation of the shelf 1340 with respect to the LED secondary optics 1335 . For the purposes of establishing equations relating the minimum shelf depth with room and fixture characteristics the following terms are defined in FIG. 13 :
h 1 1315 is the height of the room. h 2 1320 is the height of the observer's eyes 1310 . y 1 1325 is the drop from ceiling 1330 of the center of the LED secondary optics 1335 . B 1 1305 is the angle of the line of sight 1300 with respect to horizontal 1370 . D 2 1365 is the distance between the LED secondary optics 1335 and the far wall 1375 . θcenter 1350 is the angle of the central axis 1345 of the LED secondary optics 1335 with the normal vector of the ceiling 1355 .
[0105] FIG. 14 shows a fixture with the capability of independently adjusting the orientation of the LED 1465 —Secondary optics 1470 —shield 1445 —heat sink 1455 —printed circuit board 1450 sub-assembly, the orientation of the lower blocking structure 1415 and the orientation of the upper blocking structure 1405 . The orientation of the LED 1465 —Secondary optics 1470 —shield 1445 —heat sink 1455 —printed circuit board 1450 sub-assembly is accomplished by a pivot point A 1460 and a vertical adjustor 1440 . The orientation of the lower blocking structure 1415 is accomplished by pivot point C 1435 and vertical adjustor 1425 . The orientation of the upper blocking structure 1405 is accomplished by pivot point B 1430 and vertical adjustor 1420 .
[0106] Consider further several different configurations of blocking structure and LED secondary optics orientations.
[0107] One embodiment of the invention, referred to as Configuration 1 , is shown in FIG. 15 . It has the following features, according to one embodiment of the invention: (a) the blocking shelf 1510 is fixed in a horizontal orientation, i.e. parallel to the ceiling 1530 , and (b) the LED secondary optics subassembly 1500 is oriented at an angle, θ center 1540 , with respect to the normal of the ceiling 1535 . The rotation angle of the LED secondary optics subassembly can be fixed at manufacturing or could be in part or in whole adjustable in the field by a rotating mechanism 1545 . In one embodiment of the invention, the minimum depth of the blocking shelf 1515 necessary to prevent the view of the LED secondary optics sub-assembly 1500 is given by the following formula:
[0000] d 2 =w a *(sin θ center /tan β 1 −cos θ center )
[0000] where, tan β 1 =(h 1 −h 2 −y 1 −(w a *sin θ center )/2)/d 1
and furthermore the variables are associated with the following Figures:
[0108] From FIG. 15 we have d 2 1515 , θ center 1540 , β 1 1525 , and w a 1505 .
[0109] From FIG. 13 we have h 1 1315 , h 2 1320 , d 1 1365 , and y 1 1325 .
[0110] To get a better idea of the size of the shelf to use consider several cases shown in Table 1 below.
[0000]
TABLE 1
Case 1
Case 2
Case 3
Case 4
wa
inches
0.79
0.79
0.79
0.79
θ center
degrees
85.00
85.00
85.00
85.00
θ center
radians
1.48
1.48
1.48
1.48
h1
height of room
ft
8.00
8.00
10.00
10.00
h2
eye level
ft
6.00
6.00
6.00
6.00
d1
width of room
ft
15.00
20.00
20.00
50.00
y1
drop
ft
0.42
0.42
0.83
0.83
tan(β1)
0.11
0.08
0.16
0.06
β 1
radians
0.11
0.08
0.16
0.06
β 1
degrees
6.03
4.53
9.00
3.62
d2
min shelf
inches
7.36
9.84
4.89
12.32
[0111] Under this configuration, the shelf depth becomes prohibitively large as the x/y footprint of the room increases, assuming all others factors remain constant.
[0112] Another embodiment of the invention, referred to as Configuration 2 , is shown in FIG. 16 . It has the following features: (a) the blocking shelf 1640 and the central axis of the LED secondary optics sub assembly 1600 are oriented at the same angle, θ center 1615 , with respect to the normal of the ceiling 1620 and (b) the blocking shelf 1640 is offset from the central axis 1645 of the LED secondary optics sub-assembly 1600 by a distance (w a /2+a 1 ), where w a 1605 is the size of the secondary optics aperture and a 1 1610 is the offset of the LED secondary optics sub-assembly 1600 from the blocking shelf 1640 , The minimum depth of the blocking shelf necessary to prevent the view of the LED secondary optics is given by the following formula:
[0000] d 2 =( w a +a 1)/tan((π/2)−θ center +β 1 )
[0000] where, tan β 1 =(h 1 −h 2 −y 1 −w a /2)/d 1
[0113] Table 2 shows the same cases as Table 1 but with the second configuration illustrated in FIG. 16 .
[0000]
TABLE 2
Case 1
Case 2
Case 3
Case 4
wa
inches
0.79
0.79
0.79
0.79
θ center
degrees
85.00
85.00
85.00
85.00
θ center
radians
1.48
1.48
1.48
1.48
A1
inches
0.10
0.10
0.10
0.10
H1
height of room
ft
8.00
8.00
10.00
10.00
H2
eye level
ft
6.00
6.00
6.00
6.00
D1
width of room
ft
15.00
20.00
20.00
50.00
Y1
drop
ft
0.42
0.42
0.83
0.83
tan(β1)
0.11
0.08
0.16
0.06
B 1
radians
0.11
0.08
0.16
0.06
B 1
degrees
6.03
4.53
9.00
3.62
D2
min shelf
inches
4.55
5.29
3.56
5.85
[0114] Table 2 illustrates that Configuration 2 has the advantage of reducing the minimum blocking shelf depth.
[0115] It is recognized that Configuration 2 is representation of the general case where the angle Θ diff between the central axis of the LED secondary optics subassembly and the blocking shelf is fixed. For configuration 2 θ diff is zero.
[0116] The embodiment of Configuration 2 also has a characteristic that further distinguishes it from the embodiment of Configuration 1 . If θ center becomes large enough then the vertical projection of the blocking shelf on the ceiling normal vector will equal the vertical projection of the secondary optics and its offset a 1 on the ceiling normal vector. When this condition is satisfied then the depth of the blocking shelf is no longer dependent on the x/y footprint of the room. Mathematically this condition (that we shall call the infinite blocking condition for easy reference) occurs when the projection 1730 of the blocking shelf 1740 on the ceiling normal vector 1720 equals the projection of the secondary optics aperature w a and offset a 1 on the ceiling normal vector 1720 , as illustrated in FIG. 17 . This condition yields the following equation.
[0000] sin θ center *( w a +a 1 )=cos θ center *d 2
[0000] or
[0000] θ center =a tan( d 2 /( w a +a 1 ))
[0000] where d 2 1735 is the known depth of the blocking shelf 1740 and θ center 1715 is the variable to be adjusted to reach the infinite blocking condition,
[0117] or equivalently solving for d 2 :
[0000] d 2=( w a +a 1 )*tan θ center
[0000] when θ center is the variable to be adjusted to reach the infinite blocking condition.
[0118] Table 3 shows several cases where d 2 is known and θ center is the variable to be adjusted to reach the infinite blocking condition
[0000]
TABLE 3
Case 1
Case 2
Case 3
Case 4
wa
inches
0.79
0.79
0.79
0.79
a1
inches
0.10
0.10
0.10
0.10
d2
inches
7.00
6.00
4.00
3.50
θ1
radians
0.13
0.15
0.22
0.25
complement of
θ1
θcenter
degrees
7.22
8.41
12.51
14.23
θ center
radians
1.44
1.42
1.35
1.32
θ center
degrees
82.78
81.59
77.49
75.77
[0119] If one designs a fixture to meet the infinite blocking condition then the fixture can be used in any room of any size, e.g. large office space, without exposing any of the LED secondary optics to the view of the room occupant.
[0120] It is also noted that these equations show the tradeoff between fixture size, which is directly proportional to d 2 , and the horizontal distance from the fixture to where the light is incident on the ceiling, which is directly proportional to tan θ center . The objectives discussed above included (1) increase the spacing between fixtures and (2) decrease the size of the fixture. The objectives are contrary to each other. Having said that it is possible to find a compromise which is better than what is available with the CILFs.
[0121] Let us define the horizontal distance from the LED secondary optics sub-assembly 1800 to the intercept of the central axis 1850 with the ceiling 1840 as X pen , 1845 as shown in FIG. 18 .
[0000] X pen =y 1 *tan θ center
Where,
[0122] y 1 1835 is the distance from the center of the LED secondary optics sub-assembly 1800 to the ceiling 1825 .
[0123] θ center 1830 is the angle between the ceiling's normal vector 1825 and the central axis of the LED secondary optics sub-assembly 1850 .
[0124] Table 4 below shows the value of X pen (in feet) as a function of θ center and y 1
[0000]
TABLE 4
y 1 (inches)
3
5
6
7
8
10
11
13
15
17
19
22
θ center
87
4.8
8.0
9.5
11.1
12.7
15.9
17.5
20.7
23.9
27.0
30.2
35.0
86
3.6
6.0
7.2
8.3
9.5
11.9
13.1
15.5
17.9
20.3
22.6
26.2
85
2.9
4.8
5.7
6.7
7.6
9.5
10.5
12.4
14.3
16.2
18.1
21.0
84
2.4
4.0
4.8
5.6
6.3
7.9
8.7
10.3
11.9
13.5
15.1
17.4
83
2.0
3.4
4.1
4.8
5.4
6.8
7.5
8.8
10.2
11.5
12.9
14.9
82
1.8
3.0
3.6
4.2
4.7
5.9
6.5
7.7
8.9
10.1
11.3
13.0
81
1.6
2.6
3.2
3.7
4.2
5.3
5.8
6.8
7.9
8.9
10.0
11.6
80
1.4
2.4
2.8
3.3
3.8
4.7
5.2
6.1
7.1
8.0
9.0
10.4
79
1.3
2.1
2.6
3.0
3.4
4.3
4.7
5.6
6.4
7.3
8.1
9.4
78
1.2
2.0
2.4
2.7
3.1
3.9
4.3
5.1
5.9
6.7
7.4
8.6
77
1.1
1.8
2.2
2.5
2.9
3.6
4.0
4.7
5.4
6.1
6.9
7.9
[0125] In either the embodiment of configuration 1 (illustrated in FIG. 15 ) or the embodiment of configuration 2 (illustrated in FIG. 17 ) part of the optical power from the secondary optics makes contact with the interior of the blocking shelf. The percentage of the power that is intercepted by the interior surface of the blocking shelf increases as a 1 decreases and d 2 increases. However most of this light is recovered if the interior surface of the blocking shelf redirects the light back towards the ceiling. The reflected light is directed farther away from the fixture if the interior surface is specular (mirror-like) rather than diffuse. Modifications can be made to the interior surface of the blocking shelf such that the reflected light from the interior surface of the blocking shelf will be cast farther away from the fixture. Just as it is important to achieve a large X pen 1845 for non-reflected light in FIG. 18 it is important that the reflected light achieve a large X pen ,reflected 1915 , as shown in FIG. 19 (approaching the value of X pen ). X pen ,reflected 1915 is the horizontal distance from the LED secondary optics subassembly 1905 to the intercept of the reflected light ray 1920 with the ceiling 1910 . The reflected light ray 1920 is the result of the reflection of an incident light ray 1925 from the LED secondary optics subassembly 1905 reflecting off the interior surface of the blocking shelf 1940 . The reflection is specular in that the incident angle 1935 is equal to the reflected angle 1930 . It is recognized that in some cases that visual appearance of the projection of light on the ceiling may have artifacts (discontinuities in brightness) that can be filled by making some portion of the reflected light from the inner surface of the blocking shelf diffuse.
[0126] Any such embodiments that redirect intercepted light should be below the line of sight, or in the case of very large rooms below the horizontal line intercepting the highest edge of the blocking shelf. Consider FIG. 20 showing an embodiment where an internal reflection plate 2045 has been added to the blocking shelf 2040 . A representative light ray 2025 from the LED secondary optics subassembly 2005 is incident on the internal reflection plate 2045 at an angle 2035 . The resulting reflected light ray 2020 intercepts the ceiling 2010 at a horizontal distance 2015 . Note that X pen ,reflected 2015 in FIG. 20 is larger than X pen ,reflected 1915 in FIG. 19 .
[0127] In some cases it is advantageous to change the shape of the lower blocking shelf 2110 such that it has a lip 2115 as shown in the embodiments illustrated in FIG. 21 . Likewise there are cases where the shape of the upper blocking shelf 2125 advantageously should include a lip 2120 . This gives the primary beam a sharper edge to it (i.e. the projected intensity changes more abruptly, rather than a gradual fade). Self illumination of the fixture can be reduced if the upper blocking shelf 2125 has a curved contour.
Reducing Self Illumination of the Light Fixture by Stray Emissions
[0128] One of the objectives of an embodiment of the invention is to provide indirect lighting in a room while simultaneously not revealing the source of that indirect lighting. To that point it is important to reduce self illumination of the light fixture caused by stray emissions. This may be done in two parts, according to an embodiment of the invention:
[0129] 1) First, a chamber is constructed which allows only the front face of the LED Lens assembly to be visible, as shown as chamber 1445 in FIG. 14 and as chamber 2130 FIG. 21 . Most of the stray emissions from the sides and back of the LED and the secondary optics are trapped in this chamber. The chamber is formed from the combination of the printed circuit board 1450 and the shields 1445 as shown in FIG. 14 . In some embodiments the secondary optics lens holders 1470 provide a sufficient chamber. Furthermore the interior walls of this chamber be constructed of light absorbing material and exhibit only smooth curved contours, according to one embodiment, since sharp edges will cause additional scattering which could be externally visible.
[0130] 2) The exit chamber of the light fixture, chamber 2 , is defined by the volume delimited by the exit port 1475 of chamber 1 , exit port 1410 of the fixture, and the upper blocking structure 1405 and lower blocking structure 1415 . The interior of the light fixture consists of dark light absorbing material, again with no sharp edges, in one embodiment. The stray light from the front face of the LED secondary optics assembly is therefore contained in chamber 2 .
[0131] Color Control
[0132] Color management of “white” light is an issue to consider for lighting in general. Today, LED fixture consumers are forced to choose between various types of white light, e.g. cool-white (5000° K. to 10000° K.), neutral-white (4000° K.), and warm-white (3000° K.). Note that the color temperature of a light source is the temperature of an ideal black body radiator that radiates light of comparable hue to that light source. Warm-white has a better color-rendering-index and is preferred in most residential settings. Cool-white is used in the office because it creates an environment that is believed to result in higher level of energy of its occupants. In many cases it would be preferable to have a lighting system that could change to accommodate the varying needs of the room occupant by effectively changing its color temperature. This is possible by using several colors of LEDs, e.g. red, green, and blue LEDs, and mixing the appropriate relative intensities. One of the primary difficulties in implementing this approach is the rainbow effect along the edges of the illumination patterns, i.e. there is not sufficient color mixing to achieve a uniform hue of white.
[0133] Three characteristics of embodiments of the invention disclosed herein make color mixing very effective:
(1) the use of elliptical secondary optics results in a large number of LEDs contributing power at any given point on the ceiling, (2) the upper blocking structure 1405 and lower blocking structure 1415 shown in the embodiment of FIG. 14 produce a sharper edge to illumination patterns on the ceiling and the upper part of the walls, thereby reducing the instance of gradually fading from bright to dim. It is known that each color will have a slightly different fade angle due to the wavelength dependence of the optics, and therefore if such a gradual fade is allowed the color mix will change along the fade regions.
[0136] (3) the scattering phenomenon that is the origin of the indirect light is wavelength independent. Furthermore color cameras with RGB filters may be used to achieve a closed loop control system. This allows one to maintain the hue of the white light over varying temperature and the lifetime of the system. Note that such feedback control also requires addressable control of LEDs or LED groups, as discussed later.
[0137] Thermal Management
[0138] LED lifetime and performance is a function of the junction temperature of the LED. As the temperature increases, the lifetime and the optical output power (for a fixed current) both decrease. One of the biggest problems facing the LED industry today is the managing of the temperature for bulb replacement parts, e.g. using LEDs to replace incandescent bulbs. The root cause of the problem is that there is inadequate heat sinking available for bulb replacement applications. On the other hand a light fixture in accordance with an embodiment of the invention as described herein has easy access to heat sinking elements. Consider the heat sink 1455 in FIG. 14 . Also consider the heat sink 2520 in FIG. 25 . Note that in FIG. 25 the heat sink 2520 is an integral part of the subassembly that rotates together with the PCB 2525 , LEDs 2540 , secondary optics 2530 and lower blocking shelf 2505 . In FIG. 14 the heat sink rotates around pivot point 1460 as part of the subassembly that also contains the PCB 1450 , LED 1465 , and the secondary optics 1470 . Therefore in both FIG. 14 and FIG. 25 the heat sink is directly attached to the PCB that carries the LEDs. This has the distinct advantage of keeping the thermal resistance low. The combination of large easily accessible heat sinks and the low power density is ideal for keeping the LED temperature low.
[0139] Common to most of the light fixture embodiments discussed herein is securing the LED PCB assembly (PCBA) directly to a large heat sink. For the case in which the fixture provides a means for adjusting the angle of the exit beam with the ceiling, the apparatus that aims the LED/secondary optics at the ceiling should not interfere with the primary heat path. In one embodiment, the heat sink is fixed directly to the PCBA and both are rotated together.
[0140] System Control
[0141] Control of a White LED System
[0142] A lighting system consists of multiple fixtures in a room. Each fixture can be independently addressed and controlled, in one embodiment. Within each fixture the LEDs may be grouped. Consider the embodiment FIG. 23 which shows a fixture 2300 with with 16 LEDs separated into 2 groups: group A 2310 and group B 2320 . Each group has eight LEDs. Each group within a fixture may be addressed. A group may consist of only one LED. The control allows one to set the LED drive current for each group. This can be used to control the lux levels at various parts of the room. Consider FIG. 22 which shows a large room illuminated by a crisscross configuration of linear unidirectional wall mount fixtures ( 2205 , 2212 , 2220 and 2225 ) and linear bidirectional pendant fixtures ( 2206 , 2207 , 2208 , 2209 , 2210 , 2211 , 2221 , 2222 , 2223 , and 2224 ). The room is partitioned into 5 rows ( 2230 , 2231 , 2232 , 2233 and 2234 ) and seven columns ( 2240 , 2241 , 2242 , 2243 , 2244 , 2245 , and 2246 ) For example it is possible to light only a single cubicle (e.g. cubicle at row 2232 , column 2242 ) in the embodiment of the very large configuration shown in FIG. 22 .
[0143] An example of the control of a curve-linear fixture 3300 is shown in the embodiment of FIG. 33 , where the LED arrays are divided into three individually addressable groups, i.e. group A 3310 , group B 3320 and group C 3330 . The control may be centralized or distributed. An example of a centralized control would be a web based control that could be accessed through a secure password. An example of distributed control would be hardwired switches or dimmers in the room.
Control of Correlated Color Temperature of a White LED System
[0144] In much the same manner as the control of white LED systems, groups of LEDs are sub-divided into color sub-groups, e.g. red, blue, green, etc. An interesting special case is the control of the color of the white light. Instead of the PCBA having different primary color LEDs the PCBAs are populated with intermixed LEDs of different CCTs (correlated color temperatures). For example suppose a PCBA has ten LEDs. In one embodiment, the even number LEDs could be at a 2700° K. and the odd number LEDs could be at a CCT of 4000° K. The even number LEDs are wired together in series number 1 and the odd number LEDs are wired together in series number 2 . Series number 1 uses current driver A while series number 2 uses current driver B. If the secondary optics are elliptical then there will be two levels of mixing. The first level of mixing occurs because of the overlap of elliptical beams as shown in FIG. 11 . The second level of mixing occurs because of the diffuse scattering at the ceiling. Therefore the resultant light at the working plane, usually defined as 28″ from the floor, has undergone two levels of mixing. It should be noted that the two levels of mixing also facilitates the mixing of colors, and variances in white LEDs (whether by design or intentional as in the above example),
[0145] Embodiments of Light Fixtures and their Application in Indoor Lighting
[0146] There are many types of light fixtures that can be constructed according to the embodiments of the invention disclosed herein. The fixture embodiments disclosed in this section are representative of fixtures that can be constructed based on those embodiments.
[0147] So far a blocking structure for a single LED has been described. However when multiple LEDs are combined into a light fixture the block structure should be suitable for all the LEDs, in one embodiment. Two lighting fixtures discussed here are linear array fixtures and curve-linear array fixtures. For linear array fixtures the LEDs are arranged in a straight line. For curve-linear array fixtures the LEDs are arranged on a curve that is substantially coplanar. Consider that the cross section, for either a linear array or a curve-linear array, formed by a plane passing through the center axis of any LED/secondary optics in the array and perpendicular to the ceiling, should be the same as for the single element embodiment discussed above. Therefore the various blocking structures discussed for a single LED embodiment are applicable to the linear and curve-linear array embodiments.
[0148] Unidirectional Linear Array Fixture
[0149] Let us assume the array fixture is linear. Consider the fixture 2400 in FIG. 24 . Note that all LED secondary optics subassemblies 2430 , in either group A 2410 or group B 2420 are oriented in the same direction. In this embodiment, the blocking shelf is a straight planar structure 2440 .
[0150] Additional details of the embodiment are shown in FIG. 25 . Note that the PCB 2525 housing the LEDs 2540 and the secondary optics 2530 are mounted to a heat sink 2520 . The heat sink 2520 should be a material with a high thermal conductivity, in one embodiment. The heat sink 2520 should also be thick. The combination of high conductivity and thickness allows the heat generated from the LEDs 2540 to be spread over a larger area which in turn aids in the passive convective cooling of the fixture 2500 . Also note that the subassembly composed of the LEDs 2540 , secondary optics 2530 , heat sink 2520 , and blocking shelf 2505 rotate together relative to the external frame 2510 , in one embodiment. The rotation (or tilt) is accomplished by the hinge 2550 in combination with an adjustable spacer 2515 between the frame 2510 and the sub-assembly, in one embodiment. The frame 2510 provides a fixed structure presented to the observer independent of the rotation angle. Also note that there is an overlap between the downward lip 2560 of the blocking shelf 2505 and the upward lip 2570 of the frame 2510 .
[0151] Unidirectional linear array fixtures are typically wall mounted as shown in FIG. 22 , FIG. 36 and FIG. 37 . In the case of a remodel or a new build the unidirectional linear array fixtures may be recessed into the wall. This embodiment provides significant, indeed, complete, reduction of observable fixture footprint.
[0152] Bidirectional Linear Array Fixture
[0153] There are a number of embodiments for a bidirectional linear array fixture. One embodiment of a bidirectional linear fixture 2600 comprises two unidirectional linear array fixtures positioned back-to-back, i.e. 2610 and 2620 , as shown in FIG. 26 . The effective width 2630 is then twice the width of a uni-directional linear array fixture.
[0154] Another embodiment is shown in FIG. 27 . The effective width 2740 of the fixture 2700 is reduced by ½, relative to FIG. 26 , by alternating the directions of the uni-directional linear array subassemblies. Uni-directional linear array subassemblies 2705 , 2710 , and 2715 are all point in the same direction, as projected into the horizontal plane. The uni-directional linear array subassemblies 2720 and 2730 point in the opposite direction, as projected into the horizontal plane. In another embodiment, if one does not alternate directions of the LED/secondary optics but instead creates a direct cross firing situation then efficiency of the fixture decreases because the source beams may intercept part of the structure of the opposing source. One embodiment that allows for a higher density of opposing bidirectional sources employs a second vertical tier. Furthermore any given side of the fixture would alternate between tier 1 and tier 2 to make a more homogenous presentation of the light on the ceiling. Multiple vertical tiers can also be useful if additional optical power is required for the application. Bi-directional linear array fixtures may find utility as pendants in large rooms as shown in the embodiment of FIG. 22 .
[0155] Curve-Linear Array Fixtures
[0156] FIG. 28 and FIG. 29 show embodiments of curve-linear array fixtures. FIG. 28 shows an embodiment of a fixture 2800 with a circular curve-linear array of LED secondary optics subassemblies 2810 . The blocking shelf 2820 is a coplanar annular ring. FIG. 29 shows an embodiment of a fixture 2900 with a semi-circular curve-linear array of LED secondary optics subassemblies 2910 . The blocking shelf 2920 is a coplanar annular half-ring. These curve-linear embodiments find application, for example, as central fixtures 3725 and corner fixtures ( 3705 , 3710 , 3715 , and 3720 ) as shown in the room 3700 in FIG. 37 .
[0157] Alternative embodiments for blocking shelves for curve-linear array fixtures are described with reference to the cross section illustrated in FIG. 30 . FIG. 30 shows a fixture 3000 with a circular array of LED secondary optics subassemblies 3010 surrounded by an annular blocking shelf 3020 with a cross section notation 3025 . The cross section detailed in FIG. 31 employs a blocking shelf construction that is similar to that disclosed for linear array embodiments. FIG. 31 shows a fixture 3100 with LED secondary optic subassemblies 3105 and 3110 point in opposite directions, having separate blocking shelf areas 3115 and 3120 respectively. This configuration has a diameter 3125 . It is possible to achieve a smaller diameter by modifying the embodiment shown in FIG. 32 . The modified fixture 3200 has blocking walls 3215 and 3220 associated with LED secondary optics subassemblies 3105 and 3110 . This will however reduce the lighting efficiency of the fixture. As discussed earlier it is possible to use a second tier of
[0158] LED/secondary optics to resolve this problem and to use the same techniques of alternating between tier 1 and tier 2 to make a more homogenous presentation of light.
[0159] Fixtures with Integrated Reflecting Surfaces
[0160] The embodiments described thus far have used the ceiling as the surface to scatter light into the room. Consider that for some embodiments it may be advantageous to include a surface which is part of the fixture itself from which to reflect light. One embodiment comprises a rectangular configuration of bi-directional linear array fixtures ( 3410 , 3415 , 3420 , and 3425 ) as shown in the embodiment of FIG. 34 . The advantage of this embodiment is that the interior reflecting material 3430 may be chosen to have the optimum reflection characteristics. An alternate embodiment of the configuration shown in FIG. 34 uses fixtures that are all uni-directional in the direction pointing inwards to the interior surface. This fixture is similar to a traditional 2×4 troffer with the noteworthy exception that it is 16 times its area. An embodiment of this type of lighting fixture could be useful for large conference rooms.
[0161] This same embodiment could be used to light the interior of the inner circle illustrated in FIG. 28 , for example, by adding a second tier of LEDs/secondary optics 3500 pointing inwards, as shown in FIG. 35 .
[0162] Multi-Tier Curve Linear and Linear Array Fixtures
[0163] As mentioned earlier it is sometimes advantageous to use multiple tiers of curve-linear or linear arrays to achieve more efficient lighting, according to one embodiment. Another embodiment involves multi-tier unidirectional linear array fixtures in large rooms in the configuration shown in FIG. 36 . In one embodiment, if sufficient optical power is not possible from a single tier of LEDs, a second tier may be utilized. The tiers may or may not have the same angular direction. | A lighting fixture includes a directional light source that produces a plurality of light rays. An optical module is coupled to the directional light source to focus the plurality of light rays into a beam of light rays to be output by the lighting fixture. The angular distribution of a majority of the beam relative to a vector normal to a ceiling on or near which the fixture is to be installed is in a range of 70 to 95 degrees. A blocking structure is used to block a direct view of the beam of light when the fixture is installed such that only indirect light is primarily visible from a viewer at least in or around a working plane substantially parallel to the ceiling. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an embroidering machine.
2. Description of the Prior Art
Conventionally, it is well known that an embroidering machine does embroidery on a work based on embroidering data. The embroidering data which indicates embroidering designs to the embroidering machine is previously inputted in a floppy disk by an embroidering data generating device such as a digitizer. The resulting floppy disk is inserted into the embroidering machine and then various designs are embroidered on the work while the embroidering machine reads data from the floppy disk.
However, the embroidering data generating device per se is very expensive. In addition, the preparation of the foregoing embroidering data is cumbersome.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved embroidering machine which obviates the above conventional drawbacks.
It is another object of the invention to provide an improved embroidering machine which is free from the preparation of an embroidering data.
In order to attain the foregoing objects, an embroidering machine comprises a body including a bed and an arm which is formed on the bed, a frame for holding a work, a movement device for moving the frame along the bed in the horizontal direction, an embroidering device set in the body for embroidering the work, a detecting device for detecting a pattern which is drawn on the work, and a controller for controlling the movement means based on information which is detected by the detecting device.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will be more apparent and more readily appreciated from the following detailed description of a preferred exemplary embodiment of the present invention, taken in connection with the accompanying drawings, in which;
FIG. 1 is a schematic view of an embroidering machine according to the present invention;
FIG. 2 is a front view of a work on which a line stitch is sewn by an embroidering machine according to the present invention;
FIG. 3 is a front view of a work on which a zigzag stitch is sewn by an embroidering machine according to the present invention;
FIG. 4 is a block diagram of a controller according to the present invention;
FIG. 5 is a picture caught by a camera of a sensor according to the present invention;
FIG. 6 is a flow chart of a main routine showing the operation according to the present invention;
FIG. 7 is a flow chart of a sub routine showing the scanning routine according to the present invention;
FIG. 8 is a flow chart of a sub routine showing the frame moving routine in Step 50 in FIG. 6 according to the present invention;
FIG. 9 is a flow chart of a sub routine showing the frame moving routine in Step 110 in FIG. 6 according to the present invention; and
FIG. 10 is a flow chart of a sub routine showing the sewing routine according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 to 4 inclusive, there is illustrated an embroidering machine 1 which mainly includes a bed 2 having four legs 2a and an arm 3 standing on the bed 2. A frame 4 which can hold a work 6 to be sewn is located at a position near an upper surface of the bed 2. The frame 4 includes a frame body (not shown) having an installation part 4b and a frame ring 4a which is fitted in an inner surface of the frame body. At first, the work 6 is set on the frame body and the frame ring 4a is fitted, via the work 6, in the inner surface of the frame body. Thus the work 6 is held with tension between the frame body and the frame ring 4a and is in close relationship to the bed 2. The installation part 4b is connected to an operation device 5 and is operated along the bed 2 in the X-Y directions.
The operation device 5 includes an operation arm 5a which moves the frame 4 in the X direction and an operation bar 5b which moves the frame 4 in the Y direction. One end of the operation arm 5a is connected to the installation part 4b and the other end thereof is connected slidably to a groove (not shown) which is formed on the side of the operation bar 5b. The operation arm 5a is moved along the groove of the operation bar 5b by an X motor 15 installed in the bed 2. A pair of longitudinal slots 2c are formed in both sides of the bed 2 and both ends of the operation bar 5b are in sliding engagement with the corresponding slots 2c. The operation bar 5b moves in the Y direction along the slots 2c when a Y motor 16 operates. The Y motor is also installed in the bed 2, and the X motor 15 and the Y motor 16 are controlled by a controller 10. Furthermore an X encoder 20 and a Y encoder 21, both of which are shown in FIG. 4, are connected to the X motor 15 and the Y motor 16, respectively. The X and Y encoders 20 and 21 each check the rotation number of each of the X motor 15 and the Y motor 16, and the resulting numbers are provided as signals to the controller 10. Thus the controller 10 recognizes the location of the frame 4.
On the upper surface of the arm 3, there are installed an upper thread standing bar 7 which holds an upper thread 9, and a guide 8. The upper thread 9 is guided to a needle 14 through the guide 8, a beam 11, and an upper thread adjustment device 12. The needle 14 is reciprocated between the arm 3 and the bed 2 vertically when an embroidering motor 25 is operated by the controller 10. The rotation number of the embroidering motor 25 is always detected by an embroidering sensor 26 which provides the signal to the controller 10. Moreover, a lower thread shuttle device which holds the lower thread is installed under the bed 2 and is operated in synchronization with the needle 14.
A sensor 13 for detecting the pattern 6a drawn on the work is installed on the wall of the arm 3. The sensor 13 includes a camera 13a which catches the pattern 6a and a color vision circuit 13b which provides a position of the pattern 6a to the controller 10 based on the image caught by the camera 13a. The picture caught by the camera 13a is provided to the color vision circuit 13b and is divided into 9 sections A to H and Z as shown in FIG. 5. The camera 13a can take or catch the pattern 6a near the portion where the needle 14 penetrates the work 6.
The embroidering means including the needle 14 and the operation device 5 is controlled by the controller 10. The controller 10 is provided with the signal which shows the position of the pattern 6a through the color vision circuit 13b of the sensor 13 and controls the operation of the operation device 5 based thereon.
The embroidering machine 1 in this embodiment is operated as follows. At first, the operator draws the pattern 6a, which he/she will embroider on the work with different color from that of the work 6 and the resultant work 6 is fixed to the frame 4. Referring to FIG. 6, the embroidering machine is turned on or connected to the power supply in Step 10. Next, Step 15 is performed for initializations wherein all data in register and flag are reset and cleared. In Step 20, the X motor 15 and the Y motor 16 are operated and the frame 4 gets back to its starting point. When the frame 4 is on the starting point in this embodiment, the camera 13a reflects the periphery of the frame 4. In Step 30, a scanning routine is performed. Referring to FIG. 7, the register P which is set in the controller 10 is reset to "0" in Step 31. In Step 32 an increment of 1 is added to the register P. In Step 33, the frame 4 is moved for a set distance in the X direction by the X motor 15 and the work 6 is scanned in the X direction for same distance with the frame 4. If the sensor 13 detects no pattern 6a in Step 34, the Step 35 is performed and it is judged whether or not the count of the register P has attained a set point N. If the count of the register P has attained the set point N, Step 36 is performed and the frame 4 is moved in the Y direction by the Y motor 16 and the control is returned to Step 31. If the count in the register P hasn't attained the set point N, the control is returned to Step 33 without motion in the Y direction. The count N means the full movement of the work 6 from one end to the other end in the X direction.
If the sensor 13 detects a pattern 6a in Step 34, Step 40 is performed and it is checked whether or not a pattern 6a is detected in the section Z (FIG. 5). In the case of "Yes", the control goes to Step 40. If Step 60 shows a negative conclusion, the control goes to Step 50 which is shown in FIG. 8 in detail. In Step 50, the portion where the pattern 6a exists is searched from the section A to the section H in turn and the X motor 15 and/or the Y motor 16 are operated. Thus the pattern 6a is moved and an initial portion where embroidered at first is set into the section Z.
In Step 60, the initial portion of the pattern 6a is memorized in a memory MO and Step 70 is performed so that a flag is set to "1". The flag condition means the initial sewing and the flag will be reset to "0" in Step 118 which will be described later. In Step 80, if the operator gives instructions to start the sewing operation, Step 90 is performed for starting a sewing of settled stitches shown in FIG. 10. In step 100, it is judged whether a portion sewn in Step 90 is the initial portion or not, namely, whether the needle 14 is back at the initial portion or not. In the case of "No", Step 110 is performed and the frame 4 is moved so as to sew the next portion of the pattern 6a. Step 110 is described in FIG. 9 in detail. In Step 110, the next sewn portion is searched, namely, the portion where the pattern 6a exists is searched from the section A to the section H in turn. For example, in Step 111, it is judged whether the pattern 6a is in the section A or not. If it is not therein, the control goes to Step 114. If it is therein, Step 112 is performed and it is judged whether the section A is the same portion memorized in a memory M1 or not. Namely, it is judged whether the section A has been sewn yet or not. The memory M1 is inputted in Step 115 and it is cleared at first sewing. If the section A has not been sewn, the X motor 15 and the Y motor 16 are operated. Thus the portion of the work 6 which is caught in the section A is moved or transfered into the section z. In step 115, the memory M1 is reset and the distance and direction that the work 6 has been moved are memorized in the memory M1. In Step 116, it is judged whether the flag is set to "1" or not. In the case of "Yes", which means the first sewing, the distance and direction that the work 6 has been moved are memorized in a memory M2 as the data which shows the first sewn portion. Next, Step 117 is performed and the flag is reset to "0" and the control returns to the main routine.
Thus, the sewing operation is performed from Step 90 to Step 110. In step 100, if it is judged that a portion sewn in Step 90 is the initial portion, namely, the needle 14 gets back to the initial portion memorized in memory M0, Step 120 is performed and the pattern 6a is searched without the portion which is memorized in the memories M1 and M2. In this step, it is judged whether there are any branches at the pattern in the initial portion or not. In the case of "Yes", the control returns to Step 90. In the case of "No", Step 130 is performed and the upper thread 9 and the lower thread are cut. Next, the last step, that is, Step 140 is performed and sewing is stopped.
As regards the above embodiment, the sewing pattern can be selected. For example, the work 6 can be sewn with a line stitch referring to FIG. 2 or a zigzag stitch referring to FIG. 3. In the latter case, the operator can give instructions about the distance and the width which the work is sent and the work can be embroidered by more variety patterns.
As mentioned above, according to the present invention, the embroidering machine embroiders on the work 6 along the pattern 6a which is drawn thereon, which means that no preparation of embroidering data in advance is required. Thus, much time can be saved and the embroidering is made easy.
Obviously numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | An embroidering machine comprises a body including a bed and an arm which is formed on the bed, a frame for holding a work, a movement device for moving the frame along the bed in the horizontal direction, an embroidering device set in the body for embroidering the work, a detecting device for detecting a pattern which is drawn on the work, and a controller for controlling the movement means based on an information which is detected by the detecting device. | 3 |
Background of the Invention
[0001] 1. Field of the Invention
[0002] The present invention relates to a notebook computer, and more particularly, to a notebook computer with an integrated cosmetic set.
[0003] 2. Description of the Prior Art
[0004] Please refer to FIG. 1 . FIG. 1 is a perspective view of a prior art notebook computer 1 0 . Notebook computers are widely used by business travelers and sales representatives because these groups of people often have to travel to different places to attend meetings and make business deals. Further a lot of business travelers are female. They often carry a cosmetic set with them when traveling because some people believe that women wearing make-up tend to enhance their confidence and improve their appearance. Further, one day's work may require a lady to fix her make-up a few times. Therefore some women will carry a cosmetic set with them wherever they go. The cosmetic set may include a lipstick, foundation, eye shadow, mascara, eyeliner, face powder, etc. Because of all these items, a woman may have to prepare an additional cosmetic pack.
[0005] However, a business traveler often has to carry a lot of information with them. It will become a great burden for a female business traveler to carry an extra cosmetic pack. Moreover before a lady meets her client, she is likely to check her appearance again including checking on her make-up. At this time, if she is not completely satisfied with her make-up, she will have to search her cosmetic pack again to fix her appearance. Therefore the cosmetic pack becomes inseparable from the lady.
SUMMARY OF THE INVENTION
[0006] According to the present invention, a notebook computer is composed of an operation portion and a display portion. The notebook computer comprises a first slot formed at one side of the operation portion, a cosmetic set capable of being pushed into the first slot and pulled out from the first slot, a second slot formed at one side of the display portion, and a mirror capable of being pushed into the second slot and pulled out from the second slot by rotating with respect to a pivot.
[0007] According to the present invention, another notebook computer is composed of an operation portion and a display portion, characterized in that a storage portion is formed next to an operation surface of the operation portion for accommodating a cosmetic set.
[0008] These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a prior art notebook computer.
[0010] FIG. 2 is a perspective view of a notebook computer according to the first embodiment of the present invention.
[0011] FIG. 3 is a perspective view of a notebook computer according to the second embodiment of the present invention.
[0012] FIG. 4 is a perspective view of a notebook computer according to the third embodiment of the present invention.
DETAILED DESCRIPTION
[0013] Please refer to FIG. 2 . FIG. 2 is a perspective view of a notebook computer 20 according to the first embodiment of the present invention. The notebook computer 20 is composed of an operation portion 201 and a display portion 202 . The operation portion 201 is provided with at least a key operation portion 2011 and a cursor operation portion 2012 . A first slot 2013 is formed at one side of the operation portion 201 for disposing a cosmetic set 203 . In this embodiment, the cosmetic set 203 includes a plurality of cosmetic items such as a lipstick, foundation, eye shadow, mascara, eyeliner, face powder, etc. Further the cosmetic set 203 can be pulled out from the first slot 2013 when a user needs to use a cosmetic item and can be pushed into the first slot 2013 after the user finishes using the cosmetic item. The cosmetic set 203 has a side with an elongated slot 2032 . The first slot 2013 has a corresponding protruding edge 20131 for engaging with the elongated slot 2032 to avoid vibrations of the cosmetic set 203 . The cosmetic set 203 has a front side with a protruded knob 2031 . The knob 2031 allows a user to push the cosmetic set 203 into the first slot 2013 after using the cosmetic set 203 . Further an elastic hook and an elastic element are installed inside the first slot 2013 . After the cosmetic set 203 is pushed into the first slot 2013 , the elastic hook hooks the cosmetic set 203 , and then the cosmetic Page 3 of 14 set 203 is positioned against the elastic element. When the user pushes the knob 2031 , the elastic hook will unhook the cosmetic set 203 , and the elastic element will push the cosmetic set 203 away from the first slot 2013 .
[0014] Please refer to FIG. 2 again, a second slot 2021 is formed at one side of the display portion 202 . The second slot 2021 is used to accommodate a fan-shaped mirror 204 which can be pushed into the second slot 2021 and pulled out from the second slot 2021 by rotating with respect to a pivot 205 . Therefore, when a user fixes her make-up, the user does not need to use another mirror. Further, the mirror 204 has an end with a knob 2041 for the user to move in or move out the mirror 204 . Moreover, an elastic hook is installed inside the second slot 2021 for hooking the mirror 204 after the mirror 204 is pushed into the second slot 2021 , and an elastic element is also installed inside the second slot 2021 for pushing against the mirror 204 after the mirror 204 is pushed into the second slot 2021 and pushing the mirror 204 away from the second slot 2021 after the mirror 204 is unhooked from the elastic hook.
[0015] Please refer to FIG. 3 . FIG. 3 is a perspective view of a notebook computer 22 according to the second embodiment of the present invention. The difference between the notebook computer 20 and the notebook computer 22 is in the design of the mirror. The mirror 206 of the notebook computer 22 is rectangular-shaped. An edge of the mirror 206 has a knob 2061 for horizontally pulling the mirror 206 out of the second slot 2021 or pushing the mirror 206 into the second slot 2021 . Moreover, an elastic hook is installed inside the second slot 2021 for hooking the mirror 206 after the mirror 206 is pushed into the second slot 2021 , and an elastic element is also installed inside the second slot 2021 for pushing against the mirror 206 after the mirror 206 is pushed into the second slot 2021 and pushing the mirror 206 away from the second slot 2021 after the mirror 206 is unhooked from the elastic hook.
[0016] Please refer to FIG. 4 . FIG. 4 is a perspective view of a notebook computer 24 according to the third embodiment of the present invention. As shown in FIG. 4 , a cosmetic set 207 is detachable from the notebook computer 24 . Thus, when not using the cosmetic set 207 , the cosmetic set 207 can be stored in a storage portion 2014 of the notebook computer 24 . When using the cosmetic set 207 , a user can choose to remove the cosmetic set 207 from the notebook computer 24 . As shown in FIG. 4 , the storage portion 2014 faces upward, and is formed on a surface of the operation portion 201 of the notebook computer 24 . However, the storage portion 2014 is not constrained to that design. The storage portion 2014 can be formed at other parts of the notebook computer 204 such as at a side of the operation portion 201 . Further the cosmetic set 207 can comprise more than one cosmetic item 2072 , and a mirror 2071 . Thus the design of the cosmetic set 207 can be varied according to a user's demand.
[0017] The present invention inherently carries out at least following advantages:
[0018] (1) The notebook computer is integrated with the cosmetic set, thus the user does not need to spare extra space to accommodate the cosmetic set;
[0019] (2) The notebook computer is integrated with the cosmetic set, thus the cosmetic set becomes easily portable.
[0020] (3) The notebook computer is integrated with the mirror, making wearing make-up convenient and feasible.
[0021] In conclusion, a cosmetic set is integrated into a notebook computer in the present invention. Therefore, the user can carry the cosmetic set with great ease.
[0022] Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims. | A notebook computer is suitable for a user who wears make-up. In addition to the computing power, a cosmetic set is integrated into the notebook computer. Thus the user can carry the notebook computer with the cosmetic set together as one single item instead of carrying two separate items. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for treating a multifilament thread in a melt-spinning process.
2. Description of Related Art
When producing synthetic threads, a plurality of fine filament strands is extruded from a polymer melt in a melt-spinning process and then combined to form a multifilament thread after cooling down. In order to enable the subsequent guidance of the thread in further treatment steps, for example, for drawing the thread with the aid of godets, it is necessary to wet the thread. For this purpose, a spin finish fluid is applied to the thread. In order to ensure that all the filament strands disposed in the thread are wetted uniformly, the thread is interlaced with the aid of a compressed-air blast in an additional treatment step following the wetting step. This interlacing process, in other words, the so-called “pre-entangling,” results in a homogenized application of the spin finish fluid to the filament strands of the thread. At the same time, the filament strands are intermixed as a result of the interlacing process, which improves the cohesion of the filament strands disposed in the thread.
For carrying out the wetting and interlacing of the thread, an apparatus is disclosed in the prior art, for example, in EP 1 165 868 B1 or DE 10 2004 017210 A1, in which apparatus the treatment steps for wetting the thread and interlacing the same are carried out immediately one after the other in the thread path with a short interval in between. For this purpose, the devices for the application of spin finish fluid and the devices for interlacing the thread are disposed in a common housing. Immediately following the wetting process, the thread is guided with a spin finish fluid without further thread-guiding elements in a common treatment channel for subsequent interlacing. In this context, it is possible to achieve particularly compact apparatuses for treating a multifilament thread in several steps.
In the apparatus known from the prior art, it has now been observed that the interlacing of the filament strands within the thread produces dynamic effects that continue to act in the direction extending opposite to the thread path up to the wetting step and beyond the latter. However, such effects, which become particularly noticeable by way of twist effects appearing on the thread, can sometimes adversely affect the upstream treatment steps performed on the thread.
SUMMARY OF VARIOUS EMBODIMENTS
It is now the object of the present invention to develop an apparatus for treating a multifilament thread of the kind cited at the start in such a way that the dynamic effects produced by the interlacing process can be controlled for the upstream treatments carried out on the multifilament thread.
This object is achieved according to the invention by an apparatus of various embodiments.
Preferred developments of the invention are defined by the features and combinations of features of the respective dependent claims.
One particular advantage of the invention is that the dynamic effects, particularly the twist effects, produced on the thread by a compressed-air blast, cannot act on the thread uncontrollably in the direction extending opposite to the thread path. As a so-called twist stop, the baffle plate comprises a thread-guiding element in that portion of the treatment channel that is located between the nozzle bore and the inlet opening; this thread-guiding element is configured so as to protrude into the treatment channel in order to deflect the thread. The thread is thus subjected to a forced deflection, which results in a stabilization of the filament strands disposed within the thread composite. It is thus possible to advantageously avoid twist effects acting in the opposite direction.
The invention was also not suggested by the apparatus disclosed in WO 03/033791 A2 for treating a multifilament thread. The apparatus disclosed there comprises a treatment channel for interlacing a thread inside a housing plate; this treatment channel contains a projection in the groove ground on the inlet side and on the outlet side in each case. Thread guides are assigned to both the thread inlet and the thread outlet outside the treatment channel and these thread guides subject the thread to a desired forced guidance inside the treatment channel.
The apparatus disclosed in the document cited above is therefore completely unsuitable for enabling the implementation of several treatment steps on the thread one after the other at short intervals. Furthermore, the projections disposed in the groove ground of the housing plate are completely unsuitable for preventing possible twist effects from acting in the direction extending opposite to the travel direction of the thread. The compressed-air blast opening into the treatment channel from the nozzle bore thus results in a deflection of the thread against the baffle plate. Consequently, the thread is lifted off by the projections provided in the groove ground of the housing plate so that there remains no forced guidance of the thread inside the treatment channel. A twist effect produced by the compressed-air blast could thus act freely up to the thread guides disposed outside the housing plate in the known apparatus.
Another particular advantage of the invention is that irrespective of the deflection of the thread brought about by the compressed-air blast, the forced guidance remains inside the treatment channel due to the thread-guiding element. For this purpose, the thread-guiding element is disposed on the baffle plate located opposite to the housing plate. The deflection of the thread brought about by the compressed-air blast thus further enhances the deflection, for which the thread-guiding element is intended, in the direction of the groove ground of the treatment channel.
In order to be able to bring about a larger deflection on the thread particularly in the case of coarse yarn counts of the filament strands, that development of the invention is particularly advantageous in which the housing plate comprises a recess in the region of the thread-guiding element for extending the treatment channel, and the thread-guiding element can be inserted through the recess beyond a groove depth of the treatment channel. This also makes it possible to achieve larger deflections of the thread beyond the groove depth of the treatment channel. Furthermore, the recess in the groove ground enables the implementation of additional points of support on the thread guided in the treatment channel so that particularly strong twist effects can also be stopped.
In a preferred development of the invention, the thread-guiding element is formed by a molded projection on the baffle plate; this projection comprises a wear-resistant contact surface in relation to the thread. The thread-guiding elements and the baffle plate can thus be advantageously produced from the same material.
For achieving variably large deflections, the baffle plate is preferably connected to the housing plate such that the former can be replaced, it being possible to selectively combine several baffle plates having variably high projections with the housing plate. The desired twist-stopping effects can be achieved depending on the thread type and the melt-spinning process. This development of the invention enables a high degree of flexibility to be achieved in the interlacing of the thread.
However, it is likewise possible in principle, to form the thread-guiding element by a thread guide, which is held at the baffle plate such that the thread guide can be replaced. Here, the thread guide can be formed by a deflection pin or a deflection roller, the contact surfaces of which have a wear-resistant coating in relation to the thread. It is thus possible to advantageously produce the thread-guiding element and the baffle plate from different materials.
The preferred development of the invention, in which the housing plate comprises an assembly opening for connection to a wetting device in that portion of the treatment channel that is located between the thread-guiding element and the inlet opening provides a very compact design in order to be able to carry out both a wetting of the thread and an interlacing of the thread inside the treatment channel. For this purpose, a wetting element for applying spin finish fluid to the thread is held inside the assembly opening of the housing plate and this wetting element protrudes into the treatment channel.
In order to ensure flexibility in using the apparatus for different processes and thread types, the wetting element according to a preferred development of the invention is preferably connected to the housing plate such that the former can be replaced. Wetting elements adapted to suit the yarn counts of the thread can thus be integrated easily in the housing plate.
Preferably, spin finish applicators comprising a ceramic contact surface in the guide area of the thread are used as wetting elements. The spin finish fluid is preferably guided via a capillary bore toward the contact surface so that the thread can be wetted continuously.
It has been observed that the interlacing process, following the wetting process immediately, spins off a part of the spin finish fluid from the thread and this fluid accumulates inside the treatment channel. In order to prevent losses of the spin finish fluid, that development of the invention is preferred in which the housing plate comprises a collector opening in that portion of the treatment channel that is located between the nozzle bore and the outlet opening. This collector opening opens into the treatment channel and is intended for connection to a suction line. The suction line is connected to a collecting vessel for the recirculation of the spin finish fluid. An entrainment of excess spin finish fluid by the thread, which can result in contamination outside the apparatus, can thus be prevented advantageously.
In order to achieve firstly an advantageous air routing inside the treatment channel for interlacing the multifilament thread and secondly a natural slope for discharging the fluid residue accumulating in the treatment channel, that development of the invention is preferably used in which the groove ground of the treatment channel in the housing plate has an inclination directed toward the collector opening. The outlet opening of the treatment channel thus has a larger cross-section in relation to the inlet opening.
In order to achieve an advantageous air flow, which acts in the travel direction of the thread, in the treatment channel and in order to collect and discharge the spin finish fluid dripping off as a result of the deflection of the thread on the thread-guiding element, a preferred development of the invention provides the housing plate with a collector opening located opposite to the thread-guiding element. This collector opening is connected via a suction line to an external collecting vessel for receiving and depositing the fluid. It is thus possible to generate a suction power on the thread, which acts in the direction of the wetting device and further improves the wetting process by an intensive contact between the thread and the wetting element.
For protecting the contact surfaces of the housing plate and the baffle plate acting on the thread from wear, these contact surfaces can be formed by ceramic protective coatings. According to a preferred development of the invention, the housing plates and the baffle plate are made of a ceramic material for this purpose, the housing plate and the baffle plate also comprising plane-parallel sealing surfaces in addition to their contact surfaces; these sealing surfaces are held tightly on each other for sealing the treatment channel. The treatment channel can thus be provided with a seal for interlacing the thread without the use of any additional sealants.
For receiving the housing plate and the baffle plate, a preferred variant of the invention uses a support housing, in which the housing plate and the baffle plate are embedded. For this purpose, the support housing comprises a thread inlet and a thread outlet corresponding to the inlet opening and the outlet opening respectively.
For easy insertion of the thread into the treatment channel, the support housing preferably has a two-part design, one of the housing parts being formed as a swiveling housing cover, which carries the baffle plate on the lower side thereof. The treatment channel can thus be opened and closed easily by swiveling the housing cover without necessitating additional steps.
Since several threads are usually guided parallel to each other with a narrow spacing between the threads, one development of the invention is particularly suitable for the treatment of a plurality of threads. Here, a plurality of housing plates and a plurality of baffle plates are juxtaposed in the support housing.
In order to achieve the narrowest possible spacing between the threads, a plurality of treatment channels can be formed alternately in the housing plate and in the baffle plate, each treatment channel being provided with an assembly opening for receiving a wetting element and a collector opening for connection to a suction line.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The invention will be described in more detail below on the basis of several exemplary embodiments of the apparatus of the invention with reference to the attached drawings in which:
FIG. 1 schematically shows a view of the longitudinal section of a first exemplary embodiment of the apparatus of the invention
FIG. 2 schematically shows a cross-sectional view of the exemplary embodiment shown in FIG. 1
FIG. 3 schematically shows a view of the longitudinal section of another exemplary embodiment of the apparatus of the invention
FIG. 4 schematically shows a cross-sectional view of the exemplary embodiment shown in FIG. 3
FIG. 5 schematically shows a side view of the exemplary embodiment shown in FIG. 3
FIG. 6 schematically shows a side view of another exemplary embodiment of the apparatus of the invention
DETAILED DESCRIPTION
FIGS. 1 and 2 show a first exemplary embodiment of the apparatus of the invention for treating a multifilament thread. FIG. 1 illustrates a view of the longitudinal section of the exemplary embodiment and FIG. 2 shows a cross-sectional view of the same. The following description applies to both figures unless express reference is made to any one of the figures.
In the exemplary embodiment shown in FIG. 1 , a housing plate 1 and a baffle plate 2 are disposed inside a support housing 13 . The open longitudinal side of the housing plate 1 comprises a treatment channel 3 , which is formed as a groove on the longitudinal side of the housing plate 1 . The treatment channel 3 is covered by the baffle plate 2 resting against the longitudinal side of the housing plate 1 so that the housing plate 1 and the baffle plate 2 form an inlet opening 4 and an outlet opening 5 in the extended treatment channel 3 . A nozzle bore 6 , which penetrates the housing plate 1 and is connected to a compressed-air supply 16 formed on the support housing 13 , opens into the groove ground 11 of the treatment channel 3 . The compressed-air supply 16 is coupled via a compressed-air line 17 to a compressed-air source (not illustrated here).
In that portion of the treatment channel 3 that is located between the inlet opening 4 and the nozzle bore 6 , a thread-guiding element 7 is formed on the baffle plate 2 , which protrudes into the treatment channel 3 for deflecting a thread 10 guided in the treatment channel 3 . In this exemplary embodiment, the thread-guiding element 7 is formed by a projection 9 molded directly on the lower side of the baffle plate 2 . The projection 9 has a shape that has been adapted to suit the treatment channel 3 so that the thread 10 is guided securely in the treatment channel 3 . In the region of the thread-guiding element 7 , the cross-section of the treatment channel 3 is extended by a recess 8 . The recess 8 is shaped such that an extension of both the groove width and the groove depth of the treatment channel 3 are achieved.
In the exemplary embodiment shown in FIGS. 1 and 2 , the projection 9 on the baffle plate 2 protrudes up to the groove ground 11 of the treatment channel 3 at a short distance from the same. Thus, the thread 10 is deflected easily at the projection 9 within the treatment channel 3 . The contact surface of the projection 9 is preferably formed with a wear-resistant layer for this purpose.
As shown in FIG. 1 , the support housing 13 forms a thread inlet 14 corresponding to the inlet opening 4 , and a thread outlet 15 corresponding to the outlet opening 5 of the treatment channel 3 . For this purpose, the support housing 13 is preferably formed by two parts 28 and 29 which are held together by sealing them in relation to the ambience. The housing parts 28 and 29 have recesses in the region of the thread inlet 14 and the thread outlet 15 in order to hold the respective thread guides 22 . 1 and 22 . 2 in position. Only in the region of the thread inlet 14 and the thread outlet 15 , the thread guides 22 . 1 and 22 . 2 are held in the wall of the support housing 13 . The thread guides 22 . 1 and 22 . 2 can be formed by ceramic elements by way of example.
In that region inside the support housing 13 that is located between the thread inlet 14 and the inlet opening 4 , an inlet chamber 27 is formed in the extended treatment channel 3 for receiving a wetting device 18 . The wetting device 18 comprises a spin finish applicator 19 , which is held on the support housing 13 and comprises a fluid channel 20 . The fluid channel 20 opens at a contact surface of the spin finish applicator 19 . The opposite end of the fluid channel 20 is connected to a fluid connection 21 . The fluid connection 21 is formed on the support housing 13 and is connected with the aid of a fluid line 26 to a fluid source (not illustrated here) for supplying a spin finish fluid, for example, an oil-in-water emulsion.
On the opposite side of the housing plate 1 , an outlet chamber 23 is formed inside the support housing 13 in the extended treatment channel 3 . The outlet chamber 23 is connected via a collector opening 31 in the wall of the support housing 13 to a suction connection 24 . A suction line 25 , which is coupled to a collecting vessel via a vacuum source (not illustrated here), is connected to the suction connection 24 .
In the exemplary embodiment of the apparatus of the invention shown in FIGS. 1 and 2 , a multifilament thread formed by a plurality of individual restiform filaments, is supplied for treatment via the thread inlet 14 . Inside the support housing 13 , the filaments of the thread 10 are initially wetted at the spin finish applicator 19 formed as the wetting element. For this purpose, the filaments of the thread 10 are guided such that they contact the wetted surface of the spin finish applicator 19 and are wetted uniformly with a spin finish fluid.
The wetted thread 10 is then supplied via the inlet opening 4 to the treatment channel 3 . The filaments of the thread 10 are interlaced by the compressed-air blast discharged into the treatment channel 3 by way of the nozzle bore 6 . The compressed-air blast is preferably adjusted such that it results in a mere mixing of the filaments without forming knots and in particular in a homogenization of the spin finish fluid application on the thread. The dynamic effects produced by the compressed-air blast on the thread, in particular, the twist effects are prevented from acting on the thread in the direction extending opposite to the thread travel direction by deflecting the thread 10 at the projection 9 of the baffle plate 2 , which projection protrudes into the treatment channel 3 . The dynamic effects generated by the interlacing of the filaments of the thread 10 advantageously remain in the treatment channel and cannot act uncontrollably on the thread in the direction extending opposite to the thread travel direction.
The deflection of the thread 10 in the direction of the groove ground 11 , which deflection is produced in the treatment channel 3 by the baffle plate 2 , additionally improves the thread guidance and the interlacing of the thread. The projection 9 of the baffle plate 2 deflects the thread 10 in the treatment channel 3 opposite to the flow direction of the compressed air supplied. The baffle plate 2 is connected to the housing plate 1 for replacement so that the magnitude of deflection of the thread in the treatment channel can be altered by replacing the baffle plate 2 . A plurality of baffle plates 2 having varying projections 9 can thus be kept ready in order to be combined selectively with the housing plate 1 in the support housing 13 . The housing plate 1 is likewise held preferably for replacement in the support housing 13 so that a housing plate 1 comprising a larger or smaller nozzle bore 6 can be used, for example. The interlacing process can thus be adjusted to suit the respective thread type. The nozzle bore 6 preferably opens at an inclination directed in the travel direction of the thread so that a compressed-air blast that is directed toward the outlet opening 5 can be produced in the treatment channel 3 . Furthermore, excess residue of the spin finish fluid can be guided by way of the treatment channel 3 toward the outlet chamber 23 . Inside the outlet chamber 23 , the residue of the spin finish fluid is discharged by way of the collector opening 31 . For this purpose, a slight vacuum is produced in the outlet chamber 23 .
After the thread 10 is wetted and interlaced, it is guided out of the support housing 13 by way of the thread outlet 15 .
The exemplary embodiment shown in FIGS. 1 and 2 serves as an example of the selection and arrangement of individual parts of the apparatus of the invention. In principle, the wetting device 18 can be formed by other wetting elements such as nozzles or rollers, for example. Likewise, the thread-guiding element 7 provided on the baffle plate 3 and shaped as a molded projection 9 is an example of the various designs possible.
FIGS. 3 , 4 and 5 show another exemplary embodiment of the apparatus of the invention used preferably in a melt-spinning process for producing a plurality of synthetic threads. FIG. 3 is a schematic view of the longitudinal section of the exemplary embodiment, FIG. 4 is a cross-sectional view thereof and FIG. 5 is a side view thereof. The following description applies to all the figures unless express reference is made to any one of the figures.
Those apparatus parts of the exemplary embodiment that have identical functions have the same reference numerals.
In the exemplary embodiment shown in FIGS. 3 , 4 and 5 , a housing plate 1 and a baffle plate 2 are embedded in a support housing 13 . The support housing 13 is provided with a two-part design comprising a housing base 28 and a housing cover 29 . The housing cover 29 is held on the upper side of the housing base 28 such that the former can swivel about a swivel axis 30 . The baffle plate 2 and the housing plate 1 are attached for replacement to the housing cover 29 and the housing base 28 respectively. The baffle plate 2 and the housing plate 1 are thus separated from each other by opening and closing the housing cover 29 . When the housing cover 29 is opened, a thread can be inserted into a treatment channel 3 formed on the longitudinal side of the housing plate 1 . This situation is shown using dashed lines in the side view in FIG. 5 .
After the insertion of a thread into the treatment channel 3 , the housing cover 29 is closed with the baffle plate 2 so that the sealing surfaces of the housing plate 1 and the baffle plate 2 are held on each other forming a seal. The sealing surfaces of the housing plate 1 and the baffle plate 2 extend along the treatment channel 3 so that the latter is sealed in relation to the ambience. In this case, there is no requirement of creating a seal between the housing parts 28 and 29 .
As is apparent from the illustration of FIG. 3 , in particular, the baffle plate 2 and the housing plate 1 form the treatment channel 3 , an inlet opening 4 and an outlet opening 5 being formed on each of the front sides. Corresponding to the inlet opening 4 and the outlet opening 5 , a thread inlet 14 and a thread outlet 15 are formed between the housing cover 29 and the housing base 28 .
The housing plate 1 and the baffle plate 2 are substantially identical to the ones used in the exemplary embodiment described above so that only the differences will be explained below and otherwise reference is made to the above description.
As opposed to the exemplary embodiment shown in FIG. 1 , the wetting device 18 in the exemplary embodiment shown in FIG. 3 is connected to the housing plate 1 . For this purpose, the housing plate 1 comprises an assembly opening 37 in that portion of the treatment channel 3 that is located between the recess 8 and the inlet opening 4 , in which a wetting element 19 of the wetting device 18 is held. The wetting element is formed by a spin finish applicator 19 that is connected to the housing plate 1 for replacement. The spin finish applicator 19 protrudes from the assembly opening 37 into the treatment channel 3 and forms a wetted contact surface inside the treatment channel 3 , and the thread 10 comes into contact with this contact surface. The spin finish applicator 19 is connected with the aid of a fluid channel 20 to a fluid connection 21 on the housing base 28 . The fluid channel 20 opens at the contact surface of the spin finish applicator 19 inside the treatment channel 3 .
A thread-guiding element 7 , which is attached to the baffle plate 2 and which is inserted into the treatment channel 3 and the recess 8 , is disposed downstream of the spin finish applicator 19 in the travel direction of the thread.
As is apparent from FIGS. 3 and 4 , the thread-guiding element 7 in this exemplary embodiment is formed by a replaceable thread guide, in this case a deflection roller 12 . The deflection roller 12 is held, preferably for replacement, on the lower side of the baffle plate 2 . The deflection roller 12 protrudes beyond the groove ground 11 of the treatment channel 3 into the recess 8 so that the thread 10 inside the treatment channel 3 is deflected beyond the groove depth of the treatment channel 3 . Additional points of support, which are intended for supporting the thread 10 and result in an intensive stabilization of the interlaced thread, can thus be implemented advantageously in the transition sections between the recess 8 and the treatment channel 3 .
A nozzle bore 6 , which penetrates the housing plate 1 and is connected to a compressed-air supply 16 on the housing base 28 , opens into the treatment channel 3 in the central portion of the housing plate 1 .
In the further course of the treatment channel 3 , a collector opening 31 . 1 , which penetrates the housing plate 1 and is coupled to a suction connection 24 . 1 provided in the housing base 28 , is formed in the housing plate 1 in that portion of the treatment channel that is located between the nozzle bore 6 and the outlet opening 5 . The collector opening 31 . 1 results in an extension of the treatment channel 3 both in terms of its width and depth. The groove ground 11 of the treatment channel 3 in the housing plate 1 has an inclination directed toward the collector opening 31 . 1 so, that there results a natural slope toward the outlet opening 5 . The outlet opening 5 therefore has a larger cross-section than the opposite inlet opening 4 . This design of the treatment channel 3 has proved useful both for the discharge of excess fluid residue and for creating the interlacing effects on the thread.
Particularly in order to be able to discharge the residue of the spin finish fluid dripping down as a result of a deflection of the thread 10 from the treatment channel 3 , a second collector opening 31 . 2 penetrating the housing plate 1 is formed in the ground of the recess 8 . The collector opening 31 . 2 is connected to a suction line 25 . 2 in the housing base 28 .
For discharging the residue of spin finish fluid accumulating inside the treatment channel 3 , suction lines 25 . 1 and 25 . 2 are connected via a vacuum source 32 to a collecting vessel 33 so that the fluid residue is recirculated continuously to the collecting vessel 33 . In this connection, additional steps such as a processing step for the spin finish fluid can also be interposed, to advantage.
The functioning of the exemplary embodiment shown in FIG. 3 to FIG. 5 is identical to the one shown in FIGS. 1 and 2 . Reference is made at this point to the above description. Additionally, FIG. 3 shows a connection option for the supply and discharge of a spin finish fluid and for the supply of compressed air to the apparatus of the invention. Thus, the spin finish fluid is supplied to the spin finish applicator 19 from a dosing pump 35 by way of the fluid line 26 . For this purpose, the dosing pump 35 is connected to the collecting vessel 33 which maintains a supply of a spin finish fluid such as an oil-in-water emulsion for wetting a synthetic thread.
For feeding compressed air into the nozzle bore 6 , a pressure source 34 is provided, which is connected via a control valve 36 and the compressed-air line 17 to the nozzle bore 6 . The control valve 36 enables the selection of the desired pressure settings for producing the compressed-air blasts entering the treatment channel 3 .
The exemplary embodiments shown in FIGS. 1 to 5 are preferably suitable for continuously wetting and interlacing each individual thread. However, several threads are usually produced parallel to each other in melt-spinning processes so that several devices have to be arranged side-by-side in order to wet and interlace the threads in parallel. In order to be able to achieve the least possible spacing between the threads, another exemplary embodiment of the apparatus according to the invention is shown in FIG. 6 . FIG. 6 shows a side view of the exemplary embodiment.
Here, a plurality of housing plates 1 and a plurality of baffle plates 2 are held directly next to each other inside a support housing 13 . In the exemplary embodiment, a total of three housing plates 1 and three baffle plates 2 are shown which are in contact with each other and are disposed side-by-side in a row. The designs of the housing plate 1 and the baffle plate 2 are identical to those used in the exemplary embodiment shown in FIGS. 3 and 4 so that reference is made to the above description in order to avoid repetition. The adjacent housing plates 1 and the adjacent baffle plates 2 can be disposed both parallel to each other—as shown in FIG. 6 —or at an angle to each other.
In this exemplary embodiment, a housing base 28 and a housing cover 29 that are connected to each other over a swivel axis 30 likewise form the support housing 13 . The housing cover 29 carries a total of three baffle plates 2 on the lower side thereof so that three threads can be inserted simultaneously into the treatment channels 3 of the housing plates 1 in an open position of the housing cover 29 . The apparatus shown in FIG. 6 is particularly suitable to wet and interlace a beer in parallel.
Alternately, the treatment channels 3 illustrated in FIG. 6 can each be formed by a housing plate and a baffle plate. For this purpose, the housing plate 1 would comprise a plurality of treatment channels 3 , which are located parallel to each other and can be closed by a baffle plate, and three thread-guiding elements assigned to the treatment channels would be held on the baffle plate. | The invention relates to an apparatus for treating a multifilament thread in a melt-spinning process, wherein a treatment channel is formed between a housing plate and an impact plate. The housing plate has a nozzle bore which opens into the treatment channel and is connected to a compressed-air connection. Together with the housing plate, the impact plate forms an inlet opening and an outlet opening at both ends of the treatment channel. In order to check the swirling effects which are produced on the thread by the eddying within the treatment channel, according to the invention the impact plate has a thread guiding element in the part piece of the treatment channel between the nozzle bore and the inlet opening, which thread guiding element is configured so as to protrude into the treatment channel in order to deflect the thread. | 3 |
This patent application relies upon the filing date of corresponding Provisional Patent Application, Serial No. 60/010,514 entitled KIDS SAFETY LATCH of John Howard Pullen filed Jan. 24, 1996.
BACKGROUND OF THE INVENTION
This invention is directed to a door latch having an auxiliary bolt which activates the latch bolt, and the use of a latch to confine small children in the home.
DESCRIPTION OF THE PRIOR ART
U.S. Pat. No. 1,272,710 Ramsher (1918) discloses a spring pressed sliding bolt in a door lock casing. A rack bar is carried by the bolt. An outwardly spring pressed plunger is slidable within the casing and has its outer end projecting beyond the casing. A link pivoted within the casing transversely of the bolt has one end pivotally and slidably connected with the inner end of the plunger. A pawl is pivoted upon the other end of the link and normally engages the rack bar. Engagement of the projecting end of the plunger with the door jamb releases the pawl from engagement with the rack bar.
U.S. Pat. No. 1,968,285 Egan (1934) discloses a door latch having a casing and a latch bar having rack teeth mounted in the casing. A pair of slidably mounted pinions enmesh with the rack. A detent pawl is pivoted on the rack guide and is engagable with either of two slots in the bolt, depending upon whether the bolt is retracted or advanced. The latch bar has two trips depending therefrom and adapted to cooperate with the upper end of the pawl.
U.S. Pat. No. 2,136,539 Brinton (1938) discloses a night latch which allows one to open a door equipped with a night latch with one hand. When the bolt of the night latch is retracted from the keeper, as by means of the key, it is automatically held in retracted position until the door is opened and is then automatically released so as to be prepared to operate in the usual way when the door is subsequently closed. The night latch which is designed for an out opening door, may be used for an in-opening door. This is accomplished by removing the housing from the door so that the latch bolt, auxiliary bolt and the parts fixed to them may be taken out and reversed, that is turned upside down.
U.S. Pat. No. 2,279,591 Heyer (1942) discloses an improvement over the U.S. Pat. No. 2,136,539 of Brinton (1938). Heyer utilizes holding means to hold the latch bolt retracted once it is retracted, and provides an auxiliary bolt with means for releasing the latch bolt from the holding means when the auxiliary bolt is retracted. The auxiliary bolt is cammed backwardly or retracted relatively to the strike by the movement of the door into open position, once the latch bolt is retracted, the strike preferably serving to do this through its coaction with a cam surface on the auxiliary bolt. When so retracted, the auxiliary bolt releases the latch bolt for projection. The latch bolt of Heyer is held back when retracted by the usual manually operated means, even with the door or closure in open position, since in open position the auxiliary bolt is fully projected. Heyer provides suitable cam surfaces whereby the strike cams back or retracts the auxiliary bolt when the door is moved into closed position. This movement of the auxiliary bolt will, of course, release the latch bolt for projection. Heyer also provides means for maintaining his latch bolt in a deadlocking position. Heyer also provides means for maintaining his latch bolt retracted at all times. His double beveled auxiliary bolt then provides a yielding resistance to the opening and closing of the door.
U.S. Pat. No. 4,683,741 Fields (1987) discloses a battery operated electrical circuit including a switch operable by the lock turn buttons, and a light emitting diode mounted within the door knobs so as to be operable on locking the door to provide a flashing light visible from the outside of the door. This patent is representative of patents disclosing lights that indicate when a door is locked.
SUMMARY OF THE INVENTION
While the locks of the prior art all represent significant advances in the lock art, they still suffer significant short comings. For instance, the conventional prior art latch bolt is released from its retracted position when the door is opened. This requires that the conventional prior art latch bolt strike the striker plate every time the door is closed. If the force closing the door is not sufficient, the spring on the prior art latch bolt will prevent the door from closing. If the force is too strong, the conventional prior art latch bolt will twist in the housing, bind and not retract. Also continuous opening and closing of the door will tend to wear a groove in the cammed surface of the conventional prior art latch bolt causing it to malfunction. The present invention solves the problem by the use of an auxiliary bolt which only releases the latch bolt when the door is closed, thus avoiding malfunctions.
The present invention is also directed to a latch to be placed on a door at least five feet above the floor so that a child cannot reach it. The latch contains an auxiliary bolt having a trip pin. When the door is closed, the strike causes the auxiliary bolt to move into the latch. The pin on the auxiliary bolt trips a catch which releases the latch bolt, locking the door. The beveled end of the auxiliary bolt is pivoted so that opening the door causes the beveled end to pivot and not transmit force to the main body of the auxiliary bolt. However, when the beveled end of the auxiliary bolt strikes the strike plate, the auxiliary bolt is retracted, the pin trips a spring biased dog which rests in a notch in the latch bolt, releasing the latch bolt.
More specifically the latch for a hinged structure of the present invention is contained in a casing. The latch has a spring pressed latch bolt having a notch therein. A rack gear is attached to the latch bolt. A handle, operable from either side of the casing, rotates the spur gear and retracts the latch bolt into the casing to a predetermined position. A dog rotatably positioned in the notch, is held in the notch by a spring positioned between the casing and the dog. An auxiliary bolt, spring biased to project from the casing is slidable relative to the casing. A pin extending from the auxiliary bolt is movable into contact with the dog when the auxiliary bolt is retracted into the casing to release the dog from the notch and release the latch bolt to the locked position.
The auxiliary bolt has a beveled end which protrudes from the casing in an unretracted mode. A hinge joins the beveled end to a main body of the auxiliary bolt. The hinge allows the beveled end to pivot when the door is opened, but does not allow the beveled end to pivot when the door is closed. Force on the beveled end causes the auxiliary bolt to retract, and move the dog from the notch thus releasing the latch bolt and locking the hinged structure.
The beveled face of the auxiliary bolt is positioned so that the beveled face strikes a striker plate when the door is closed.
The latch is placed on a door at least five feet above the bottom of the door so that a child cannot reach it. A guard plate extends parallel to the latch and perpendicular to the door and below the latch to prevent a child from opening the latch by using a long object such as a stick to turn the latch handle.
The latch has no protrusions extending from either side that would prevent it from being mounted on a door other than the removable handles and handle shaft, thus allowing a single latch to be mounted on a right or left hand swing door, on either side of the door without modification.
The latch has two rack gear driven spur gears, one spur gear spaced further than the second spur gear from where the auxiliary bolt projects from the casing, whereby one spur gear could be used for narrow framed doors such as storm or screen doors and the other spur gear could be used for a wide framed door to open the latch.
The latch has a pin positioned for insertion into the latch bolt to hold the bolt in an unlocked position or in a locked position.
The latch also has a switch activated by movement of the latch bolt and a light or buzzer activated by the switch to indicate whether the latch bolt was in the locked on unlocked position. A timer prevents the light or buzzer activation if the door is only temporarily unlocked.
While the present invention is primarily directed to the above identified latch, it is also directed to the safety feature of any lock being positioned at least 5 feet above the bottom of the door to prevent a small child from activating the lock. The additional feature of any lock positioned at least five feet above the bottom of the door or the floor is a guard plate positioned below the lock to prevent a child from using a long object such as a stick to open the lock.
Also the auxiliary bolt of the present invention can be used in many other types of latches. The auxiliary bolt has a beveled end to activate a latch bolt. The improvement of the present auxiliary bolt over prior art auxiliary bolts is a spring biased hinge between the beveled end of the auxiliary bolt and the remainder of the auxiliary bolt whereby movement only in one direction causes the auxiliary bolt to activate the latch bolt.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of the latch, having a guard plate positioned under a handle, mounted on a door and a strike mounted on a door frame.
FIG. 2 is a side sectional view of the mechanism of the latch mechanism of the present invention with the cover removed in the latched condition.
FIG. 3 is a side sectional view of the latch mechanism of the present invention with the cover removed and the latch's main bolt in the retracted open position.
FIG. 4A is a side sectional view of the secondary or auxiliary bolt showing the spring biased, hinged break-away beveled end and position of the trip pin.
FIG. 4B is a top sectional view of the auxiliary bolt showing the beveled end in extended position.
FIG. 4C is a view of the auxiliary bolt of FIG. 4B rotated 180°.
FIG. 4D is a top sectional view of the auxiliary bolt showing the pivot pin for the beveled end in the break away position and the spring providing the bias for the beveled end of the auxiliary bolt.
FIG. 5 is a side sectional view of the latch mechanism of the present invention in the dead lock condition and the secondary bolt retracted by contact with the strike to release the main bolt to latched position.
FIG. 6A is a side view of the main bolt latch.
FIG. 6B is a top view of the main bolt latch.
FIG. 7 is a sectional end view of the night lock showing the dead latch pin assembly and the latch casing.
FIG. 8 is a side view of the main latch bolt in open or retracted position and held in the retracted position by the dead latch pin where it will stay until manually released.
FIGS. 9A and 9B are views of the electrical warning system and its operation.
FIG. 10 shows the outside of a door having an extension handle to allow a child to unlatch the door.
FIGS. 11A and 11B show a strike to be mounted on a door frame extending perpendicular from a door.
FIGS. 12A and 12B show a strike to be mounted on a door frame extending parallel from a door.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and more especially to FIGS. 1-3, there is shown the latch assembly of the present invention having a screw hole 6 to allow the casing to be held together and casing alignment dowels and holes 8 to properly align the two sections of the casing (see FIG. 3). The latch casing 10 containing the latching mechanism is secured by suitable screws 12 through mounting holes 14 to a door 16 cooperable with a door jamb 18 on which is supported a strike 20. Guard plate 21 extends outwardly from the latch casing to prevent a small child from using a stick to reach up and open the latch from the inside. Spur gears 22a and 22b are rotatably mounted in casing 10 and are rotated by turning a handled shaft 24, optionally having a pendant extension rod 25, in a square hole 26a or 26b. The two spur gears 22a and 22b are provided to allow for a door knob or handled shaft 24 to be mounted different distances from the strike 20. If locks are to be made for a specific type of door, only one spur gear 22a or 22b is necessary. The latch casing 10 with spur gear 22b is designed for storm doors, screen doors or other doors with narrow frames. Spur gear 22a is designed for regular doors. It does not matter which spur gear 22a or 22b is turned so for further discussion reference will be made to spur gear 22 which may be considered to be either spur gear 22a or 22b. The extension rod 25 provides a means whereby the handle is extended by from one to three feet on the outside of a door whereby a small child can open the door from the outside.
The rotation of spur gear 22 will drive rack 28 and retract main latch bolt assembly 30 into the latch housing 10. The movement of the main latch bolt assembly 30 will cause the main bolt latch trip 32 to drop into a notch 34 holding the main latch bolt assembly 30 in a retracted position as is shown in FIG. 3. The latch trip 32 is spring loaded by spring 36 positioned in cylindrical recess 38. The door 16 can now be opened.
When the door 16 is opened, the secondary bolt 40 will break away as is shown in FIG. 4D. By "break away" is meant that tapered end 42 of secondary bolt 40 which is normally biased to its extended position by spring 43 will pivot on pin 44 and release from strike 20. Once released from strike 20 the tapered end 42 of secondary bolt 40 will extend to its normal position as shown in FIG. 4B. Secondary bolt 40 is biased in a position extending from latch casing 10 by spring 46 the other end of which is attached to a pin 48. The major portion of pin 48 is coaxial with spring 46. The part of the pin 48 which extends from spring 46 is bent at a right angle and the end of the pin 48 adjacent the bend is embedded in latch casing 10.
When the door 16 is closed, the secondary bolt 40 will wedge on strike 20 because tapered end 42 can only pivot in one direction. The movement of tapered end 42 against strike 20 will cause secondary bolt 40 to be retracted into housing 10. Trip pin 50 is partially embedded in and partially extending from secondary bolt 40. The movement of secondary bolt 40 into housing 10 causes trip pin 50 to come into contact with the main bolt latch trip 32 wedging the main bolt latch 32 out of notch 34 releasing main latch bolt 30 assembly allowing main latch bolt 30 assembly to return to normal or door closed position (see FIG. 2). Spring 46 will then push the secondary bolt 40 back out to the normal position shown in FIG. 2.
When fully projected the main latch bolt 30 assembly can be deadlocked by movement of deadlock pin 52 behind rear latch bolt section 54 of main latch bolt 30. Deadlock pin 52 prevents spur gear 22 from turning, thus preventing rack gear 28 from retracting the protruding section 56 of main latch bolt 30 which extends into strike 20. Rear latch bolt section 54 is normally biased against retraction by rear main latch bolt spring 58 which is positioned on pin 60 in the rear inner wall of housing 10. Rear latch bolt section 54 is prevented from forward movement out of housing 10 by dowel pins 61. See FIGS. 6A, and 6B for the structure of the main latch bolt 30.
Deadlock pin 52 is moved into position by pressing on pushbutton 70 in housing 10. Deadlock pin 52 extends from and is attached to pushbutton 70. A bridge 74 attached to pushbutton 70 is also attached to a second push button 76 which is coaxial or parallel to pushbutton 70 (see FIG. 7). Push button 76 is positioned in cylindrical recess 78a. Bridge 74 extends around the path of travel of rear latch bolt section 54.
It is also a feature of the present invention that when the main latch bolt assembly 30 is retracted as shown in FIG. 8, it can be held retracted. This is accomplished by turning latch handle 24 to the open position. This retracts the main latch bolt assembly 30 into housing 10. Push button 70 is then used to push pin 52 into cylindrical cavity 80 of rear latch bolt section 54 (see FIGS. 6A and 6B). Upon release of latch handle 24, the main latch bolt assembly 30 will be held in the retracted position by pin 52. A spring retaining flange 82 around rod 84 prevents the end of rod 84 extending beyond the flange 82, from passing set screw 88 in the cylindrical cavity 90 as shown in FIG. 6B. The spring retaining flange around rod 84 maintains rod spring 86 in compression and biases the protruding section of latch bolt 56 to an extended position. Push button 76 is held in its in or out position by a detent consisting of a spring 92 and a ball 94 which is held in one or the other of two V shaped recesses 96 and 98 in push pin 76 (see FIGS. 2, 3 and 7). This is useful for grandparents when there are no grandchildren around and there is no necessity to open the safety latch each time the door is opened. A grandparent could retract the main bolt 30 and push in on button 70 which would lock in main bolt 30. This would keep the main bolt retracted until the grandchildren returned or the grandparents wanted to put the lock back in service by pushing in on button 76.
The electrical system used in FIG. 9 is another safety feature that would let a person who opened the door know if the main bolt 30 is retracted in the housing and not in the locked position, for example, if a person were to go outside and unlocked the latch and the telephone rang and the person returned to answer the phone and forgot the latch was unlocked. After ten to fifteen seconds a light and buzzer reminding the person that the latch was unlocked would be activated. The person could then open the door and close it again and relock the latch.
The operation of the electrical system is as follows. The housing for the electrical system is shown as 100. The housing 100 contains a small battery 102, an electronic timer, light and buzzer assembly 104, contact points 106 and 108 and electrical wire 110. When the main bolt 30 is retracted it trips the contact points 108 and closes them closing the circuit to the timer, light and buzzer 104. The light and buzzer will be activated after fifteen seconds. The hot or + side of the battery 102 is electrically connected by a wire 110 to the timer, light and buzzer 104 directly. The ground or - wire completes a circuit through points 106 or 108. If the night lock button 70 is pushed in, it will trip another set of contact points 106 and this will open the circuit and nothing will happen even if the main bolt 30 is retracted to the open position. | This invention is directed to a door latch having an auxiliary bolt which activates the latch bolt, and the use of a latch to confine small children in the home. The auxiliary bolt has a hinged beveled end which pivots when the door is opened but is fixed when the door is closed to activate the latch. The latch is placed five feet above the floor to prevent a small child from opening the door. The latch has a guard plate below the door handle to prevent a small child from opening the latch with a stick. The latch can be mounted on any side of any door. | 8 |
This is a Divisional of application Ser. No. 08/159,401 filed Nov. 30, 1993 abandoned, which is a continuation-in-part of application Ser. No. 08/075,657 filed Jun. 11, 1993, now abandoned, which is a continuation-in-part of application Ser. No. 07/897,721 filed Jun. 12, 1992, now abandoned.
FIELD OF THE INVENTION
This invention relates to compositions and methods for reducing or preventing the backstaining of blue indigo dye onto denim during the stonewashing of denim fabric and garments utilizing cellulase enzymes.
BACKGROUND OF THE INVENTION
Denim is cotton cloth which has been dyed, usually blue, with the dye indigo. One desirable characteristic of indigo-dyed denim cloth is the alteration of dyed threads with white threads, which upon normal wear and tear gives denim a white on blue appearance. A popular look for denim is the stonewashed look. Traditionally stonewashing has been performed by laundering the denim material in the presence of pumice stone which results in fabric having a faded or worn appearance with the desired white on blue contrast appearance described above. This stonewashed look primarily consists of removal of dye in a manner to yield a material with areas which are lighter in color, while maintaining the desirable white on blue contrast, and a material which is softer in texture.
Enzymes, particularly cellulases, are currently used in processing denim. In particular cellulases have been used as a replacement for or in combination with pumice stones for the traditional “stonewashing” process used to give denim a faded look. Use of enzymes to stonewash has become increasingly popular because use of stones alone has several disadvantages. For example, stones used in the process cause wear and tear on the machinery, they cause environmental waste problems due to the grit produced and result in high labor costs associated with the manual removal of the stones from pockets of garments. Consequently, reduction or elimination of stones in the wash may be desirable.
Contrary to the use of pumice stones, enzymes (particularly cellulases) are safe for the machine, result in little or no waste problem and drastically reduce labor costs. Therefore, it may be beneficial to use enzymes for stonewashing. However, even though the use of enzymes such as cellulase may be beneficial as compared to stones alone, there are some problems associated with the use of enzymes for this purpose. For example, one problem with some cellulases, such as cellulases from Trichoderma, is what could be described as an incomplete removal of dye caused by “redeposition” or “backstaining” (both terms used interchangeably herein) of some of the dye back onto the fabric during the enzymatic stonewashing process. Such redeposition or backstaining causes blue coloration of the surface, resulting in less contrast between the blue and white threads and abrasion points (i.e., a blue on blue look rather than the preferred white on blue). See American Dyestuff Reporter, September 1990, pp. 24-28.
Redeposition or backstaining is objectionable to some users. Even though Trichoderma cellulases exhibit backstaining, they are preferable to Humicola cellulases, which do not generally exhibit backstaining, because of the higher specific activity on denim material seen with Trichoderma cellulases. In addition, cellulases with a higher degree of purity may be beneficial in the present invention. High specific activity or a high level of purity may result in a higher degree of abrasion in significantly shorter processing times and, therefore, is preferable to the denim processors.
The problem of redeposition of dye during stonewashing has been a concern of denim processors. Previous attempts to address the problem include addition of extra anti-redeposition chemicals, such as surfactants or other agents, into the cellulase wash to help disperse the loosened indigo dye and reduce redeposition. In addition, denim processors have tried using cellulases with less specific activity on denim, along with extra rinsings. This results in additional chemical costs and longer processing times. Another method attempting to address the redeposition problem includes adding a mild bleaching agent or stain removing agent in the process. This method affects the final shade of the garment and increases processing time.
While these methods aid to some limited degree in the reduction of redeposition, the methods are not entirely satisfactory and some objectionable backstaining remains. Use of enzymes and stones together may be advantageous in overcoming this redeposition problem; however, it leaves the processor with some of the problems associated with the use of stones alone.
Based on the shortcomings of previously attempted methods for reducing or preventing redeposition, there is a need for more environmentally favorable and more cost effective methods to address the issue of redeposition or backstaining of dye during stonewash treatment.
Accordingly, it would be desirable to find an enzymatic composition or method that would enhance the removal of the dye during stonewashing when redepositing or backstaining cellulases are used which, although exhibiting backstaining, have a high degree of specific activity on denim material.
FIGURES
FIG. 1 shows graphics of comparative reflectance measurements of stonewashing with a redepositing cellulase and different added proteases, as described in Examples 1, 2 and 3, vs. a redepositing cellulase control.
FIG. 2 shows graphics of comparative reflectance measurements of stonewashing with a redepositing cellulase and different added proteases vs. a redepositing cellulase control, as exemplified in Example 4.
SUMMARY OF THE INVENTION
Applicants have found that treatment of cotton indigo-dyed denim with an effective amount of a redepositing or backstain inhibiting composition comprising a redepositing cellulase composition and added protease that is in excess of the amounts naturally present in a redepositing cellulase preparation produced by a natural organism is an improvement over redepositing cellulase alone as a method for introducing variations in color density into the surface of the indigo-dyed denim. The result of treatment with such a composition is an improvement in the contrast between white and blue threads, achieving more complete dye removal (more like that achieved with pumice stones). The improvement in the contrast is due to a reduction in dye redeposition, resulting in abrasion points which are more distinct and display greater contrast between white and blue yarns, giving a superior stonewashed look. A small percentage of surface active chemical surfactant may optionally be added to the compositions or methods described herein. If a surface active agent is added, it may be added either with the cellulase and protease in the wash or with the protease as an after treatment rinse to enhance the proteolytic effect.
DETAILED DESCRIPTION OF THE INVENTION
Denim that is stonewashed with the addition of an effective amount of added protease during cellulase treatment with a redepositing cellulase shows a dramatic reduction in the level of backstaining and a visible increase in the contrast between white and blue threads, i.e., a more complete stonewash effect. While applicant does not wish to be held by any particular theory, one possible explanation for this might be that certain components present in redepositing cellulase compositions (see definition below) which comprise mixtures of several enzymes may bind tightly to the denim surface. These components may also bind dye-stained cellulose fragments and/or the dye itself, thus binding the colored materials or dye back on to the fabric. The addition of added protease effectively removes or prevents the cellulase proteins from binding the colored particles back onto the surface of the denim and yet, surprisingly, does not adversely effect the resultant abraded look caused by the action of the cellulase.
Prior to discussing this invention in further detail, the following terms will be defined.
The term “added protease” refers to an incremental amount of protease over the amount which is produced naturally by a microorganism. This incremental amount will result in reduction of backstaining when added to a redepositing cellulase composition during the stonewashing process. Preferably, such an incremental amount is at least 1% more than the amount of total protease protein naturally occurring in the microorganism that produces the redepositing cellulase composition. The amount of added protease is determined by many factors such as the purity, activity and specificity of the added protease, for example. Therefore, the incremental amount of added protease will vary with the type of protease added to the redepositing cellulase composition.
“Added protease”, as used herein, may be derived from either exogenous or endogenous sources. Added exogenous protease refers to those proteases which degrade proteins that are derived or developed externally from those naturally present in the cellulase composition of the microorganism. Alternatively, the added protease may be endogenous. In this case, added endogenous proteases refers to an amount of protease in a redepositing cellulase composition that is over and above what is naturally produced by the microorganism by overexpression of the gene encoding the naturally occurring protease. The amount of enhanced protease produced by overexpressing the gene encoding the protease is an amount that will result in inhibiting or reducing backstaining in the stonewashing process. Preferably, the enhancement is at least 1% greater than the amount of protease naturally occurring in the microorganism.
Proteases are available from several sources including microbial, plant and animal sources and are well documented in the literature. Some important commercial proteolytic sources include Bacillus licheniformis, Bacillus subtilis and Aspergillus oryzae. Proteases suitable for the invention include, for example, serine, metallo and acid proteases, as well as endo- and exo-proteases. Subtilisins are serine proteases which generally act to cleave internal peptide bonds of proteins and peptides. Metallo proteases are exo- or endo-proteases which require a metal cofactor for activity. One of the preferred serine proteases is subtilisin. Particularly preferred proteases useful in the present invention are proteases obtained from a microorganism genetically modified as described in U.S. Pat. Nos. 4,760,025 and 5,185,258, each of which is incorporated herein by reference.
The term “cellulase composition” comprises one or more exo-cellobiohydrolase (CBH), endogluconase (EG) and β-glucosidase (BG) components produced by a naturally occurring microorganism, wherein each of these components is found at the ratio naturally produced by the microorganism and sometimes referred to herein as a “complete or natural cellulase composition.”
It is contemplated that the cellulase compositions of the present invention may also include a cellulase composition obtained from a microorganism genetically modified so as to overproduce, underproduce or not produce one or more of the CBH, EG and/or BG components of cellulase. Additional modified cellulase compositions may include truncated cellulase proteins comprising either the binding domain or the core domain of the CBHs or EGs, or a portion or derivative thereof. Other examples of modified cellulase compositions may include alterations in the degree of glycosalation, or substitution(s) of amino acid(s) of the primary sequence of the cellulases or truncated cellulases.
A “redepositing or backstaining cellulase” as used herein refers to those cellulases, for example Trichoderma, which in the enzymatic stonewashing of denim tend to backstain the fabric leading to incomplete stonewashing when compared with stones alone or to cellulases which do not backstain, such as from Humicola. Redepositing or backstaining cellulases are derived from microorganisms such as fungal microorganism Trichoderma sp. or any other microorganism that produce cellulases displaying a backstaining or redepositing effect on denim in the stonewashing process.
The methods of the present invention comprise contacting the denim to be partially or wholly enzymatically stonewashed with an added protease in an amount sufficient to reduce backstaining and thus, to increase the contrast between blue and white fibers. The protease may be mixed together with the cellulase and then added to the wash containing the indigo-dyed denim fabric or each can be added separately and directly to the wash or the protease may be added subsequent to the cellulase wash in the rinse cycle. Alternatively, the protease may be added to the wash cycle prior to the addition of the cellulase to the same wash cycle. It should be noted that the cellulase stonewash bath may or may not include the liquor from the previous desizing step.
The redepositing or backstain inhibiting compositions of the present invention comprise added protease(s) and redepositing cellulase(s). In a particular embodiment, the redepositing or backstain inhibiting composition of the present invention comprises a redepositing or backstaining cellulase and added protease in a ratio of from about 5 ppm total protein in the redepositing cellulase: 1,000 ppm total protein in the added protease to 1,000 ppm total protein in the redepositing cellulase: 1 ppm total protein in the added protease. In a more preferred embodiment, the ratio is from about 10 ppm total protein in the redepositing cellulase: 200 ppm total protein in the added protease to 200 ppm total protein in the redepositing cellulase: 1 ppm total protein in the added protease. Total cellulase and protease protein can be measured by various assay methods known in the art. The assay preferably used herein is a commercially available biuret Lowry assay sold by Sigma Company, using bovine serum albumin (BSA) as the reference standard.
The redepositing or backstain inhibiting compositions may further comprise various adjuvants as known to those skilled in the art. For example, a surfactant (anionic or nonionic) compatible with the redepositing cellulase and added protease would be useful in the compositions of the present invention. Preferable surfactants are nonionic, such as the polyoxyethylated alcohols found in the TRITON® series of surfactants (octylphenoxypolyethoxyethanol nonionic surfactants) which are commercially available from Union Carbide. See, for example, U.S. Pat. No. 5,006,126 for a sample of these compatible surfactants. It should be noted that inclusion of a surfactant may further increase the stonewashing effect in combination with the redepositing cellulase and added protease. Other materials can also be used with or placed in the composition as desired, including stones, fillers, solvents, buffers, pH control agents, enzyme activators, builders, enzyme stabilizers, other antiredeposition agents and the like.
The backstain inhibiting composition may be formulated as a solid product wherein the solid may be granular, spray dried or agglomerated. For example, enzyme containing granules wherein the layer may comprise one or more enzymes including cellulases, proteases, amylases, and other proteins as recited in U.S. Ser. No. 07/957,973 filed on Oct. 7, 1992 which is a continuation in part of U.S. Ser. No. 07/772,510 filed on Oct. 7, 1991. These applications are incorporated herein by reference in its entirety. One contemplated application for a particle coated with cellulase, protease and amylase is to combine the desizing and stonewashing treatment in a single wash cycle.
Alternatively, the backstain inhibiting compositions may be formulated as a liquid gel or paste product. In this particular embodiment, redepositing cellulase is mixed with added protease in a ratio of from about 5 ppm total protein in the redepositing cellulase: 1,000 ppm total protein in the added protease to 1,000 ppm total protein in the redepositing cellulase: 1 ppm total protein in the added protease. To prepare a stable aqueous preparation of the above mixture, stabilizing ingredients must also be adding comprising oxygen containing, water soluble organic solvents in a buffer ranging from pH 4-6. Preferably sorbitol and glycerol are the stabilizing ingredients of choice.
In a preferred embodiment, the above liquid formulation mixture is incubated at elevated temperatures ranging from about 30° C. to about 60° C. from about 1 hour to 2 weeks prior to application on the denim fabric. In the most preferred embodiment, a temperature of about 37° C. and incubation time of about 120 hours are employed. One skilled in the art will recognize the amount of time for incubation which depends on the temperature chosen to prepare the mixture. It is further contemplated that the pretreated liquid formulation may be converted to a solid, i.e. granular, form to preserve the stability of the composition.
Added proteases used in the present invention may be added together with the redepositing cellulase to the stonewashing bath, or each added separately to the stonewash cellulase bath. Alternatively, the protease may be added in a separate cycle either prior to the cellulase bath or in a subsequent rinse treatment solution. In all methods contemplated above, the redeposition is reduced by about 5%, preferably about 10%, via measurement of reflectance off the backside of treated garments when compared to the stonewashing with cellulase alone. The measurement of reflectance values is described more fully in the Experimental section of this application. It should be noted, however, that the values measured for reflectance are compressed as compared to the visual differences seen when comparing treated versus untreated fabric. Visual observation is a more sensitive indicator of the stonewashing effect. Thus, visual observation of the backstaining on the backside of the garment reveals greater differences between treated and untreated fabric, as compared to measurements determined by a reflectometer.
In an embodiment of the present invention, the redepositing cellulase and added protease are present in a ratio of from about 5 ppm total protein in the redepositing cellulase: 1,000 ppm total protein in the added protease to 1,000 ppm total protein in the redepositing cellulase: 1 ppm total protein in the added protease. In a more preferred embodiment, the ratio is from about 10 ppm total protein in the redepositing cellulase: 200 ppm total protein in the added protease to 200 ppm total protein in the redepositing cellulase: 1 ppm total protein in the added protease.
One skilled in the art will realize that the effective amount of added protease will vary depending upon a number of well understood parameters, including the amount and purity of redepositing cellulase used, as well as the amount of redeposition which occurs without protease, the contact time, the amount of dye removed during stonewashing, the specific activity of the redepositing cellulase and/or added protease, the pH and temperature of the stonewashing process, the formulation of the product (liquid versus granular) and the like. It is well known in the art that specific activity of added protease and/or redepositing cellulase can be modified by genetically engineering a strain to change or modify components of interest. For example, the overexpression of certain cellulase components is demonstrated in U.S. application Ser. No. 07/770,049, which is incorporated herein by reference. Protein engineering techniques can also be used to modify enzyme activity or specificity, see for example U.S. Pat. No. 4,760,025, which is incorporated herein by reference.
It will be a simple matter to titrate the added protease with several washings and visually observe the resultant denim samples to achieve an effective amount which results in a reduction in backstaining. It should be noted, however, that there is a balance between the proteolytic effect on reducing backstaining and the proteolytic effect on reducing abrasion. One must find the optimum ratio of redepositing cellulase to added protease to achieve the antiredeposition effect without adversely affecting abrasion.
Reflectance values can be used as well to track the degree of redeposition on the backside of the garment but do not accurately reflect the contrast between fibers on the abraded front side of the garments. Differences in redeposition determined visually are more pronounced than with reflectance values, but reflectance values do show the effect to a lesser extent.
Redepositing or backstain inhibiting compositions of the present invention for addition to denim stonewash solutions (either as a solid or liquid) while comprising a redepositing cellulase(s) and added protease(s), may further comprise other adjuvants, such as surfactants, fillers, dispersants, buffers or pH control agents, enzyme activators, builders, enzyme stabilizers or other antiredeposition ingredients. One skilled in the art can readily compare the results of various combinations and ratios of solutions to optimize the selected components of such compositions. However, applicants have found that depending on the type of enzymes used and the particular mixture of selected ingredients mentioned above, the range of enzyme ingredients will preferably be within a ratio of from about 5 ppm total protein in the redepositing cellulase: 1,000 ppm total protein in the added protease to 1,000 ppm total protein in the redepositing cellulase: 1 ppm total protein in the added protease, as previously defined. In a more preferred embodiment, the ratio is from about 10 ppm total protein in the redepositing cellulase: 200 ppm total protein in the added protease to 200 ppm total protein in the redepositing cellulase: 1 ppm total protein in the added protease. This ratio will accommodate various combinations of specific activity of both redepositing cellulase and added protease, from both high specific activity to both low to variations in between, where one enzyme is relatively high in specific activity and the other relatively low. In addition, this ratio will accommodate various combinations of different purity of enzymes, from both highly pure to both having low purity to variations in between where one enzyme is relatively pure and the other has relatively low purity.
Where a surfactant is included in the composition, it will be about 5-85% of the total weight of either the liquid or dry composition. However, based on the Examples, one skilled in the art may lower the concentration of surfactant to amounts below 5% of the total weight of the liquid or dry composition without departing from the scope of the present invention. It is also possible to add the components separately, all at once, or sequentially (including separate rinse cycles). The amount of composition to use to treat denim would depend on the amount of enzymes active on the denim substrate and their specific activity on that substrate, the desired amount of stonewash effect and other parameters within the skill in the art.
The following examples are illustrative of the effectiveness of the compositions and processes of the present invention and are not intended to be limiting. Other choices of added protease or redepositing cellulase, as well as wash conditions such as concentration, measurement, pH, temperature and the like, will be evident to those skilled in the art based on the teachings herein.
EXPERIMENTAL
EXAMPLE 1
A 50 lb. Unimac dye/washing machine was used. Approximately 10 lbs. (˜3.8 kgs.) of desized test denim garments were placed in the machine. The machine was filled with 10 gals. (38 L) hot water and brought to 131° F. (55° C.). The liquor ratio was 10:1 (kg. garment:liters liquor). The liquor was buffered to Ph ˜4.9 with 44 grams citric acid, monohydrate, and 100 grams sodium phosphate dibasic.
Once pH was established, redepositing cellulase enzyme INDIAGE® 44 L (Trichoderma cellulase composition, commercially available from Genencor International, Inc.) was added at a rate of about 0.5 ml of product/L of wash liquor (62.5 ppm total protein). Protease enzyme, GC899 (a serine endopeptidase from Bacillus subtilis, available from Genencor International, Inc.) was then added at about 2.5 ml of product/L of wash liquor (163 ppm total protein). This resulted in a dose ratio of about 1:2.6 based on total protein. The garments were washed at 36 rpms for 60 minutes. After this, the bath was dropped.
The garments were then rinsed according to a standardized protocol in three consecutive cycles of clean liquor. Rinse #1=24 gals. hot water, approximately 50° C., plus ˜100 grams standard detergent WOB (from American Association of Textile Chemists and Colorists [AATCC], WOB=without brighteners). Agitation was for 12 minutes at 36 rpms. The bath was dropped. Rinse #2=24 gals. warm water, ˜40° C., with no additional detergents, agitated for 5 minutes. The bath was dropped. Rinse #3=24 gals. cold water, ˜30° C., with no additional detergents, agitated for 5 minutes. The bath was dropped. Garments were extracted and dried in a standard electric clothes dryer.
Reflectance readings were taken off the backside of the garments using a Hunter Color Difference Meter (reflectometer apparatus). Reflectance was measured as the percent reflectance (or transmittance of light off treated fabric) where L=100 units is white, and L=0 units is black. Compared to redepositing cellulase treatment only (redepositing cellulase control=0.5 ml of INDIAGE® 44 L product/L wash liquor), the redepositing cellulase plus added protease treated garments resulted in significantly reduced backstaining with similar levels of abrasion (39.07 [redepositing cellulase control] vs. 42.87 [redepositing cellulase and added protease] reflectance values). These reflectance values confirmed visual observations. The added protease treatment resulted in a better abraded contrast overall. See FIG. 1 .
EXAMPLE 2
This test was substantially similar to Example 1 with the same type and amount of redepositing cellulase being used but with a different amount of the same added protease. This was about 0.5 ml of product/L of wash liquor (33 ppm total protein) of the added protease. This resulted in a dose ratio of about 1:0.5 based on total protein. All other processing parameters were the same.
Compared to redepositing cellulase control, reflectance readings were significantly different between the two treatments, but level of abrasion was not. Cellulase control=39.07 vs. cellulase and protease=41.21. The final abraded look had better contrast for the added protease treated garments as compared to untreated (no protease) control, however, added protease treatment in Example 1 was better than Example 2, showing the titration effect of added protease. See FIG. 1 .
EXAMPLE 3
The redepositing cellulase treatment was the same as in Example 1 but without the addition of added protease. The bath was dropped and the standard rinse cycle was begun, as described in Example 1 with the following exception: 1 ml of GC899 protease per liter of rinse liquor was added at the beginning of Rinse #1. A total of 100 mls of added protease product was used (65 ppm total protein). All other conditions remained the same.
Use of the added protease with detergent in the rinse cycle resulted in significantly reduced backstaining when compared to cellulase control rinsed with detergent alone. Reflectance values were 40.66 for the added protease rinse vs. 39.07 for the standard rinse without added protease. The degree of abrasion was the same for both treatments, although the added protease rinsed garments showed better overall contrast than the standard rinse without added protease. See FIG. 1 .
EXAMPLE 4
Utilizing the cellulase washing protocol described in Example 1, the following added protease products were tested, along with 0.5 ml of product/L of wash liquor of redepositing cellulase enzyme (62.5 ppm total protein) INDIAGE® 44 L (Trichoderma cellulase composition, commercially available from Genencor International, Inc.):
1. MULTIFECT™ P64 (bacterial protease derived from Bacillus licheniformis and commercially available from Genencor International, Inc.), dosed at about 5 g of product/L of wash liquor (71 ppm total protein) to yield a dose ratio of about 1:1 based on total protein;
2. MULTIFECT™ P53 (bacterial protease derived from Bacillus subtilis and commercially available from Genencor International, Inc.), dosed at about 5 g of product/L of wash liquor (88 ppm total protein) to yield a dose ratio of about 1:1.5 based on total protein;
3. MULTIFECT™ P41 (fungal protease derived from Aspergillus orvzae and commercially available from Genencor International, Inc.), dosed at about 5 g of product/L of wash liquor (172 ppm total protein) to yield a dose ratio of about 1:2.75 based on total protein;
4. Subtilisin GC399 (available from Genencor International, Inc.), dosed at about 2.5 g of product/L of wash liquor (238 ppm total protein) to yield a dose ratio of about 1:4 based on total protein.
All added protease treatments resulted in less redeposition with similar abrasion levels when compared to redepositing cellulase control garments. In each case, added protease treatment improved overall contrast of the abraded look. See FIG. 2 . This example shows the effect of added proteases from various microbial sources which show the same antiredeposition effect as the added protease used in the previous examples.
EXAMPLE 5
A series of cellulase washes were run in order to demonstrate the efficacy of added protease protein per se as opposed to the formulation components of the added protease product in reducing the degree of redeposition. GC899 protease protein was used, which contained no enzyme product formulation components other than the protease protein. The same cellulase washing procedure was used as described in Example 1.
The following treatments were run:
1. Buffer Control (no protease or cellulase).
2. Redepositing Cellulase Control=0.5 ml of product/L wash liquor (62.5 ppm total protein) dose of INDIAGE® 44 L (Trichoderma cellulase composition, commercially available from Genencor International, Inc.).
3. Nonredepositing Cellulase Control=2.5 ml of product/L wash liquor (100 ppm total protein) dose of DENIMAX™ L (endoglucanase derived from Humicola, a non-pathogenic mold and commercially available from Novo Nordisk). This was the recommended dose of the manufacturer.
4. Added Protease Treatment=0.5 ml of product/L wash liquor (62.5 ppm total protein) dose of INDIAGE® 44 L (Trichoderma cellulase composition, commercially available from Genencor International, Inc.) plus about 0.18 mls of GC899 protease protein/L wash liquor (25 ppm total protein). This resulted in a dose ratio of about 1:0.4 based on total protein.
All treatments were run at Ph 5 except for the nonredepositing cellulase treatment, which was run at Ph 7 according to the manufacturer's recommendations. The reflectance readings are shown in the following Table 1:
TABLE I
TREATMENT
REFLECTANCE (L VALUE)
Buffer Control
43.25
Redepositing Cellulase Control
37.92
Nonredepositing Cellulase Control
42.60
Added Protease Treatment
43.51
Reflectance results correspond with visual observations that the addition of protease protein reduces the degree of redeposition on garments. The protease treated garments have similar reflectance readings to a nonredepositing cellulase treatment. Quality of abraded contrast is improved with protease treatment as well over redepositing cellulase treatment.
EXAMPLE 6
Use of added protease in combination with a surfactant, either added separately with the redepositing cellulase or added as a redeposit inhibiting composition is demonstrated in the following treatments. Again, the same cellulase washing protocol was used for all cases, as described in Example 1.
1. Buffer Control (no protease or cellulase).
2. Redepositing Cellulase Control=0.5 ml of product/L of wash liquor (100 ppm total protein) dose of a redepositing cellulase, CELLUSOFT™L (Trichoderma cellulase preparation, commercially available from Novo Nordisk), plus 0.25 ml of product/L of wash liquor (250 ppm) dose of nonionic surfactant, TRITON® X-100 (octylphenoxypolyethoxyethanol nonionic surfactant, commercially available from Union Carbide Chemicals and Plastics Co., Inc.).
3. Added Protease/Surfactant Treatment=0.5 ml of product/L of wash liquor (100 ppm total protein) dose of a redepositing cellulase, CELLUSOFT™L (Trichoderma cellulase preparation, commercially available from Novo Nordisk), plus 0.25 ml of product/L of wash liquor (250 ppm) dose of nonionic surfactant, TRITON® X-100 (octylphenoxypolyethoxyethanol nonionic surfactant, commercially available from Union Carbide), plus about 0.2 mls of GC899 protease protein/L wash liquor (40 ppm total protein). this resulted in a dose ratio of about 1:0.4 based on total protein.
4. Nonredepositing Cellulase Control=2.5 ml of product/L of wash liquor (100 ppm total protein) dose of DENIMAX™ L (endoglucanase derived from Humicola, a non-pathogenic mold and commercially available from Novo Nordisk).
5. Backstain Inhibiting Composition Blend=a blend comprising of redepositing Trichoderma cellulase (from Genencor International, Inc.), subtilisin protease (GC399 from Genencor International, Inc.) and nonionic surfactant (TRITON® X-120, octylphenoxypolyethoxyethanol nonionic surfactant, commercially available from Union Carbide) was dosed at 2 g of blend/L of wash liquor. This is about a 1:0.4 ratio of cellulase to protease protein as defined previously. This dose of the blended product resulted in doses of 60 ppm total protein from the cellulose product, 24 ppm total protein from the protease product and 120 ppm surfactant. The blend was made up of 3% total protein from the cellulase, 1.2% total protein from the protease and 6% of the surfactant.
TABLE II
TREATMENT
REFLECTANCE (L VALUE)
Buffer Control
43.25
Redepositing Cellulase Control
35.65
Protease/Surfactant Treatment
42.48
Nonredepositing Cellulase Control
42.60
Backstain Inhibiting Composition
42.33
Blend
As can be seen, the addition of protease to a redepositing cellulase in the presence of surfactant, either as separate components added altogether (protease/surfactant treatment), or as a single backstain inhibiting composition (backstain inhibiting composition blend), markedly reduces the degree of redeposition. Reflectance values of protease treatments are similar to those of a nonredepositing cellulase or buffer treatment. Visual observations confirm this. The contrast of the abraded look is also improved with protease treatment which is better than treatment with the redepositing cellulase control.
EXAMPLE 7
The test was performed in a substantially similar manner as Example 1, except that the protease and redepositing cellulase are mixed together prior to the addition in the wash cycle. The mixture, INDIAGE 44 L and Protease GC899 is prepared in a ratio of about 10:1 based on total protein. In this example, the amount is about 111 ppm total protein. Once the pH of the washing liquid was established, the redepositing cellulase and protease mixture was added at a concentration of about 1.0 ml of mixture/L of wash liquid. All other processing parameters were the same as Example 1 except that a different lot of denim was employed in this Example and Example 8 below.
Compared to the redepositing cellulase control, reflectance readings of the sample treated with redepositing cellulase/protease were significantly different. Reflectance results correspond with the visual observation that the addition of protease protein in the mixture reduces the degree of redeposition on the denim garments compared to the redepositing cellulase control. The protease treated garments show similar reflectance readings to a non-depositing cellulase treatment. The quality of abraded contrast in the fabric was also improved with the redepositing cellulase/protease mixture compared to the redepositing cellulase alone. See Table III below.
EXAMPLE 8
The test was performed in a similar manner as Example 7 using the same redepositing cellulase and protease mixture, however, the ratio of cellulase to protease was changed and an additional heating process was included.
The mixture comprising INDIAGE 44 L and Protease GC899 was prepared in a ratio of about 60:1 based on total protein. The mixture was further heated to a temperature of 37° C. for 120 hours before addition to the wash cycle. In this example, the amount is about 122 ppm total protein. All other processing parameters were the same as those described in Examples 1 and 7.
TABLE III
TREATMENT
REFLECTANCE (L VALUE)
Redepositing Cellulase Control
45.08
Redepositing
52.58
Cellulase/Protease Mixture
(Example 7)
Redepositing
52.53
Cellulase/Protease Mixture
Heat Treatment
(Example 8)
Nonredepositing Cellulase
51.86
Control
Similar to results in Example 7 where garments are treated with a redepositing cellulase/protease mixture, treating garments with the redepositing cellulase/protease mixture that has been previously heated results in improved reduction of backstaining compared to the garments treated with redepositing cellulase alone. Moreover, the contrast of the abraded look is markedly improved using the pre-incubated cellulase/protease mixture compared to the redepositing cellulase control and the redepositing cellulase/protease mixture of Example 7. | During the desizing and enzymatic stonewashing of denim fabric and/or garments, redeposition of blue color often occurs back onto the surfaces of the denim. The invention relates to a redepositing or backstain inhibiting composition and a method requiring the inclusion of an added protease prior to, during or subsequent to the stonewashing process which reduces the redeposition of the blue dye and hence improves the stonewashing process when using redepositing or backstaining cellulases to give an appearance closer to that when using stones alone or nonredepositing cellulases in the stonewashing process. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to ghost cancelling circuits and, more particularly, is directed to a circuit for detecting waveform distortion of a video signal used in a ghost eliminating or cancelling circuit.
2. Description of the Prior Art
In the television receivers, cancellation or removal of a ghost wave component of a received video signal can be performed in the following manner.
That is, a reference signal for ghost cancellation (hereinafter referred to simply as a GCR signal) is added to the video signal in a transmitter side.
In a receiver side, a waveform of the GCR signal (including a ghost wave component) of the received video signal is compared with a waveform of a GCR signal formed in the receiver side to extract the ghost wave component and to control the transmission characteristic of a transversal filter, for example, so as to eliminate the extracted ghost wave component.
As the GCR signal, such a signal SGCR shown in FIG. 1A has been used.
In FIG. 1A, a symbol HD represents a horizontal synchronizing pulse and BRST a burst signal. As shown in FIG. 1A, a first GCR signal is formed to have a bar pattern waveform which is disposed succeeding to a horizontal period and has a width of 44.7 μ sec. and a level of 70 IRE. The rising characteristics of the bar pattern waveform is a ringing characteristics of sin X/X.
Further, a second GCR signal PDS is formed to have a pedestal waveform whose flat-topped level is 0 as shown in FIG. 1B.
As shown in FIG. 2A, the GCR signal is constituted with a repetition period of 8 fields of the video signal in a manner that the first GCR signal GCR is inserted in a 18'th or a 281'th line of each of the 1st, 3rd, 6th and 8th fields while the second GCR signal PDS is inserted in a 18'th or a 281'th line of each of the remaining 2nd, 4th, 5th and 7th fields and the thus constructed GCR signal SGCR is inserted in the video signal and transmitted.
Supposing that the first to eighth GCR signals SGCR are called signals S1-S8, respectively, if these signals S1 to S8 are operated in the receiver side based on the equation of FIG. 2B, the result of the operation will be a signal GCR. If the ghost wave component is included in the received GCR signal, the result of the operation also includes a ghost wave component Sg of the signal GCR.
Thus, it is possible to eliminate the ghost component on the basis of the signal GCR (and the component Sg) of the operation result.
In this case, each of the burst signal BRST, chrominance signals and the horizontal synchronizing pulses HD exhibits the same phase every eight fields, so that each of the burst signal BRST, chrominance signal and horizontal synchronizing pulse HD is cancelled when performing the operations of the signals S1-S8.
Thus, the signal GCR (and the ghost wave component Sg) obtained through the operation does not include any of the burst signal BRST, chrominance signal and the horizontal synchronizing pulse HD, so that the elimination or cancellation of a so-called front ghost and rear ghost and waveform equalization can be performed within a range of 45 μ sec. at maximum. Further, an erroneous detection can be prevented for a long ghost having a width of about 80 μ sec.
FIG. 3 is a block diagram showing an example of the conventional ghost cancelling circuit using the GCR signal SGCR In FIG. 3, a composite color video signal SY added with the above-described GCR signal SGCR is picked up from a video signal detecting circuit 1 and applied to an analog-to-digital (A/D) converter 2 to be converted into a digital video signal SY of 8 bits for one sample, for example. The digital video signal SY is then applied to a digital-to-analog (D/A) converter 4 through a transversal filter 3 with 640 steps or taps, for example, to be converted into an original analog video signal SY and then taken out from a terminal 5.
In that time, in a detecting circuit 10, a ghost wave component is detected from the GCR signal SGCR to control the transmission characteristic of the transversal filter 3 on the basis of the detected output to thereby eliminate the ghost wave component from the video signal.
The operation shown in FIG. 2B can be rewritten into the equation of FIG. 2C which means that the operation can be performed by sequentially accumulating the GCR signals SGCR in the respective fields.
Thus, in the detecting circuit 10, the digitized video signal SY from the filter 3 is applied to a gate circuit 11 to extract the GCR signal SGCR (including foregoing and succeeding detection periods), and then the extracted signal SGCR is applied to a buffer memory 12 to hold at every one field period, all of the GCR signals SGCR during the period.
The GCR signals SGCR stored in the memory 12 are applied to an operation circuit 21. This operation circuit 21 and the following circuits 22 to 25 are constituted by a microcomputer 20 and software in practice but in this figure they are represented by hardware.
In the operation circuit 21, the GCR signals SGCR stored in the memory 12 are sequentially read out and added or subtracted according to the equation of FIG. 2C at every one field period to thereby obtain the signal GCR and the ghost wave component Sg as the result of the operation of the eight fields. The signal GCR and the component Sg thus obtained are applied to the subtracting circuit 22, to which a reference GCR signal 23 with a reference waveform of the signal GCR shown in FIG. 1A generated by a reference GCR signal forming circuit 23 is also applied.
The subtracting circuit 22 performs the subtraction operation between these signals to thereby deliver the ghost wave component Sg of the received signal GCR. Now, this ghost wave component Sg also represents an error component resulting from the fact that the ghost wave component can not be cancelled completely from the received video signal.
The transversal filter has a pulse response characteristic but the signal GCR has a bar pattern waveform, and so the ghost wave component Sg delivered from the subtracting circuit 22 is applied to the differentiating circuit 24 to be converted into a differentiated pulse Pg which is in turn applied to the converting circuit 25.
The pulse Pg is converted in the converting circuit 25 into a signal ST representing a correction or modification value of a tap coefficient or a tap gain of the transversal filter 3 and then applied to the filter 3 to thereby control the transmission characteristic thereof to a direction of cancelling and eliminating the ghost wave component Sg of the GCR signal SGCR delivered from the filter 3.
This operation is repeatedly performed to gradually adjust the characteristic of the transversal filter 3 to thereby gradually converge the characteristic thereof to that for eliminating the ghost wave component Sg of the GCR signal SGCR.
When the characteristic of the filter 3 is converged sufficiently, the ghost wave component Sg of the GCR signal SGCR delivered from the filter 3 will be decreased to a negligible small level and also the ghost component of the inherent video signal SY is decreased to a negligible small level by the filter 3.
Accordingly, the video signal SY from which the ghost wave component is cancelled can be taken out from the terminal 5.
The above-described conventional ghost cancelling circuit is described in "Ghost Cancel Reference Signal System", the Journal of National Conference held by the Institute of Television Engineers of Japan, 1989.
In this conventional circuit, the characteristic of the transversal filter 3 is gradually adjusted to thereby converge it to a required characteristic.
In the system having an adaptive function as described above, as an algorithm for improving an evaluation value by repeatedly adjusting the parameter of the system, the hill climbing method is well known. According to the ADA (active division algorithm) methods as one of the hill climbing method, a value Cj(v) of a parameter at a γ'th process is modified according to the following equation. ##EQU1## where D represents the evaluation function, Cj the parameter (j= 1 ˜ n), Cj(γ) the value of a parameter at a γ'th process, α the coefficient, and ΔC the value to be modified.
This ADA method can be applied to the setting or adjustment of the tap coefficient of the transversal filter 3 and in this case the value ΔC of the above-described equation will be the correction or modification value of the tap coefficient of the signal ST.
However, if the tap coefficient of the transversal filter 3 is set according to the ADA method, it takes as long a time as about 5 seconds depending on the processing ability of the microcomputer 20 to converge the characteristic of the transversal filter to the required characteristic.
If it requires such a long time as 5 seconds to converge the characteristic, the GCR signal SGCR delivered from the filter may include a noise component if a noise signal is received at the receiver side during a converging period of the characteristic. If a noise signal is included in the GCR signal SGCR, the converging operation in the filter is distorted to thereby delay the convergence thereof.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to provide an improved circuit for detecting a wave distortion in which the aforementioned shortcomings and disadvantages of the prior art can be substantially eliminated.
More specifically, it is another object of the present invention to provide an improved circuit for detecting a wave distortion which is capable of swiftly and stably converging the characteristic of the transversal filter.
According to an aspect of the present invention, in a circuit for eliminating a ghost wave component, wherein a received video signal is applied to a transversal filter, a reference signal for cancelling a ghost signal (GCR signal) is taken out from an output signal from the transversal filter, a ghost wave component is picked up from the GCR signal, a signal for controlling a transmission characteristic of the transversal filter is formed on the basis of the picked-up ghost wave component, and the control signal is applied to the transversal filter to thereby extract from the filter a video signal from which the ghost wave component is eliminated, a circuit for detecting a wave distortion is comprised of a variable limiter provided on a signal line for transmitting the control signal to said transversal filter and an unit for controlling a limiter level of the variable limiter to be decreased with time.
The above and other objects, features, and advantages of the present invention will become apparent from the following detailed description of illustrative embodiments thereof to be read in conjunction with the accompanying drawings, in which like reference numerals represent the same or similar parts in the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are diagrams illustrating waveforms of GCR signals;
FIGS. 2A to 2C are diagrams for explaining a method of extracting a signal GCR from a received video signal;
FIG. 3 is a block diagram illustrating an example of a conventional ghost cancelling circuit;
FIG. 4 is a block diagram of FIGS. 4A and 4B, as FIGS. 4A and 4B are block diagrams illustrating an embodiment of a ghost cancelling circuit having a circuit for detecting a wave distortion according to an embodiment of the present invention;
FIGS. 5A to 5D are waveform diagrams, respectively, illustrating waveforms of signals appearing at various portions of the circuit of FIG. 4; and
FIG. 6 is a block diagram illustrating a part of the ghost cancelling circuit having another example of the waveform distortion detecting circuit according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described with reference to the accompanying drawings.
Referring now to FIG. 4 (formed of FIGS. 4A and 4B drawn on two sheets of drawings so as to permit the use of a suitably large scale), which illustrates a ghost cancelling circuit having a circuit for detecting a waveform distortion according to an embodiment of the present invention, like reference numerals as those in FIG. 3 denote like or corresponding elements and so the explanations of functions thereof will be omitted hereinafter merely to simplify the explanation thereof.
In the embodiment of FIG. 4, a variable limiter 29 is provided on a signal line provided between the converting circuit 25 and the transversal filter 3 for transmitting the signal ST representing a correction or modification value of a tap coefficient or a tap gain of the filter 3. The limiter 29 may be realized by any one of software and hardware but in this embodiment it is realized by software in a microcomputer 20.
The video signal SY from the video signal detecting circuit 1 is applied to the analog-to-digital (A/D) converter 2 and also to a switching circuit 31. A video signal from the digital-to-analog (D/A) converter 4 is also applied to the switching circuit 31.
A trigger circuit 32 is provided for delivering a trigger pulse Pt as shown in FIG. 5A at a time point t1 where such operations as a channel switching, turning-on of a power source or an operation of a ghost cancelling key by a user is performed.
The pulse Pt is applied to the microcomputer 20 as a signal for starting the calculation and setting of the tap coefficient of the transversal filter 3. The pulse Pt is also applied to a time constant circuit 33 which in turn generates a control signal St which becomes a high level from the time point t1 for a predetermined period, for example 5 seconds, that is, for a period Tt required for performing a process for eliminating a ghost wave component to a time point t2, as shown in FIG. 5B. This signal St is applied to the switching circuit 31 as a control signal thereof.
The output signal of the switching circuit 31 is taken out from the terminal 5.
The signal St is also applied to a waveform shaping circuit 34 which in turn delivers a signal Sc which maintains a level of 100% for 2 seconds, for example, from the time point t1 but decreases in its level monotonically thereafter, as shown in FIG. 5C. The signal Sc is applied to the variable limiter 29 as a control signal for controlling a limiter level Lth thereof, so that the limiter level Lth is controlled to correspond to the level of the signal Sc, as shown in FIG. 5D.
According to this circuit configuration, in the stationary state (before the time point t1 and after the time point t2, for example), the signal level of the signal St is "0" and so the switching circuit 31 is connected to the D/A converter 4 as shown in FIG. 4. Thus, in the stationary state, the ghost cancelling circuit of FIG. 4 constitutes the circuit configuration equivalent to that of FIG. 3 and so the ghost cancelling operation is performed in the same manner as that of the circuit of FIG. 3.
However, if any one of the operations among the channel switching, turning-on of the power source or the operation of the ghost cancelling key by a user is performed at an arbitrary time point t1, the trigger pulse Pt is delivered from the trigger circuit 34 as shown in FIG. 5A and so the signal level of the signal St becomes "1" during the period Tt in response to the pulse Pt as shown in FIG. 5B.
Further, in response to the pulse Pt delivered at the time point t1, the microcomputer 20 is triggered to start the calculation and setting of the tap coefficient of the transversal filter 3.
In this case, the signal ST representing the tap coefficient from the converting circuit 25 is applied to the filter 3 through the variable limiter 29, while the limiter level Lth of the limiter 29 is decreased gradually by the signal Sc as shown in FIG. 5D.
However, the signal ST representing the tap coefficient is also decreased gradually from the time point t1 as described above, and so the signal ST is passed through the limiter 29 and applied to the filter 3 without being limited in its level even if the limiter level Lth is decreased gradually as shown in FIG. 5D, so that the calculation and setting of the tap coefficient of the filter 3 can be executed normally in the microcomputer 20.
That is, the limiter level Lth of the limiter 29 is changed in correspondence to the level change of the original signal ST so that the signal level of the signal ST can not be limited by the limiter 29 and so the calculation and setting of the tap coefficient of the filter 3 can be executed normally.
At the time point t2, the calculation and setting of the tap coefficient of the filter 3 are basically finished, but, in this example, the limiter level Lth of the limiter 29 does not decrease to 0 completely after the time point t2 and so the calculation and setting of the tap coefficient of the filter 3 is continued in the microcomputer 20, so that the ghost can be eliminated when a slow change of the ghost occurs.
On the other hand, if a noise component is included in the GCR signal SGCR during the period Tt, a noise component is also included in the signal ST. However, the part of the noise component of the signal ST whose level is larger than the level of the signal ST is removed by the limiter 29 and then the signal ST whose noise component is partially removed is applied to the filter 3 to thereby set the characteristic thereof.
Accordingly, even if a noise component is included in the GCR signal SGCR, the influence to the characteristic of the filter 3 by the noise can be minimized, so that the characteristic of the transversal filter 3 can be converged swiftly and stably.
During the period Tt where the setting of the characteristic of the filter 3 is performed, the level of the signal St is "1" and so the switching circuit 31 is connected to the video signal detecting circuit 1 instead of the D/A converter 4 in response to the signal St opposite to that shown in FIG. 3. Thus, the video signal SY from the detecting circuit 1 is directly applied to the terminal 5 through the switching circuit 31, so that even if the level of the video signal SY from the filter 3 is disturbed during the period Tt, an image on a display (not shown) can not be influenced at all.
Thus, according to the present invention, on a signal line for transmitting the signal ST representing the modification value of the tap coefficient, the variable limiter 29 whose limiter level Lth is changed in correspondence to the original level of the signal ST is provided, so that even if a noise component is included in the signal ST, the influence to the characteristic of the filter 3 by the noise can be minimized, thereby making it possible to converge the characteristic of the transversal filter 3 readily and stably.
The additional circuit configuration required for performing this operation is only the limiter 29, and further the cost for providing the limiter 29 is not particularly required since the limiter 29 can be realized by software.
FIG. 6 is a block diagram illustrating a main part of another embodiment of the ghost cancelling circuit according to the present invention.
In the embodiment of FIG. 6, a video signal SY from an analog-to-digital (A/D) converter 2 is applied to a first subtracting circuit 41 and also applied thereto through a first transversal filter 42. An output signal from the subtracter 41 is applied to a second subtracter circuit 43, which in turn applies its output signal thereto through a second transversal filter 44 and also to the D/A converter 4.
The signal ST representing a modification value of a tap coefficient of the transversal filter is applied from the variable limiter 29 of the detecting circuit 10 to each of the first and second transversal filters 42 and 44 as a control signal for controlling the transmission characteristic thereof.
In this circuit configuration, the subtracting circuit 41 and the filter 42 constitute a loop of a feedforward type and so the subtracting circuit 41 can deliver a video signal SY from which a near-by ghost wave component including a front ghost is eliminated. On the other hand, the subtracting circuit 43 and the filter 44 constitute a loop of a feedback type and so the subtracting circuit 43 can deliver a video signal SY from which a long ghost wave component is eliminated. Accordingly, it is possible to take out from the terminal 5 a video signal SY from which the near-by ghost component and the long ghost component are eliminated.
As described above, according to the present invention, on the signal line for transmitting the signal ST representing the modification value of the tap coefficient, the variable limiter 29 whose limiter level Lth is changed in correspondence to the original level of the signal ST is provided, so that even if a noise component is included in the signal ST, the influence to the characteristic of the filter 3 (42, 44) by the noise can be minimized, thereby making it possible to converge the characteristic of the transversal filter 3 readily and stably. The additional circuit configuration required for performing this operation is only the limiter 29, and further the cost for providing the limiter 29 is not particularly required since the limiter 29 can be realized by software.
Having described the preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments and that various changes and modifications could be effected by one skilled in the art without departing from the spirit or scope of the invention as defined in the appended claims. | A circuit for detecting a wave distortion in a circuit for eliminating a ghost wave component, wherein a received video signal is applied to a transversal filter, a reference signal for cancelling a ghost signal (GCR signal) is taken out from an output signal from the transversal filter, a ghost wave component is picked up from the GCR signal, a signal for controlling a transmission characteristic of the transversal filter is formed on the basis of the picked-up ghost wave component, and the control signal is applied to the transversal filter to thereby extract from the filter a video signal from which the ghost wave component is cancelled. This circuit includes a variable limiter provided on a signal line for transmitting the control signal to the transversal filter and an unit for controlling a limiter level of the variable limiter to be decreased with time. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of the invention is that of digital mobile radio. To be more precise, the invention concerns the exchange of digital data by means of a mobile radio system to enable communications between two data terminal equipments (DTE), for example, at least one of which is mobile.
2. Description of the Prior Art
In known means of communication between two DTE using a wired line (such as the public switched telephone network) each DTE cooperates with an asynchronous modem, usually one conforming to the V.24 standard and to a modem protocol (such as the "Hayes" protocol (registered trademark), for example). These standards define an interface between a DTE and a data communication-terminating equipment (DCE) or modem.
Known digital mobile radio systems include the European GSM (Global System for Mobile communications) cellular system. Cellular mobile radio systems divide a geographical territory into small portions or cells each served by one or more base stations. This subdivision into cells enables optimum use of the radio frequency spectrum as more than one cell can use the same portion of the spectrum.
On the other hand, the cellular approach gives rise to various problems concerning call management, especially when a mobile changes cell ("handover"). There are further specific constraints in the case of the GSM system such as frequency redefinition, the use of frequency hopping, etc.
Another standard, the V.110 standard, has been drawn up for connecting a DTE to an integrated services digital network (ISDN). This standard has been adapted to the specific features of the GSM system. Accordingly, a DCE can communicate via the GSM system.
However, conventional portable DTE (microcomputers, etc.) are not equipped to communicate to the V.110 standard, but only via modems. It is not possible to connect such DTE to a cellular mobile radio network.
Also, the use of a cellular network is usually associated with the concept of mobility, and consequently with limitations as to the size of and connections between units. Consequently, the use of a dedicated adapter device is not an acceptable solution.
An object of the invention is to offer a solution to these problems. To be more precise, an object of the invention is to provide means enabling easy connecting of a conventional DTE to a cellular network.
Another object of the invention is to provide such means able to receive data signals and speech signals alternately.
SUMMARY OF THE INVENTION
The present invention consists in a station of a digital mobile radio network for exchanging speech signals and data signals comprising:
connection means to a first data processing terminal equipment for bidirectional exchange of data to a first data exchange standard using a single transfer channel carrying data and commands simultaneously,
first means for sending data to and receiving data from a second data processing terminal equipment via said mobile radio network according to a second data exchange standard using a data transfer channel and a command transfer channel,
second means for sending speech signals to and receiving speech signals from a remote terminal via said mobile radio network according to a third data exchange standard, and
means for monitoring a bidirectional call between said station and remote station comprising:
means for selecting either said first or said second transmitting and receiving means according to whether said call carries data or a speech signal,
interface means between said first and second data exchange standards comprising:
* in the direction from the first standard to the second standard:
means for separating data and commands delivered by said first terminal equipment,
first transcoding means for transcoding said data delivered by said separator means from said first standard to said second standard and delivering data to be transmitted on said data transfer channel,
first sorting means for sorting said commands into two sets of commands, a first set of commands to be transmitted to said second terminal equipment and a second set of commands to be executed by said station,
means for interpreting commands of said second set of commands and delivering a second set of interpreted commands,
first mapping means for mapping commands of said first set of commands and delivering commands to be transmitted on said command transfer channel,
* in the direction from the second standard towards the first standard:
second sorting means for sorting commands received on said command transfer channel and delivering a third set of commands to be transmitted to said first terminal equipment and a fourth set of commands to be executed by said station:
second mapping means for mapping commands of said third set of commands and delivering commands to be transmitted to said first terminal equipment
second transcoding means for transcoding data received on said data transfer channel from said second standard to said first standard and delivering data to be transmitted to said first terminal equipment,
means for grouping said commands and said data to be transmitted to said first terminal equipment in order to transmit them over said single transfer channel, and
* means for supervising said call from said second set of interpreted commands and said fourth set of commands and handling initialization, monitoring and interruption of said call.
The station of the invention can therefore be used to exchange data and to exchange speech alternately. The exchanges of data are managed by the station, without any additional external equipment.
Said supervisor means advantageously generate commands to be transmitted on said single transfer channel and/or said command transfer channel according to said second set of interpreted commands, said fourth set of commands and external information.
Said selector means preferably select said second speech signal transmit and receive means by default and said first data transmit and receive means are selected on reception of a call request sent by said first or said second terminal equipment.
Said selector means optionally send a specific instruction to enable/disable certain modules of said station when said first data transmit and receive means are selected.
In one advantageous embodiment of the invention:
said first data standard is the V.24 standard associated with a modem protocol;
said second data standard is the V.110 standard;
said digital mobile radio network is a GSM network.
Said station advantageously comprises means for selecting between at least two different data bit rates for exchanges of data to said first data standard.
In this case, it can also comprise means for adapting the format of the data exchanged according to said second data standard depending on said bit rate selected.
In one advantageous embodiment of the invention the station comprises means for controlling the flows sent and/or received by said station.
Said first sorting means preferably deliver a fifth set of commands for configuring said station to suite the requirements of said first equipment.
Other features and advantages of the invention emerge from the following description of one preferred embodiment of the invention given by way of non-limiting illustrative example and from the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing the general principle of the invention, including a mobile station able to communicate in data mode and in speech mode.
FIG. 2 is a functional block diagram of the interface means (112) of the station from FIG. 1.
FIG. 3 is a functional block diagram showing the structure of the program controlling the interface means from FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment described below is intended to interconnect two DTE 11 and 12 (microcomputers, relay stations, etc., for example) at least one of which (11) is mobile and able to exchange data (13) in conformance with the V.24 standard (also known as the RS232 standard) and a modem protocol (or, more generally, to any standard for exchange of data using a single transfer channel conveying data and commands).
The mobile DTE 11 communicates (14) with the other DTE 12 (the remote DTE, which can also be mobile) via the GSM mobile radio network, which provides two separate channels:
a data transfer channel 15;
a command transfer channel 16.
The mobile station (or DCE) 17 according to the invention provides:
on the one hand, and conventionally, exchange of speech 110 with a remote speech terminal 18 using a speech exchange control module 111, and
on the other hand, exchanges of data between two DTE using a data exchange control module 112 providing the interface means between the DTE 11 and the GSM network (i.e. fulfilling the modem function). Most DTE are provided with V.24 communication means. Accordingly, in accordance with the invention ,the digital mobile radio network is transparent to the DTE and there is no need to provide it with an adapter.
A selector module 113, functioning as a selecting means, selects one of the two exchange modules 111 and 112. The speech exchange module 111 is selected by default. The data exchange module 112 is selected on reception of a connection request from one of the two DTE 11 and 12.
The mobile station 17 in accordance with the invention therefore has two essential features, namely:
the facility to select speech mode or data mode; thus the same equipment, of compact size, can provide both these functions in a manner that is virtually transparent for the user; the reduction in size and the absence of external interface means, and therefore of numerous connections, is essential in the context of a mobile application;
interfacing two totally different standards, requiring among other things a specific analysis of each command (including distinguishing between commands relating to the dialogue between the two DTE and those concerning communication at the GSM level).
Thus, selecting means 113 and interface means 112 define a means for monitoring a bidirectional call between a mobile station and a remote station, which embodies these two essential features.
FIG. 2 shows in more detail the interface in accordance with the invention implemented in the module 112 from FIG. 1.
The data and commands 211 received from the local DTE on a single transfer channel 212 (V.24 standard+modem protocol (registered trademark), for example)) are directed to a separator module 21 which delivers V.24+modem protocol data 213 and V.24+modem protocol commands 214.
The data 213 is passed to a first flow control module 240 which ensures that the data 213 is not delivered at a rate higher than that which the station can accept (to prevent the risk of congestion if the DTE transmits at too high a rate).
If the timing rate is too high an indication of this (243) is sent to the DTE. Otherwise the data is transmitted (244) to a transcoder module 22 which converts the V.24+modem protocol data into date 215 to the V.110 format (including grouping of the data into frames). The data 215 is then transmitted to the remote DTE via the data transfer channel 216 of the GSM network.
The commands 214 are processed by a first sorter module 23 which distinguishes between three sets of commands:
a first set of commands 217 which comprises commands addressed to the remote DCE (a repeat request, for example),
a second set of commands 218 comprising commands addressed to a call supervision module 210 (an interrupt call command, for example), and
a fifth set of commands 245 (the third and fourth sets are defined below) addressed to a configurator module 242 which configures the station according to the nature of the DTE.
Of course, some commands may be included in the two sets of commands 217 and 218.
The first set of commands 217 undergoes mapping 25 to adapt the format of the commands 217 (V.24+modem protocol) into a format 219 compatible with the GSM command transfer channel 220. The second set of commands 218 is interpreted by an interpreter module 24 which delivers to the supervisor module 210 commands 221 that it can interpret.
The procedure is substantially symmetrical in the other call direction.
The V.110 format data 222 received on the data transfer channel 223 is transmitted to a second flow control module 241 which ensures that the data 222 is not delivered at a rate greater than that which the station can accept.
If the timing rate is too high an indication 246 is sent on the command transfer channel. Otherwise the data (247) undergoes transcoding 28 to produce data 224 to the V.24+modem protocol format. The commands 225 received on the command transfer channel 226 are subjected to sorting 26 to distinguish between:
a third set of commands 227 addressed to the local DTE, and
a fourth set of commands 228 addressed to the supervisor module 210.
Once again, some commands can be included in both sets of commands.
The set of commands 227 is delivered to a mapping module 27 which produces corresponding commands 229 to the V.24+modem protocol format. The set of commands 228 is delivered direct to the supervisor module.
The data 223 and commands 229 to the V.24+modem protocol format are grouped (29) to form a set 230 of data and commands delivered on the single transfer channel 231 to the DTE. The grouping module 29 also receives the commands 243 sent by the first flow control module 240.
The supervisor module monitors the call at the GSM level. It handles the start, control and end of calls, including conventional GSM operations including handover, frequency redefinition, etc.
In addition to the commands 221 and 228 it can act on external commands such as those 232 from the keypad of the station. It can also receive information 233 from the speech exchange module 111 (FIG. 1), in order to deal with conflicts between two speech and data connection requests, for example. It can also implement the function of the selector module 113 by issuing a command 234 to enable/disable the speech exchange module (and possibly specific commands, for example to disable the keypad during exchange of data).
The supervisor module can also send messages 235 to a display for monitoring of the call in progress.
Finally, the supervisor module can itself generate commands to one or other of the DTE, when necessary:
commands 236 addressed to the local DTE are transmitted to the grouping module 29;
commands 237 addressed to the remote DTE or to the GSM network are transmitted to a second grouping module 238 which delivers commands 239 to the command transfer channel 220.
The second grouping module 238 also receives the command 246 sent by the second flow control module 241.
These various resources can be grouped together in the mobile station in the form of software. FIG. 3 is a functional block diagram showing the structure of a program controlling these interface means.
The basic "data transmit" function 30 can be broken down into four main (level 0) functions:
1) DTE-DCE link control (31),
2) DTE-DCE data flow analysis (32),
3) GSM communications (33),
4) call supervision (34).
These functions break down as follows:
1) DTE-DCE link control (31)
This DTE-DCE link is of the standard RS232C type.
2. DTE-DCE data flow analysis (32)
2.1 "Command/data separation" function (321).
This function redirects data from the DTE/DCE LINK CONTROL function (31) to the terminal function COMMAND PROCESSING (322) or DATA PROCESSING (324).
The separation of command and data is effected in one of two mutually exclusive modes:
Command mode:
Characters from the DTE/DCE LINK CONTROL function (31) are stored one by one in a command string until the string can be interpreted, causing a change to data mode.
Data mode:
Characters from the DTE/DCE LINK CONTROL function (31) are stored one by one in a data string until the string can be interpreted, causing a change to command mode.
The change from command mode to data mode is defined so that:
Command mode is the default mode on initializing a data call.
In the case of a call initialized by the DTE, the change to data mode occurs on interpreting a specific command.
In the case of a call initialized by the mobile, the "call request" is sent to the supervisor layer after a specified number of rings.
The return to command mode is effected on three consecutive receptions of the character defined in a register.
The return to command mode is automatic in the case of an "end of call indication" by the CALL SUPERVISION block (34).
2.2. "DTE command processing" (322).
This function interprets characters from the COMMANDS/DATA SEPARATION function (331).
The processing of commands uses four types of data:
Commands:
They pass from the DTE to the DCE either in the form of signals (so that 108/2 "terminal not ready" is considered to be a command) or in the form of interpretable characters. These characters constitute a subset of the standard modem commands.
Information:
Information passes from the DCE to the DTE either in the form of signals or in the form of characters bracketed by a ,CR. ,LF. string or specific codes.
Result indications:
These pass from the DCE to the DTE in the form of characters bracketed by a ,CR. ,LF. string or specific codes.
Echo:
This refers to the return of characters received in command mode.
The function is activated by the COMMAND/DATA SEPARATION function (321) which invokes it at each valid command line. The commands are then interpreted one by one. For each command the interpreter waits for an indication from the CALL SUPERVISION block (34), if necessary. Where appropriate, it sends to the DTE the information and/or result indications relating to the command interpreted. A command line executed correctly causes the "OK" indication to be sent to the DTE. If a command in the line cannot be interpreted or executed the remainder of the line is ignored and an "ERROR" indication is sent back.
The function is de-activated on changing to data mode after all of the current command line has been interpreted or on receipt of an "end of call indication".
2.3. "Indications processing" function (323)
This terminal function is part of the DTE DATA ANALYSIS block (32). It manages indications from the DATA PROCESSING function (324) (322) and the CALL SUPERVISION functional block (34) and propagates these indications to the COMMAND DATA SEPARATION function (321), COMMAND PROCESSING function (322), DATA PROCESSING function (324) and the DTE/DCE LINK CONTROL block (31).
The processing is specific to the following indications:
"Initialization request" from the CALL SUPERVISION block (34).
"Initialization" to the COMMAND/DATA SEPARATION function (321), COMMAND PROCESSING function (322), DATA PROCESSING function (324) and the DTE/DCE LINK CONTROL block (31).
"Connection indication" from DATA PROCESSING (324).
"Disconnection indication" from DATA PROCESSING (324).
"Disconnection confirmation" from DATA PROCESSING (324).
"Incoming call indication" from the CALL SUPERVISION block (34).
"Call set up indication" from the CALL SUPERVISION block (34).
"End of call indication" from the CALL SUPERVISION block (34).
2.4. "Data processing" function (324)
This function manages data at character level and manages control bits of V.110 frames to the DTE and to the GSM network.
It is used to manage the DCE-GSM data flow in the form of characters. The data flows are effective only in the nominal operating mode of the function.
DCE → GSM direction flow control:
The COMMAND PROCESSING function (322) sends a "Connection request" to request the change to the "Data transmission" phase.
The COMMAND PROCESSING function (322) sends a "Disconnection request" to request termination of data transmission.
GSM → DCE direction flow control:
The states of the received command bits are supplied by the CHANGE TO CHARACTER MODE function (332). The function filters out the time allowed for these control bits to stabilize.
The "Idle" phase is set during the initialization of the mobile.
The bit rate class used is supplied by the COMMAND PROCESSING function (322) during this phase. The asynchronous bit rates authorized are: 2 400 bit/s, 4 800 bit/s and 9 600 bit/s.
The character structure (start bit, number of data bits, parity bit, number of stop bits) is given by the COMMAND PROCESSING function (322).
Idle Phase:
The "Idle" phase is used to refuse transfer of data.
The function is in this phase either after an initialization process or after a disconnection phase following local or remote data transfer termination.
Connection Phase:
The function enters this operating phase on receipt of a "Connection request" from the COMMAND PROCESSING function (322).
The function requests the CHANGE TO V.110 MODE function (333) and the CHANGE TO CHARACTER MODE function (332) to go to their connection phase.
Data Transfer Phase:
This phase follows on either from a successful connection phase or from an interrupted V.110 disconnection phase.
Disconnection Phase:
The function enters this operating phase in various cases:
Network disconnection.
Local disconnection.
V.110 disconnection.
3. Communicating via GSM (33)
3.1. "GSM data transmission" function (331)
The GSM C1 software relevant to the "Data transmission" application is limited to three functions:
initialization of the GSM C1 in data communication mode,
exchanges on the TCH/9600, TCH/4800 or TCH/2400 channel,
exchanges on the trace channel.
These functions must be transparent for the other call mode applications.
Multiframe call mode (26 frames).
The GSM C1 call mode is established on allocation of a TCH channel by the network (Immediate assignment).
The "speech" or "data" call is known to the GSM C3. The latter must configure the change from the GSM C1 into the "data transmission" mode by means of a specific item of information.
Once established, speech transfer mode handles:
transmission of TCH/FS blocks
transmission of a signaling burst every 26 frames (for call quality control),
supervision of neighbouring cells during the idle frame (for the purposes of handover),
transmission of FACCH blocks by stealing TCH frames,
averaging of the receive signal level,
management of frequency hopping,
encryption of the call,
monitoring of physical entities.
All GSM C1 functions are retained for the Telestation application of the invention, and the following are added to them:
transmission of TCH/9600 blocks
transmission of TCH/4800 blocks,
transmission of TCH/2400 blocks
exchanges with the trace channel.
Blocks received on the radio channel must be transmitted on the trace channel synchronously and transparently for the C1, and vice verse.
The interfaces are:
TCH/9600 channel: 4 packets of 60 bits are transmitted together. `TCH/4800 channel: 2 packets of 60 bits are transmitted together.
TCH/2400 channel: 2 packets of 36 bits are transmitted together.
The station also handles:
conservation of the existing code for all other call mode functions:
* hopping,
* handover,
* frequency redefinition, etc.
differing management of the physical entities:
*EP4 (speech processing) is not used for data transmission,
*EP3 (data processing) must be connected via the trace channel for sending and receiving data of the Telestation application.
3.2. "Change to character mode" function (332)
This function changes the data flow from the GSM network to the Telestation from V.110 mode to character mode.
A V.110 frame contains:
either 36 bits in the case of an asynchronous bit rate of 2 400 bit/s,
or 60 bits in the case of asynchronous bit rates of 4 800 bit/s and 9 600 bit/s, for which two classes of bit rates the frame structure is identical.
This function receives blocks whose size and structure depend on the current bit rate class.
Each block is broken down into consecutive V.110 frames as follows:
*asynchronous bit rate 2 400 bit/s: 72 bits, i.e. two V.110 frame of 36 bits,
*asynchronous bit rate 4 800 bit/s: 120 bits, i.e. two V.110 frames of 60 bits,
*asynchronous bit rate 9 600 bit/s: 240 bits, i.e. four V.110 frames of 60 bits.
During the "Data transfer" phase characters contained in all the V.110 frames must be extracted. Extraction is effected character by character, synchronizing on the start bits. The characters are stored in the "peeled" form (without their start and stop bits). If the last character of the block is incomplete (i.e. straddling this block and the next block) the received part must be memorized pending arrival of the next block to complete it.
3.3. "Change to V.110 mode" function (333)
This function changes the data flow from the Telestation to the GSM network from character mode to V.110 mode.
The structure (number and V.110 frame structure) of the blocks to be sent to the GSM DATA TRANSMISSION function (331) depends on the current bit rate class.
This function is used to recover the character mode data flow form the DATA PROCESSING function (324). This data is stored by the DATA PROCESSING function (324). This data is routed via the SPI link to the GSM DATA TRANSMISSION function (331) in the form of V.110 frames.
Recovery of the characters stored by the DATA PROCESSING function comprises the following operations:
The start bit and the stop bits are added to each recovered character, in conformance with the current character format for the V.110 frames;
These characters are placed consecutively (without stuffing bits) in V.110 frames constituting the block in course of preparation;
The total number of bits reserved for data in the blocks of V.110 frames depending on the current bit rate (2×24=48 bits if this is 2 400 bit/s, 48 bits if this is 4 800 bit/s, 4×48=192 bits if this is 9 600 bit/s);
In the case of a DTE overspeed, it is possible to compensate up to 1% by eliminating at most one stop bit every eight characters;
If the number of characters stored by the DATA PROCESSING function is less than the capacity of the current series of frames the remaining data bits are stuffing bits.
The block of V.110 frames is then sent to the GSM DATA TRANSMISSION function.
4. "CALL SUPERVISION" (34)
As its name indicates, the object of this function is to supervise the call between the DTE connected to the mobile and a remote DTE. It consists in call set up, maintenance and clearing down, whether the call is incoming or outgoing.
This function adds to the standard software the functions for seizure and management of a data terminal in addition to the operating terminal.
Supervision of a data mode call is very similar to supervision of a speech mode call. It differs in terms of the function of each terminal.
In Speech Mode
Any request from the DTE is rejected.
In Data Mode
The call set-up and disconnection (Call Control) phases are identical to those for speech mode, as are S.I.M. management and Mobility Management.
* Outgoing Call:
The DTE submits a request accompanied by the number to be dialed, the call set-up phase (until the call is set up) is identical to that of a call in speech mode, the request is understood as a hands free call request in order to generate the tones in the external loudspeaker. The station therefore remains active and keystrokes are acted on.
* Incoming Call:
On receiving a data mode incoming call the DTE is advised and can accept the call or not. The call set-up phase (until the call is set up) is identical to that for a call in speech mode. The T.E. (station) therefore remains active and keystrokes are acted on.
Immediately the call is set up the T.E. becomes inactive and keystrokes are ignored.
Also, the CALL SUPERVISION function (34) must now accept transparent asynchronous data mode calls at 2 400 bit/s, 4 800 bit/s and 9 600 bit/s (incoming call accounting management).
* Outgoing Call:
On receipt of a "data mode call request" from the DTE, the CALL SUPERVISION function (34) submits a "network connection request" if the mobile is located and if an SIM is present.
The following conditions must be met first:
the party must be on-hook
a channel must have been allocated for the call,
the call is set up end-to-end.
The network or the DTE DATA ANALYSIS function (32) can submit an "end call request" at any time. Likewise removal of the SIM or pressing the "halt" key terminates the call.
If an incoming call request ("data mode call request" from the network) is received during setting up of an outgoing call the latter is aborted.
* Incoming Call.
On receipt of a "data mode call request" from the network the type of call requested is checked for compatibility with the type of call accepted by the mobile (asynchronous call in transparent mode at 2 400 bit/s, 4 800 bit/s or 9 600 bit/s).
When the call has been set up the T.E. displays a message indicating that the call has been set up in data mode and all keystrokes (except the "halt" key) are ignored. The audio circuits are turned off.
Following confirmation of disconnection from the network the keys are again enabled.
The software thus enables set-up, maintenance and clearing down of a call between two DTE at least one of which is connected to a GSM mobile used like a modem.
The call is in transparent asynchronous mode at 2 400 bit/s, 4 800 bit/s or 9 600 bit/s depending on the capability of the network.
Mobiles equipped with the software must be able to communicate in speech mode using a T.E. or in data mode exclusively in the presence of a connected DTE. | A mobile station of a mobile radio network includes speech exchange arrangements and data exchange arrangements. Selector arrangements select the speech exchange arrangements by default and change to the data exchange arrangements when necessary. The data exchange arrangements comprise a set of components for sorting, analyzing and processing the data and the commands exchanged between two terminal equipments so that a mobile terminal equipment capable of exchanging data according to a first standard (the V.24 standard+modem protocol, for example) can communicate with another, remote terminal equipment via a digital network using a second standard (V.110+GSM network, for example). | 7 |
BACKGROUND OF THE INVENTION
The present invention concerns window buck construction ultimately used as a form to define an opening in a cast wall for subsequent installation of a window.
Window bucks are commonly used in the construction of buildings of concrete wall construction and serve to block out an area in the wall during pouring of concrete. The window buck is supported in place on front and rear wall surfaces and left in place to receive a window assembly.
Homes and other buildings utilizing concrete as the major wall component may include inner and outer surfaces of insulative sheet material applied to reinforcing steel prior to pouring of the concrete to become an integral part of the wall. The insulative sheet material may serve as a wall form with the insulative qualities of the foam material U.S. Pat. No. 5,996,293 discloses a window buck for blocking out a wall area for later reception of a window. Elongate buck members are joined at their ends, in one form, by right angular locking members, each having a protruding frictional member for retention of an arm of the locking member within a selected interior channel of a buck member. The buck members define multiple internal channels. To retain the buck in assembled configuration the locking members must be of precise shape and size and become a part of the installed buck. A preferred form of the window buck disclosed dispenses with the right angular insertable locking members and achieves interlocking of the buck member ends by the cutting of the ends of the members to form tongues for insertion within slots cut in the intersecting end of an adjacent buck member. In both forms of the window buck disclosed no provision made for use of the window buck in the formation of window openings in walls of other than a single specified thickness. Further, the channels within which right angular connectors are inserted are all internal channels open only at their ends.
U.S. Pat. No. 5,791,103 discloses a window buck having members formed with internal channels extending along each side of the member and along a central wall of the member to receive inserts of right angular shape for joining intersecting ends of two buck members.
U.S. Pat. No. 4,831,804 discloses a plastic window frame wherein right angular gussets serve as locking members to join horizontal and vertical frame members by insertion into interior channels of corresponding cross section. The gussets and an overlapping stiffener in each buck member fit within a partially open internal channel defined by each buck member.
The provision of a buck being laterally adjustable to accommodate installation in walls of two predetermined thicknesses is disclosed in U.S. Pat. No. 4,589,624. The buck disclosed is adjustable to accommodate 8 inch or 9 inch thick walls. A clamp is secured in one of two positions by a key inserted through aligned slots in the clamp and a lip on two adjustable buck members.
A wall vent is disclosed in U.S. Pat. No. 5,444,947 for incorporation into a foundation wall with the vent having interengageable inner and outer members which may be joined in a manner enabling the vent to be adjusted to suit one or two thickness of the wall under construction. No provision is made for infinite adjustment of the wall vent.
SUMMARY OF THE PRESENT INVENTION
The present invention is embodied within a window buck for installation in a concrete wall being formed with the buck readily assembled using angular connectors in external channels.
A window buck is provided, in one form, for use in forming window openings in walls of various thicknesses with the buck having members each with front and rear components slidably adjustable relative one another. Laterally open channels or grooves formed in the buck members receive connectors placed therein to join the members. The connectors may be of rebar material and reusable if so desired. A yieldable lip on each channel ensures retention of a connector.
Objectives include the provision of a window buck of extruded synthetic material with the buck members assembled into a framework using low cost, reusable connectors set into place in open sided channels; the provision of a window buck for use in walls of a wide range of thicknesses with the buck having, in one form, a central component adding to the range of adjustment of the buck for such thicknesses; the provision of a window buck having a bottom member which is positionable on a wall under construction permitting the discharge of fluid wall material into that area of the wall under the window buck; the provision of a window buck having connectors retaining the buck in a configuration for later reception of a window with one of said connectors serving as a pivot for a bottom member of the buck permitting outward positioning of the bottom member to allow discharge of fluid wall material into that wall area below the buck.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a front elevational view of the present window buck with building wall fragments;
FIG. 2 is an enlarged fragmentary view of that portion of the window buck encircled at 2 in FIG. 1;
FIG. 2A is a vertical sectional view taken along line 2 A— 2 A of FIG. 2;
FIG. 3 is a vertical sectional view taken along line 3 — 3 of FIG. 1;
FIG. 4 is a horizontal sectional view taken along line 4 — 4 of FIG. 1;
FIG. 5 is a vertical sectional view of a buck member of a modified window buck;
FIG. 6 is a vertical sectional view of a buck member of a still further modified window buck.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With continuing attention to the drawings wherein applied reference numerals indicate parts similarly hereinafter identified, the reference numeral 1 indicates generally the present buck installed within a wall structure of a building under construction having a front wall 2 and a rear wall 3 . The present window buck when installed serves to block out an area in a cast wall having a central mass of concrete 4 intermediate front wall member 2 and rear wall member 3 which preferably are of foam construction to provide insulative qualities to the wall as well as serving as wall forms during wall construction. The wall members 2 and 3 are retained in a spaced relationship by a bridge at 5 which may be configured to receive reinforcing bar R, termed rebar in the trade. Integral with bridge 5 are molded plastic blocks 5 A- 5 B embedded in the wall members.
With attention now to the present invention, the present window buck 1 may be of rectangular shape in frontal elevation or of other shapes.
In FIG. 3, a cross section is shown of a buck top member generally at 6 which cross section is representative of side and bottom members of the window buck and accordingly the following description of buck top member 6 is applicable to side members generally at 7 and bottom member generally at 8 . Top member 6 as best shown in FIG. 3, preferably comprises a front component 11 and a rear component 12 with respect to front and rear building walls 2 and 3 . Front component 11 is of hollow construction having webs as at 13 extending lengthwise of the component. An inner wall 14 of the component terminates, along with an outer wall 15 , at a frontal edge of component 6 and, along with a web 16 , defines a laterally open channel 17 .
A rear component 20 of the window buck includes spaced apart outer and inner walls 21 and 22 which terminate at the rear of the buck, to define, along with a web 23 , a laterally open channel 24 . Channels 17 and 24 are coterminous with their respective front and rear buck components to receive connectors at 25 having arms 25 A- 25 B and bent at 30 , as shown in FIG. 2. A snug fit between channel defining walls and connector arms is desirable to ensure connector retention with the fit enhanced by means of flexible lips at 32 canted toward the channel. When the connectors 25 are formed from reinforcing bar, (rebar), the channels 17 and 24 , dimensioned to provide a snug fit, the somewhat irregular external surface of the rebar contributes to such retention. A wall at 29 on rear component 12 projects into concrete 4 to support the mid-portion of an installed buck member.
The outer walls 15 and 21 of components 11 and 12 terminate respectively forwardly and rearwardly in outwardly projecting flanges 26 and 27 enabling securement to external front and rear walls 2 and 3 as by screws 28 . The components 11 and 12 are in tongue and groove engagement at their joined edges.
With attention to FIG. 4, a side member generally at 7 is shown in section while a bottom member generally at 8 is shown in fragmentary fashion with a front component swung to an open position as later explained. The reference numerals indicated above in the description of the buck top member are applicable to side member 7 and bottom member 8 . FIG. 4 best illustrates the feature of the present buck which permits the direct discharge of concrete into an area at 31 directly below the bottom buck member 8 and partially defined by spaced apart front and rear building walls 2 and 3 . Subsequent to installation of the window buck on walls 2 and 3 , using fasteners 28 passing through buck flanges 26 - 27 , locking screws as at 33 are removed from inserted engagement with bottom buck member components 11 and 12 . Upon removal of fastener 33 , front buck component 11 may be swung about an axis 34 of an arm 25 A of a connector 25 . The remaining arm 25 B of the connector remains in laterally open channel 17 of front member 11 to support same during arcuate opening of bottom front member 11 as shown in full lines. Heretofore, in existing window bucks, filly charging the area below a buck in a wall under construction constituted a problem solved with time consuming manual effort. Upon filling of area 31 with concrete, bottom front member 11 of the bottom buck member 8 is swung back into place in inserted engagement with bottom rear member 12 of the buck and locking screws 33 are re-inserted. Screws 33 are preferably self tapping to facilitate locking of the front and rear components 11 and 12 of a buck after the components have been adjusted relative one another to accommodate the width of the wall under construction.
In FIG. 5, a modified window buck member is shown in cross section wherein front and rear buck components at 40 — 41 are joined by a center component 42 of tubular or hollow construction with spaced apart walls 43 - 44 reinforced by webs 45 . Rear component 41 would be similar to earlier described rear component 12 , while front component 40 would be, in cross section, a mirror image of rear component 12 . Locking fasteners at 33 are seated upon lateral adjustment of front and rear components 40 - 41 on the center component to accommodate the extraordinary thickness of the wall under construction.
In FIG. 6 a unitary or one piece buck member is shown generally at 46 and is for use in a wall construction where wall thickness of several concrete walls will be to a fixed or standard dimension. The cross section shown is of a top member and is also typical of the side and bottom buck members of the modified buck except as disclosed below. Inner and outer walls are at 51 and 52 both terminate endwise in flanges 57 and 59 . Walls 51 - 52 define, along with webs 53 and 54 , laterally open channels 55 and 56 in which connectors 25 are received. Reinforcing webs are shown at 47 . Walls at 59 project from outer wall 52 and have a head 60 thereon for embedment in poured concrete. Upon setting of the concrete the walls retain the mid-portion of buck member 47 in place.
A still further modified window buck would comprise top and side buck members having a cross section as viewed in FIG. 6 . To achieve the desirable feature enabling changing of a form defined area below a bottom buck member, the bottom buck member would be of two piece construction as shown in FIGS. 3 and 4 but, of course, inverted from that shown. Front buck component 11 would swing about the axis of a connector arm to provide access permitting the deposit of concrete below the window buck followed by re-positioning of component 11 and re-installation of the temporarily detached connector arm 25 in channel 17 of repositioned buck component 11 .
In use of the present buck invention, a building wall is partially completed up to the level whereat the wall provides partial walls 2 and 3 including rebar R therefor.
Window buck members are assembled to accommodate wall thickness by positioning of buck member components 11 and 12 and the insertion of locking screws 33 therethrough. With the buck members lying in place on their flanges 26 on a hard flat surface, the members are positioned in a rectangular or other polygonal shape desired with the ends of the top, side and bottom members 6 , 7 and 8 in intersecting orientation to receive arms 25 A- 26 A of connectors 25 . For installation of the connector arms into intersecting or converging channels 17 and 24 , a connector 25 is placed on two channels with the connector bend 30 therebetween. An impact tool such as a mallet or hammer is utilized to seat each connector arm in its respective channel. Upon installation of the connectors on one side of buck (presently lying on its side) the buck is turned over and the remaining side provided with the requisite number of connectors. The assembled buck is subsequently placed on the partially completed building wall and attached thereto by fasteners 28 inserted through buck flanges 26 , 27 of bottom buck member 8 . Thereafter the building walls 2 and 3 are completed with the remaining buck members 7 and top member 6 being attached to walls 2 and 3 by fasteners 28
The window buck is braced at B prior to pouring of concrete with the bracing removed upon setting of the concrete.
While we have shown but a few embodiments of the invention, it will be apparent to those skilled in the art that the invention may be embodied still otherwise without departing from the spirit and scope of the claimed invention. | A window buck having members forming a frame with the members including adjustable components enabling use of the buck in walls under construction of different thicknesses. Extruded front and rear components of each buck member are adjustably interengaged with one another and fixable in a desired relationship to suit the wall being constructed. External channels formed in the buck members are open lengthwise to permit reception of angular connectors for joining the buck members at their intersecting ends. The connectors may be of reusable rebar and removable upon completion of the wall. The components of each buck member are lockable by inserted fasteners. A modified window buck includes a central component for use in walls of extraordinary thicknesses. A further modified window buck may include buck members of unitary construction. | 4 |
CROSS-REFERENCES
None.
FIELD OF THE INVENTION
This invention relates generally to thermally fusing overlapped thermoplastic sheet materials, and particularly concerns both press apparatus and press operating methods for bonding together two or more overlapped thermoplastic sheet components together to efficiently form a fluid-impervious seal in the resulting seam-like region or regions of sheet material joinder.
BACKGROUND OF THE INVENTION
It is often desirable to fuse component sheets of a thermoplastic material such as sheets of polyethylene, polyvinyl chloride (PVC), or polyurethane to form larger sheets, to fabricate more-complicated shapes, or to make attachments. The desired fusion may occur in connection with the fabrication of air-supported building space enclosures, liquid containment tanks, building awnings, or any of numerous other generally similarly constructed products.
Thermoplastic sheet components are made from a number of different materials or combinations of materials. They also are available in various thicknesses, styles, and surface textures. Because of the diversity of such materials, the variety of forms into which they may be fabricated, and varying aesthetic and reliability requirements, many different manufacturing systems have been proposed and utilized for joining thermoplastic sheet components.
The most basic equipment for fusing thermoplastic sheets consists of a hand-held hot air blower device and a hand roller. An operator uses the blower to apply heat between the material plies to be fused as they are rolled together using the roller element. This system is regularly used throughout industry to make repairs because it is highly portable and is readily adaptable to small and irregular jobs. It is also used to fabricate complex shapes as one would find in articles of protective clothing or fuel-containment cells for race cars. Although such techniques have been used effectively, it is slow and its success is limited by the skill of the operator. Poor joinder seams can occur if the hot air is applied for too long or too short a period of time or if the roller element is not used properly or in a timely fashion.
Automated equipment for fusing thermoplastic sheets can be divided into two groups. One group can be referred to as comprising rotary machines (the other group is comprised of press-type machines), and in this rotary machine group either the machine travels along the fused seam regions of the sheets to be joined or the sheet seam regions are passed through the machine. As the machine and thermoplastic sheets are moved relative to each other a heat source such as a hot air blower, infrared radiator, or heated wedge is used to heat the sheet areas to be fused. The heat source is followed by a pressure roller or combination of pressure rollers and sometimes by pressure exerting belt surfaces. Such rollers or belt surfaces force the sheet seam areas together and allow them to fuse together.
Machines of the rotary type are particularly useful for assembling large membranes in factories as well as in the field and are used extensively in the roofing and water containment industries. Due however to distortion of the sheets introduced by the motion of the pressure rollers and also due to sheet seam shrinkage during cooling, seams made with this equipment are seldom adequate in applications requiring a high degree of aesthetics as in awning applications or requiring a very flat seam such as is used in sign facings. Also, these machines generally do not maintain the seam under pressure throughout the cooling process and such allows certain materials to generate gasses within their structure and often results in seams weakened by large quantities of contained gas bubbles.
The second group of thermoplastic sheet fusing machines (the press type) are usually stationary during operation, and the thermoplastic sheet seam components to be joined are placed in the machine in their desired position with respect to each other. The machine is then actuated and seam fusing takes place over an extended area at one time rather than over the area linearly with time.
One commonly used press type machine is the radio-frequency welder. This type of machine usually consists of a frame supporting two opposing dies or platens, one of which is relatively stationary and the other relatively movable. Thermoplastic sheets to be fused are placed between the dies/platens and pressed. The sheets are then heated by passing radio-frequency energy through the sheets using the die/platen elements as antennas. When adequate heat has been generated to fuse the sheets, the radio-frequency energy is withdrawn (stopped) and the fused area is allowed to cool. The dies or platens are afterwards separated and the fused sheets removed.
Radio-frequency welders produce highly reliable and aesthetically superior seams, largely because the seam remains pressed between the press platens throughout the heating and cooling cycles. This stabilizes the fused area preventing shrinkage and warpage as well as insuring a uniformly consistent seam surface texture. Although the machine is generally successful, it does however suffer from certain shortcomings. When a sealed seam is being made, the area between the machine platens or dies must be filled with a material of uniform dielectric constant value. If such is not the case, radio-frequency energy will tend to concentrate in areas of least dielectric resistance and cause overheating at those locations. Such makes it very difficult to fuse sheet pieces smaller than the platens, to do intermittent seals, or to incorporate any metallic items in or near the fused areas.
A second press-type machine is the hot platen welder which is made in a number of different configurations. Generally the hot platen welder utilizes one or two heated platens to both press the materials together and transfer heat to the area to be fused. Although hot platen welders are effective for heating thermoplastics they do not provide control of the cooling process. The result being that some materials fuse successfully while others suffer from shrinking or distortion. Further problems arise from the tendency of some materials to generate gas bubbles if not maintained under pressure when heated and cooled. This may cause a sponge-like texture within the fused area thus making the seam weak and unacceptable.
Although many machines are available commercially for fusing thermoplastic sheet materials, none has yet adequately addressed the problems involved in making highly reliable and aesthetically superior seals of varying size and shape. Nor is automatic equipment available to do complex fabrications, especially those incorporating varying numbers of plies.
There is therefore the need for a machine capable of applying even heating to thermoplastic sheets in complex product configurations of varying thicknesses, and to maintain those sheets under controlled pressure and in a stabilized condition throughout controlled heating and cooling cycles.
Other objects of the present invention will become apparent during a careful consideration of the descriptive materials and claims which follow.
SUMMARY OF THE INVENTION
The press apparatus of the present invention is basically comprised of a pair of opposed press platen elements and actuation means for moving at least one such press platen element relative to the other to establish both a press open condition whereat thermoplastic sheet material components may be inserted/removed before and after thermal processing and a press closed condition whereat thermal processing is accomplished. Each press platen element includes or contains an interiorly-positioned diaphragm set element. The press platen diaphragm sets are positionally located in opposed relation to each other and each set is comprised of a pair of peripherally-joined diaphragm members that are functionally connected to inlet and outlet fluid lines. Such fluid lines are selectively activated to conduct a flow of pressurized fluid such as compressed air or a thermally-conductive liquid to and from the diaphragm set. Also, the diaphragm set diaphragm members are each preferably fabricated of a conventional compliant (flexible) and fluid-impervious membrane material that preferably is fiber-reinforced, thermally-conductive, and capable of utilization at relatively high press operating temperatures (e.g., to 600° F.).
In addition, the press apparatus of the present invention includes a heat source, which in a preferred embodiment takes the form of a copper or aluminum heater block element of high compressive strength having an embedded or otherwise cooperating electrical resistance heating element, and independently operable actuating means for advancing and retracting the heater block elements into and from physical contact with the diaphragm sets contained in the press platen elements for heat transfer control purposes.
From a method standpoint, the present invention basically involves: placing the thermoplastic sheet materials to be joined into the press apparatus with their intended seam regions in alignment with and between the opposed press platen elements and included diaphragm sets which are in an open condition; advancing the opposed press platen elements and included diaphragm sets relative to each other and into contact with the properly placed thermoplastic sheet materials; locking or maintaining the press platen elements and their contained diaphragm sets in their closed condition; advancing the press apparatus heater block elements into contact with the collapsed diaphragm sets and lock or otherwise maintain the same in position; introducing moderately-pressurized fluid into said diaphragm sets to particularly inflate their peripheries thereby to both tighten the diaphragm set compliant membrane element interior surface portions and securely clamp the thermoplastic material components in place between such interior surface portions; transferring sufficient heat from the heater block elements, and by conductance, successively through the press platen diaphragm set diaphragm members in their collapsed condition, and into the clamped thermoplastic sheets to fuse the clamped thermoplastic sheets throughout an essentially diaphragm-defined product seam area; separating each heater block element from contact with it's respective diaphragm set by a small distance; flowing relatively cool pressurized fluid through the diaphragm sets and particularly between the compliant membrane element interior surface portions to thereby cool the still clamped-in-position and thermally bonded thermoplastic sheet materials; and, after adequate seam cooling has been obtained, relieving the fluid pressure from within the diaphragm sets and separating the resulting collapsed diaphragm sets sufficiently to permit removal of the completed product assembly or permit advancing the product assembly to its next position for continued seam joining. The method steps may then be repeated as often as necessary to complete fabrication of the product assembly.
A more detailed understanding of the apparatus and method aspects of the present invention will developed by the description of the drawings, detailed description, and claims which follow.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation view of a preferred embodiment of the press apparatus of this invention as readied for the insertion of overlapped thermoplastic sheet materials which are to be thermally fused;
FIG. 2 is an enlarged isometric view of a portion of the apparatus of FIG. 1 better illustrating the relative positioning of the press opposed platen elements and one of the included pair of diaphragm sets;
FIG. 3 is a sectional view through a portion of the apparatus of FIGS. 1 and 2 illustrating the positioning of the included pair of diaphragm sets in their initial, spaced-apart condition;
FIG. 4 is a sectional view similar to FIG. 3 but illustrating the position of the included pair of diaphragm sets in a subsequent closed and material-contacting condition; and
FIG. 5 is a sectional view similar to FIG. 4 but illustrating the inflated condition of the included pair of diaphragm sets during product assembly cooling.
DETAILED DESCRIPTION
Referring to FIG. 1, a preferred embodiment of the press apparatus of the present invention is referenced generally as 10 and such is basically comprised of a press frame 12 and a pair of opposed platen assemblies 14 and 16 situated in the press throat area positioned between the press frame head portion 18 and press frame base portion 20. In the FIG. 1 press configuration, upper platen assembly 14 may be moved vertically toward and from platen assembly 16. Lower platen assembly 16 in the FIG. 1 press configuration is fixedly mounted on the press frame base 20. A work table element 22 is also provided adjacent platen assembly 16 and functions to support thermoplastic sheet material components inserted in apparatus 10 for thermal fusion. The platen assemblies 14 and 16 each have a diaphragm set 32 and 34 described in detail hereinbelow.
Press apparatus 1O also includes two aluminum heater block assemblies 26 and 28 which each cooperate with, but are movable vertically with respect to, one of the platen assemblies 14 and 16. Heater block assembly 28 may be raised into engagement with the diaphragm set 34 of stationary platen assembly 16 or retracted out of engagement therewith by means of any conventional actuating means. Looking at FIGS. 2 through 5, it may be seen that the upper heater block assembly 26 carries platen assembly 14 and may be moved vertically by a press cylinder/piston combination (not shown). Platen assembly 14 includes a diaphragm set 32 which is mounted in a frame subassembly 36 having a plurality of vertical support members 38. Support members 38 are connected to a pair of horizontal support members 37 which rest upon the top surface of heater block assembly 26 such that platen assembly 14 is loosely suspended from the heater block assembly 26. Consequently, as heater block assembly 26 is lowered, diaphragm set 32 of platen assembly 14 also is lowered into contact with diaphragm set 34 of platen assembly 16. Assembly 14 may be clamped into position against lower platen assembly 16 by a locking bar mechanism 41. Subsequent to the engagement of upper platen assembly 14 with lower platen assembly 16, heater block assembly 26 may be lowered further to contact diaphragm set 32. From this it may be seen that heater block assembly 26 may be moved vertically a limited distance independently of platen assembly 14. Of course, platen assembly 14 need not be suspended from heater block assembly 26. Platen assembly 14 may be constructed to be raised and lowered vertically entirely independently of heater block assembly 26.
Referring to FIGS. 3 through 5, it may be seen that diaphragm sets 32 and 34 each are comprised of a pair of compliant membrane elements 40 and 42. Each of the membrane elements 40 and 42 preferably is fabricated using a thin and commercially available fluid-impervious material such as a relatively thin, silicone and polytetrafluoroethylene film having embedded and cross-woven graphite fiber reinforcement strands. Glass fiber reinforcement strands also may be utilized. In addition to having a characteristic of being relatively impervious to the penetration or fluids such as compressed air or pressurized heat-transfer fluids, membrane elements 40 and 42 also preferably have the properties of being good conductors or transmitters of heat with excellent physical integrity at elevated operating temperatures in the range of 300° F. to 600° F.
Platen assembly 14 includes a frame subassembly 36 comprised of an upper frame plate element 44 having an interior opening 46, an upper frame plate element 48 having an interior opening 50, a spacer frame gasket element 52 having an interior opening somewhat larger than either of interior openings 46 and 50, and various fastener elements 54 and 56 for joining components 40 through into a unitary subassembly 36 shown secured to support members The frame subassembly 36 included in lower platen assembly 16 is essentially comprised of the same elements 40 through 56 but secured to platen support elements 39 in a relatively inverted position.
It should also be noted that each platen assembly 14 and includes a schematically illustrated fluid line 58 which functions to supply pressurized fluid to that assembly and which communicates with the interior of its respective diaphragm set 32 or 34 through an opening 60 in frame plate element 48. Each of assemblies 14 and 16 also includes a schematically illustrated fluid line 62 which also communicates with the interior of its respective diaphragm set but through another opening 64 in frame plate element. Each of fluid lines 62 functions to flow pressurized fluid from within a diaphragm set interior. Valving and valve controls associated with fluid lines 58 and 62 are conventional and are not illustrated in the drawings.
FIG. 3 also illustrates two thermoplastic sheet workpieces 66 and 68 which are positioned intermediate platen assemblies 14 and 16 and that are to be subsequently joined into a unitary structure by the operation of apparatus 10. For clarity of illustration, workpieces 66 and 68 are shown suspended intermediate platen assemblies 14 and 16; in practice, however, those workpieces are supported on the lower platen frame assembly 36 and its surrounding work table 22 with the workpiece area at which the workpiece seam is to be formed being positioned in alignment with the diaphragm sets 32 and 34 of opposed platen assemblies 14 and 16
Additional FIGS. 4 and 5 are similar to FIG. 3 but illustrate the positioning and operating condition of apparatus 10 at critical points in the method of apparatus operation. Referring to FIG. 4, for instance, following the proper positioning of workpieces 66 and 68 on worktable 22, platen assembly 14 is advanced from its retracted position to a point where such workpieces become clamped in their proper position and between the opposed platen assembly plate elements 44. Each of heater block elements 26 and 28, preferably in a preheated condition, is then advanced to a position whereby it contacts its respective cooperating diaphragm set 32 and 34 compliant membrane member 40 or 42 and also functions to additionally clamp workpieces 66 and 68 together, particularly in the seam area that is to be formed. Next a pressurized fluid, frequently compressed air at an operating pressure of approximately 10 psig. (pounds per square inch gauge), is introduced through fluid line 58 and retained in the interior of each diaphragm set 32 and 34 to further clamp the workpieces together. (Fluid lines 62 previously are valved to a "closed" condition). Simultaneously, heat is transferred from each heater block element 26 and 28 by conductance through membrane members 40 and 42 and into the workpieces. Heat transfer is continued for a sufficient time to cause the thermoplastic resin in the coextensive seam areas of workpieces 66 and 68 to fuse together. Depending on the thickness of the workpieces, the nature of the workpiece thermoplastic resins involved, the thicknesses and thermal conductances of diaphragm sets 32 and 34, and the surface temperatures of heater block elements 26 and 28, the time required for adequate seam area fusion may be to a little as 15 seconds.
FIG. 4 also illustrates the "inflated" condition of each of diaphragm sets 32 and 34 during workpiece seam area heating.
When the fusing of workpiece seam area thermoplastic resins is sufficiently complete each of heater block elements 26 and 28 is retracted (withdrawn). Pressurized fluid used in the processing is then caused to be flowed through each of diaphragm sets 32 and 34 to act as a coolant while the workpiece seam area remains fully restrained by the adjacent compliant membrane members 40 and (The valving for fluid lines 62 is changed to an "open" condition and frequently the operating pressure of the pressurized fluid is increased sufficiently (e.g., compressed air at 15 psig.) to give an adequate coolant flow rate. Adequate cooling often is accomplished in apparatus 10 in as little time as 30 to 60 seconds. Since workpiece cooling is accomplished with simultaneous workpiece seam area restraint by platen assemblies 14 and 16 and their pressurized compliant membrane members 40 and 42, workpiece material in and also surrounding the seam area is prevented from bubbling, stretching, or otherwise undergoing some type of deformation or distortion.
Subsequently, locking bar mechanism 41 is unlocked to enable press platen assembly 14 and heater block assembly 26 to be returned to their initial, spaced-apart position relative to platen assembly 16. Thereafter, the joined workpieces are then either removed from apparatus 10 or are moved to their next position on worktable 22 for continued seaming operations.
It is to be understood that the foregoing detailed description of a preferred embodiment is illustrative only and that it will be apparent to those skilled in the art that various changes as to size, shape, and composition of the elements of this invention and changes as to process step parameters may be made without departing from the scope or intent of the present invention. | Press-type apparatus for thermally bonding thermoplastic sheet material workpieces is provided with a pair of opposed platen assemblies which each include an inflatable set of compliant diaphragm members, a pair of opposed heat sources which may be brought into and retracted from contact with the diaphragm members, and a source of pressurized fluid for inflating the diaphragm sets and for cooling the heated workpieces. The method for operating the press-type apparatus basically involves both heating and cooling the assembled workpieces while they are simultaneously being retained in a condition of being clamped by the inflatable sets of the diaphragm members. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of U.S. Provisional Patent Application Ser. No. 60/673,657 filed Apr. 20, 2005 entitled “Fabric for the Production of High Bulk Tissue and Towel and Nonwovens”, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the papermaking arts. More specifically, the present invention relates to through-air-drying (TAD) fabrics used in the manufacture of bulk tissue and towel, and of nonwoven articles and fabrics on a paper machine.
[0004] 2. Description of the Prior Art
[0005] Soft, absorbent disposable paper products, such as facial tissue, bath tissue and paper toweling, are a pervasive feature of contemporary life in modern industrialized societies. While there are numerous methods for manufacturing such products, in general terms, their manufacture begins with the formation of a cellulosic fibrous web in the forming section of a paper machine. The cellulosic fibrous web is formed by depositing a fibrous slurry, that is, an aqueous dispersion of cellulose fibers, onto a moving forming fabric in the forming section. A large amount of water is drained from the slurry through the forming fabric, leaving the cellulosic fibrous web on the surface of the forming fabric.
[0006] The cellulosic fibrous web is then transferred to a through-air-drying (TAD) fabric or belt by means of an air flow, brought about by vacuum or suction, which deflects the web and forces it to conform, at least in part, to the topography of the TAD fabric or belt. Downstream from the transfer point, the web, carried on the TAD fabric or belt, passes through a through-air dryer, where a flow of heated air, directed against the web and through the TAD fabric or belt, dries the web to a desired degree. Finally, downstream from the through-air dryer, the web may be adhered to the surface of a Yankee dryer and imprinted thereon by the surface of the TAD fabric or belt, for further and complete drying. The fully dried web is then removed from the surface of the Yankee dryer with a doctor blade, which foreshortens or crepes the web and increases its bulk. The foreshortened web is then wound onto rolls for subsequent processing, including packaging into a form suitable for shipment to and purchase by consumers.
[0007] As noted above, there are many methods for manufacturing bulk tissue products, and the foregoing description should be understood to be an outline of the general steps shared by some of the methods. For example, the use of a Yankee dryer is not always required, as, in a given situation, foreshortening may not be desired, or other means, such as “wet creping”, may have already been taken to foreshorten the web.
[0008] It should be appreciated that TAD fabrics may take the form of endless loops on the paper machine and function in the manner of conveyors. It should further be appreciated that paper manufacture is a continuous process which proceeds at considerable speeds. That is to say, the fibrous slurry is continuously deposited onto the forming fabric in the forming section, while a newly manufactured paper sheet is continuously wound onto rolls after it is dried.
[0009] Those skilled in the art will appreciate that fabrics are created by weaving, and have a weave pattern which repeats for flat weaving in both the warp or machine direction (MD) and the weft or cross-machine direction (CD). Woven fabrics take many different forms. For example, they may be woven endless, or flat woven and subsequently rendered into endless form with a seam. It will also be appreciated that the resulting fabric must be uniform in appearance; that is, there are no abrupt changes in the weave pattern that result in undesirable characteristics in the formed paper sheet. Due to the repeating nature of the weave patterns, a common fabric deficiency is a characteristic diagonal pattern in the fabric. In addition, any pattern marking, desired or not, imparted to the formed tissue will impact the characteristics of the paper.
[0010] Contemporary papermaking fabrics are produced in a wide variety of styles designed to meet the requirements of the paper machines on which they are installed for the paper grades being manufactured. Generally, they comprise a base fabric woven from monofilament and may be single-layered or multi-layered. The yarns are typically extruded from any one of several synthetic polymeric resins, such as polyamide and polyester resins, used for this purpose by those of ordinary skill in the paper machine clothing arts.
[0011] The present application is concerned, at least in part, with the TAD fabrics or belts used on the through-air dryer of a bulk tissue machine. More specifically, the present application is concerned with a TAD fabric of the variety disclosed in U.S. Pat. No. 6,763,855 to Rougvie (which is incorporated herein by reference). Rougvie discloses a TAD fabric comprising a woven base fabric having a coating of a polymeric resin material. Although the present fabric does not have a resin coating, many of the teachings of Rougvie relating to TAD fabrics are relevant.
[0012] Fabrics of this kind may also be used in the forming section of a bulk tissue machine to form cellulosic fibrous webs having discrete regions of relatively low basis weight in a continuous background of relatively high basis weight. Belts of this kind may also be used to manufacture other nonwoven articles and fabrics by processes such as hydroentangling, which have discrete regions in which the density of fibers is less than that in adjacent regions.
[0013] The properties of absorbency, strength, softness, and aesthetic appearance are important for many products when used for their intended purpose, particularly when the fibrous cellulosic products are facial or toilet tissue, paper towels, sanitary napkins or diapers.
[0014] Bulk, cross directional tensile, absorbency, and softness are particularly important characteristics when producing sheets of tissue, napkin, and towel paper. To produce a paper product having these characteristics, a fabric will often be constructed so that the top surface exhibits topographical variations. These topographical variations are often measured as plane differences between strands in the surface of the fabric. For example, a plane difference is typically measured as the difference in height between a raised weft or warp yarn strand or as the difference in height between MD knuckles and CD knuckles in the plane of the fabric's surface. Often, the fabric surface will exhibit pockets in which case plane differences may be measured as a pocket depth.
[0015] The present invention provides a TAD fabric which exhibits favorable characteristics for the formation of tissue paper and related products.
SUMMARY OF THE INVENTION
[0016] Accordingly, the present invention is a TAD fabric, although it may find application in the forming, pressing and drying sections of a paper machine. As such, it is a papermaker's fabric which comprises a plurality of warp yarns interwoven with a plurality of weft yarns.
[0017] The present invention is preferably a TAD fabric comprising a plurality of warp yarns interwoven with a plurality of weft yarns to produce a paper-side surface pattern characterized by alternating first pockets and second pockets. The first and second pockets are bounded by raised warp yarns and raised weft yarns produced by knuckles in the fabric pattern. The first pockets are preferably larger in area than the second pockets. The fabric base in the interior of the first pocket is preferably a plain weave pattern. The interior of the second pocket may also be bisected by a raised weft yarn.
[0018] The present invention will now be described in more complete detail with frequent reference being made to the drawing figures, which are identified below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] For a more complete understanding of the invention, reference is made to the following description and accompanying drawings, in which:
[0020] FIG. 1 shows a paper side view and a machine side view illustrating the paper side and machine side surface weave patterns for a preferred embodiment of the present invention;
[0021] FIG. 2 is a surface depth view highlighting the relative pocket sizes on the paper side surface of the fabric shown in FIG. 1 ;
[0022] FIG. 3 is a surface depth view highlighting the raised wefts and warps in the paper side surface of the fabric shown in FIG. 1 ;
[0023] FIG. 4 is a schematic plan view of the paper side surface weave pattern for the fabric shown in FIG. 1 ;
[0024] FIG. 5 shows the warp yarn contour patterns for the fabric pattern shown in FIG. 4 ;
[0025] FIG. 6 shows the weft yarn contour patterns for the fabric pattern shown in FIG. 4 ;
[0026] FIG. 7 shows cross-sectional views in the CD illustrating different weft yarn contour patterns for the fabric shown in FIG. 1 ; and
[0027] FIG. 8 shows cross-sectional views in the MD illustrating different warp yarn contour patterns for the fabric shown in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] The present invention is preferably a TAD fabric having at least two different sized pockets which alternate on the paper-side surface. The pocket sizes are a function of the weave pattern, mesh count, and yarns used in the pattern. Pocket sizes can be characterized by an MD/CD dimension and/or by a pocket depth. The pockets are formed/bounded by weft yarns and warp yarns which are raised from the base plane of the fabric surface. The raised weft yarns and warp yarns are produced by long knuckles in the weave pattern. The fabric base weave inside each pocket can be a plain weave pattern or any other suitable pattern. In addition, a pocket may include one or more raised or semi-raised warp yarns or weft yarns inside the pocket perimeter. For example, one size pocket may have a raised weft yarn bisecting the pocket area.
[0029] Fabrics according to the present invention may have mesh/end counts in the range of 12-20 yarns/cm in the MD and 10-18 yarns/cm in the CD. The pocket depth of the present fabrics may range between 300 and 500 μms.
[0030] Advantages of the present fabric are a relatively high percentage of open area resulting in a high air permeability as compared to other TAD fabrics. The present fabric produces a distinct and visible pattern in the tissue paper while limiting manufacturing stresses to maintain tensile strength and prevent ruptures. As a result, the present fabric may reduce or not cause pinholes in the tissue paper, as seen with other highly structured TAD fabrics.
[0031] A preferred embodiment of the present fabric may be produced with a 10-shed pattern comprising 3 different warp yarn contours and 3 different weft yarns contours. This pattern forms two sizes of pockets (or depressions) on the fabric surface. The smaller pocket encompasses an area which is between 45% and 65% of the area encompassed by the larger pocket. Both the large and small pockets are surrounded by higher out of plane long knuckles created by warp yarns and weft yarns. The interior of the large pocket has a plain weave surface pattern. The interior of the small pocket is bisected by a raised weft yarn across its center. This raised weft yarn may or may not be in-plane with the high long knuckles forming the pocket. Other embodiments alternatively may have a raised warp yarn bisecting the pocket.
[0032] FIG. 1 shows a paper side view and a machine side view illustrating the paper side and machine side surface weave patterns for the preferred embodiment of the present invention. In this preferred embodiment all MD yarns are 0.35 mm in diameter and all CD yarns are 0.40 mm in diameter. The mesh count is 18.9 yarns/cm in the MD and 13.0 yarns/cm in the CD. The pocket depth for this fabric is approximately 430-440 μms. This pattern also has shute runners on the machine side of the present fabric for abrasion resistance.
[0033] FIG. 2 is a surface depth view of the preferred embodiment taken with a MarSurf TS 50 high-precision optical 3D measuring instrument manufactured by Mahr GmbH Gottingen, Gottingen, Germany, and the relative pocket sizes on the paper side surface are highlighted. FIG. 2 provides a close-up view of the paper side surface shown in FIG. 1 . The fabric shown in FIG. 2 has two different sized pockets: a small pocket 200 and a large pocket 210 , 220 . The small pocket 200 has an area of approximately 4.03 mm 2 . The large pocket has a minimum area measurement of 7.84 mm 2 (as shown by highlighted pocket 210 ) and a median area measurement of 10.52 mm 2 (as shown by highlighted pocket 220 ).
[0034] FIG. 3 is a surface depth view of the preferred embodiment also taken with a MarSurf TS 50 high-precision optical 3D measuring instrument manufactured by Mahr GmbH Gottingen, Gottingen, Germany, showing the raised wefts and warps on the paper side surface. The pockets are formed/bounded by raised weft yarns 330 and raised warp yarns 310 . Note the interiors of the large pockets have a plain weave pattern, while the interiors of the small pockets have a raised weft yarn 320 which bisects the pocket. This raised weft yarn 320 may or may not be in the same plane as the raised weft yarns and warp yarns which bound the pockets.
[0035] FIG. 4 is a schematic plan view of the paper side surface weave pattern for the fabric shown in FIG. 1 . In FIG. 4 , the MD runs vertically and the CD runs horizontally. Each column corresponds to a warp yarn and each row corresponds to a weft yarn. The numbered boxes indicate knuckles where that numbered warp yarn is on the top (paper) surface of the fabric. Accordingly, the empty boxes indicate locations where a warp yarn passes under a weft yarn.
[0036] FIG. 5 shows the warp yarn contour patterns for the fabric pattern shown in FIG. 4 . The numbers to the right of each warp yarn contour pattern indicate the number of the warp yarn followed by the contour pattern number for that warp yarn. For example, warp yarns 1 , 4 , 6 , and 9 each weave a staggered/shifted version of contour pattern number 1. Note, the present fabric pattern incorporates 3 different warp yarn contours in a 1, 2, 2, 1, 3 sequence which repeats twice in one pattern repeat. Each warp yarn corresponds to a column in FIG. 4 . For example, warp yarn 1 corresponds to the pattern shown in the first column in FIG. 4 . As shown by the contour pattern for warp yarn 1 , the warp yarn passes under weft yarns 1 - 3 , over weft yarn 4 , under weft yarn 5 , over weft yarns 6 and 7 , under weft yarn 8 , over weft yarn 9 , and under weft yarn 10 . Accordingly, in column 1 of FIG. 4 , the boxes corresponding to weft yarns 4 , 6 , 7 , and 9 indicate that warp yarn 1 forms knuckles where it passes over the weft yarns in the contour pattern. Alternatively, the boxes in FIG. 4 are blank where the warp yarn passes under the weft yarn.
[0037] FIG. 6 shows the weft yarn contour patterns for the fabric pattern shown in FIG. 4 . As in FIG. 5 , the numbers to the right of each weft yarn contour pattern indicate the number of the weft yarn followed by the contour pattern number for that weft yarn. For example, weft yarns 1 , 4 , 6 , and 9 each weave a staggered/shifted version of contour pattern number 1. Note, the present fabric pattern incorporates 3 different weft yarn contours in a 1, 2, 2, 1, 3 sequence which repeats twice in one pattern repeat. Each weft yarn corresponds to a row in FIG. 4 . For example, weft yarn 1 corresponds to the pattern shown in the first row in FIG. 4 . As shown by the contour pattern for weft yarn 1 , the weft yarn passes over warp yarn 1 , under warp yarn 2 , over warp yarn 3 , under warp yarn 4 , over warp yarn 5 , and under warp yarns 6 - 10 . Accordingly, in row 1 of FIG. 4 , the boxes corresponding to warp yarns 2 , 4 , and 6 - 10 indicate those warp yarns form knuckles where they pass over weft yarn 1 in the contour pattern. As above, the boxes in FIG. 4 are blank where the warp yarn passes under the weft yarn.
[0038] FIG. 7 shows cross-sectional views in the CD illustrating two of the three different weft yarn contour patterns for the fabric shown in FIG. 1 . FIG. 8 shows cross-sectional views in the MD illustrating two of the three different warp yarn contour patterns for the fabric shown in FIG. 1 .
[0039] The present invention is intended to cover other fabric patterns having different sizes and shapes of pockets, different pocket depths, and different yarn contours. Accordingly, the present invention should not be construed as being limited to the preferred embodiment disclosed above.
[0040] The fabric according to the present invention preferably comprises only monofilament yarns, preferably of polyester, polyamide, or other polymers. Any combination of polymers for any of the yarns can be used as identified by one of ordinary skill in the art. The CD and MD yarns may have a circular cross-sectional shape with one or more different diameters. For example, the raised weft yarns and warp yarns may be a different diameter than the weft yarns and warp yarns forming the base fabric (i.e. the pocket interiors). The weft yarn and warp yarn diameters may range from 0.20 mm to 0.55 mm, and are preferably between 0.35 mm and 0.45 mm. However, any combination of diameters can be used and these exemplary diameters should not be construed as limiting the invention in any way. Further, in addition to a circular cross-sectional shape, one or more of the yarns may have other cross-sectional shapes such as a rectangular cross-sectional shape or a non-round cross-sectional shape.
[0041] Modifications to the above would be obvious to those of ordinary skill in the art, but would not bring the invention so modified beyond the scope of the present invention. The claims to follow should be construed to cover such situations. | A through-air-drying (TAD) fabric for producing tissue paper and related products on a papermaking machine comprising a plurality of warp yarns interwoven with a plurality of weft yarns to produce a paper-side surface pattern characterized by alternating first pockets and second pockets. The first and second pockets are bounded by raised warp yarns and raised weft yarns produced by knuckles in the fabric pattern. The first pockets are preferably larger in area than the second pockets. The fabric base weave in the interior of the first pocket is preferably a plain weave pattern. The interior of the second pocket may also be bisected by a raised weft yarn. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the US National Stage of International Application No. PCT/EP2005/000405, filed Jan. 17, 2005 and claims the benefit thereof. The International Application claims the benefits of European Patent application No. 04002158.6 filed Jan. 30, 2004. All of the applications are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] The invention relates to a process for removing a layer as described in the claims.
BACKGROUND OF THE INVENTION
[0003] After they have been used, components, such as for example turbine blades or vanes, have corrosion products, such as for example oxides, sulfides, nitrides, carbides, phosphates, etc. which form a layer. Components of this type, after they have been used, can be reused if, inter alia, the corrosion products have been removed. The complete removal of the corrosion products is effected, for example, by sand-blasting, although this can lead to damage to the substrate.
[0004] It is also possible for the component to be completely treated by means of acid stripping or fluoride ion cleaning (FIC). However, this is very time-consuming since the material-removal rates of the corrosion products over the course of time are in some cases too low with respect to the acid or the fluorine and/or fluoride.
[0005] U.S. Pat. No. 5,575,858 describes a process for removing a removal region, in particular a corrosion product of a component, in which the removal region is pretreated prior to final cleaning, so as to damage the removal region, so that then the material-removal rate during the final cleaning of the removal region is greater than without the damage to the removal region.
SUMMARY OF THE INVENTION
[0006] Similar processes are disclosed in U.S. Pat. No. 4,439,241, U.S. Pat. No. 5,464,479 and EP 1 013 797. Therefore, the object of the invention is that of providing a process in which the removal of layers on a component is facilitated and therefore takes less time.
[0007] The object is achieved by the process as claimed in the claims.
[0008] The subclaims list further advantageous measures of the process according to the invention.
[0009] The measures listed in the subclaims can be combined with one another in advantageous ways.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention is explained schematically with reference to the figures, in which
[0011] FIG. 1 shows a component with a corrosion product,
[0012] FIG. 2 diagrammatically depicts the execution of the process according to the invention,
[0013] FIG. 3, 4 , 5 show the component after the process according to the invention has been carried out,
[0014] FIG. 6 shows a gas turbine,
[0015] FIG. 7 shows a combustion chamber,
[0016] FIG. 8 shows a turbine blade or vane, and
[0017] FIG. 9 shows a steam turbine.
DETAILED DESCRIPTION OF THE INVENTION
[0018] FIG. 1 shows a component 1 which can be treated by the process according to the invention.
[0019] The component 1 comprises a ceramic or metallic substrate 4 (base body) which is for example, in particular for turbines, a cobalt-base, iron-base or nickel-base superalloy.
[0020] The component 1 is, for example, a guide vane 130 or rotor blade 120 ( FIGS. 6, 8 ) of a gas turbine 100 ( FIG. 6 ), of a steam turbine 300 , 303 ( FIG. 9 ) or of an aircraft turbine, a combustion chamber lining 155 ( FIG. 7 ) or another component of a turbine which is exposed to hot gases.
[0021] The component 1 may be either newly produced or refurbished. Refurbishment means that components 1 , after they have been used, if appropriate have layers (thermal barrier coating) detached and corrosion and oxidation products removed. If appropriate, cracks may also have to be repaired.
[0022] A component 1 of this type can then be coated again; this is particularly advantageous because the base body is very expensive.
[0023] For use, the component 1 may have at least one ceramic or metallic layer on the surface 13 , such as for example an MCrAlX layer and/or a thermal barrier coating resting thereon, which can be roughly removed in a first process step.
[0024] The MCrAlX layer may also represent the removal region 10 which is treated by the process according to the invention.
[0025] In the text which follows, the removal region 10 is considered to be a corrosion product 10 (corrosion layer 10 ). However, the removal region 10 may equally be a functional layer without corrosion products.
[0026] The removal region 10 may be a metallic and/or ceramic layer, in which case the layer may be metallic and includes corrosion products. The corrosion product 10 , for example an oxide, a sulfide, a nitride, a phosphide or a carbide, etc., may be present on a surface 13 of the component 1 or in a crack 7 in the component 1 .
[0027] The corrosion products 10 have to be removed from the crack 7 or from the surface 13 so that the crack 7 can be filled with a solder or welding material and the surface 13 can be coated again. Corrosion products 10 would otherwise prevent or at least reduce good bonding of the solder or renewed coating.
[0028] The corrosion product 10 according to the prior art has a defined material-removal rate (mass per unit time) when it is cleaned for example using the FIC process. However, this material-removal rate is too low and after a certain time may even be zero.
[0029] FIG. 2 diagrammatically depicts the execution of the process according to the invention.
[0030] By way of example, a material 16 , for example a salt 16 , which can react chemically with the corrosion product 10 in order to damage the removal region 10 , is applied to the corrosion product 10 in order to damage the latter.
[0031] The salt used is preferably Na 2 SO 4 (sodium sulfate) and/or CoSO 4 (cobalt sulfate). Further salts or combinations are conceivable.
[0032] The corrosion products aluminum oxide and/or cobalt oxide and/or titanium oxide of the metals titanium, aluminum and/or cobalt which are contained in the alloy (for example super-alloy) of the substrate 4 can be removed very successfully in particular using these salts.
[0033] It is also possible for a fused salt to be applied directly in the crack 7 or to the corrosion product 10 or for the component 1 to be immersed in a fused salt.
[0034] It is also possible for the salt to be applied into the crack 7 and to the surface 13 in the form of a slurry. In the case of large-area applications, it is appropriate to lay down a sheet which contains the material 16 or salt 16 .
[0035] The salt 16 can, for example, be heated, in particular locally, by means of a laser 19 and its laser beams 22 , resulting in a chemical reaction of the salt 16 with the corrosion product 10 or a thermal shock.
[0036] The heating can also be effected by electromagnetic induction, in particular if the substrate 4 is metallic. The heating of the component 1 can be effected, for example locally, by means of induction or by means of a light source, for example by means of a laser, by the laser 19 radiating the laser beam 22 only into the crack 7 .
[0037] The local heating can also be effected by means of tunable microwaves. Tunable means that, inter alia, the wavelength and intensity can be varied.
[0038] FIG. 3 shows a component 1 with a corrosion product 10 following the damaging of the corrosion product 10 by a pretreatment according to the invention.
[0039] The pretreatment produces cracks 25 which run from the surface 14 of the layer 10 in the direction of the substrate 4 , resulting in a larger attackable surface area of the corrosion product 10 with respect to the acid and/or the fluoride ions, etc.
[0040] Cracks 25 of this type can also be produced by means of laser beams, high-pressure water jets, sand-blasting, in particular with coarse grains. The intensity and duration of the sand-blasting treatment, however, has to be set in such a way that the substrate 4 is not reached and the corrosion product 10 is only partially removed.
[0041] In a final process step, the component 1 is subjected to a final cleaning by means of an acid or fluoride ion treatment, which leads to complete removal of the corrosion product 10 , since the damage to the corrosion product 10 means that the material-removal rate during FIC or another process is considerably increased and there is no significant reduction in the material-removal rate over the course of time.
[0042] FIG. 4 shows another way of damaging the corrosion product 10 .
[0043] The corrosion product 10 , which rests on a surface 13 of the substrate 4 , is subjected to a thermal shock. The thermal shock can be effected by immersion in a hot metal or salt bath or by rapid heating by means of electron beams or a laser 28 .
[0044] The corrosion product 10 may also be partially melted during the thermal shock.
[0045] FIG. 5 shows further damage to the corrosion product 10 in accordance with the process of the invention.
[0046] If the material of the corrosion product 10 has, for example, been melted, the material contracts again as it cools, resulting in mechanical stresses which can lead to crack formation.
[0047] In addition to cracks 25 in the surface of the corrosion product 10 , it is also possible for cracks 31 to be produced within the corrosion product 10 .
[0048] It is also possible for delaminations 34 to form between the corrosion product 10 and a surface 13 on which the corrosion product 10 rests.
[0049] The particular feature of the process is that the component 1 having the corrosion products 10 , which has been damaged by these corrosion products 10 and needs to be repaired, is damaged still further in the region of the corrosion products 10 .
[0050] FIG. 6 shows, by way of example, a partial longitudinal section through a gas turbine 100 .
[0051] In the interior, the gas turbine 100 has a rotor 103 which is mounted such that it can rotate about an axis of rotation 102 and is also referred to as the turbine rotor.
[0052] An intake housing 104 , a compressor 105 , a, for example, toroidal combustion chamber 110 , in particular an annular combustion chamber 106 , with a plurality of coaxially arranged burners 107 , a turbine 108 and the exhaust-gas housing 109 follow one another along the rotor 103 .
[0053] The annular combustion chamber 106 is in communication with a, for example, annular hot-gas passage 111 , where, by way of example, four successive turbine stages 112 form the turbine 108 .
[0054] Each turbine stage 112 is formed, for example, from two blade or vane rings. As seen in the direction of flow of a working medium 113 , in the hot-gas passage 111 a row of guide vanes 115 is followed by a row 125 formed from rotor blades 120 .
[0055] The guide vanes 130 are secured to an inner housing 138 of a stator 143 , whereas the rotor blades 120 of a row 125 are fitted to the rotor 103 for example by means of a turbine disk 133 . A generator (not shown) is coupled to the rotor 103 .
[0056] While the gas turbine 100 is operating, the compressor 105 sucks in air 135 through the intake housing 104 and compresses it. The compressed air provided at the turbine-side end of the compressor 105 is passed to the burners 107 , where it is mixed with a fuel. The mix is then burnt in the combustion chamber 110 , forming the working medium 113 .
[0057] From there, the working medium 113 flows along the hot-gas passage 111 past the guide vanes 130 and the rotor blades 120 . The working medium 113 is expanded at the rotor blades 120 , transferring its momentum, so that the rotor blades 120 drive the rotor 103 and the latter in turn drives the generator coupled to it.
[0058] While the gas turbine 100 is operating, the components which are exposed to the hot working medium 113 are subject to thermal stresses. The guide vanes 130 and rotor blades 120 of the first turbine stage 112 , as seen in the direction of flow of the working medium 113 , together with the heat shield bricks which line the annular combustion chamber 106 , are subject to the highest thermal stresses.
[0059] To be able to withstand the temperatures which prevail there, they have to be cooled by means of a coolant.
[0060] The substrates may likewise have a directional structure, i.e. they are in single-crystal form (SX structure) or have only longitudinally oriented grains (DS structure). Iron-base, nickel-base or cobalt-base superalloys are used as material.
[0061] It is also possible for the blades or vanes 120 , 130 to have coatings which protect against corrosion (MCrAlX; M is at least one element selected from the group consisting of iron (Fe), cobalt (Co), nickel (Ni), X stands for yttrium (Y) and/or at least one rare earth element) and heat by means of a thermal barrier coating. The thermal barrier coating consists, for example, of ZrO 2 , Y 2 O 4 —ZrO 2 , i.e. unstabilized, partially stabilized or fully stabilized by yttrium oxide and/or calcium oxide and/or magnesium oxide.
[0062] Columnar grains are produced in the thermal barrier coating by suitable coating processes, such as for example electron beam physical vapor deposition (EB-PVD).
[0063] Despite the protective layers, corrosion products 10 can form on the component. For refurbishment, the corrosion products have to be removed by the process according to the invention if the component is to be coated again. If appropriate, cracks in the substrate of the component are then repaired.
[0064] The guide vane 130 has a guide vane root (not shown here), which faces the inner housing 138 of the turbine 108 , and a guide vane head which is at the opposite end from the guide vane root. The guide vane head faces the rotor 103 and is fixed to a securing ring 140 of the stator 143 .
[0065] FIG. 7 shows a combustion chamber 110 of a gas turbine. The combustion chamber 110 is configured, for example, as what is known as an annular combustion chamber, in which a multiplicity of burners 102 arranged circumferentially around the turbine shaft 103 open out into a common combustion chamber space. For this purpose, the combustion chamber 110 overall is of annular configuration positioned around the turbine shaft 103 .
[0066] To achieve a relatively high efficiency, the combustion chamber 110 is designed for a relatively high temperature of the working medium M of approximately 1000° C. to 1600° C. To allow a relatively long service life even with these operating parameters, which are unfavorable for the materials, the combustion chamber wall 153 is provided, on its side which faces the working medium M, with an inner lining formed from heat shield elements 155 . On the working medium side, each heat shield element 155 is equipped with a particularly heat-resistant protective layer or is made from material that is able to withstand high temperatures. A cooling system is also provided for the heat shield elements 155 and/or their holding elements, on account of the high temperatures in the interior of the combustion chamber 110 .
[0067] The materials of the combustion chamber wall and their coatings may be similar to the turbine blades or vanes 120 , 130 .
[0068] The combustion chamber 110 is designed in particular to detect losses of the heat shield elements 155 . For this purpose, a number of temperature sensors 158 are positioned between the combustion chamber wall 153 and the heat shield elements 155 .
[0069] FIG. 8 shows a perspective view of a blade or vane 120 , 130 , which extends along a longitudinal axis 121 . The blade or vane 120 , 130 has, in succession along the longitudinal axis 121 , a securing region 400 , an adjoining blade or vane platform 403 and a main blade or vane region 406 . A blade or vane root 183 , which is used to secure the rotor blades 120 , 130 to the shaft, is formed in the securing region 400 . The blade or vane root 183 is designed in hammerhead form. Other configurations, such as a fir-tree or dovetail root are possible. In the case of conventional blades or vanes 120 , 130 , solid metallic materials are used in all the regions 400 , 403 , 406 of the rotor blade 120 , 130 . The rotor blade 120 , 130 may in this case be produced by a casting process, by a forging process, by a milling process or combinations thereof.
[0070] FIG. 9 illustrates, by way of example, a steam turbine 300 , 303 with a turbine shaft 309 extending along an axis of rotation 306 .
[0071] The steam turbine has a high-pressure part-turbine 300 and an intermediate-pressure part-turbine 303 , each with an inner casing 312 and an outer casing 315 surrounding it. The high-pressure part-turbine 300 is, for example, of pot-type design. The intermediate-pressure part-turbine 303 is of two-flow design. It is also possible for the intermediate-pressure part-turbine 303 to be of single-flow design. Along the axis of rotation 306 , a bearing 318 is arranged between the high-pressure part-turbine 300 and the intermediate-pressure part-turbine 303 , the turbine shaft 309 having a bearing region 321 in the bearing 318 . The turbine shaft 309 is mounted on a further bearing 324 next to the high-pressure part-turbine 300 . In the region of this bearing 324 , the high-pressure part-turbine 300 has a shaft seal 345 . The turbine shaft 309 is sealed with respect to the outer casing 315 of the intermediate-pressure part-turbine 303 by two further shaft seals 345 . Between a high-pressure steam inflow region 348 and a steam outlet region 351 , the turbine shaft 309 in the high-pressure part-turbine 300 has the high-pressure rotor blading 354 , 357 . This high-pressure rotor blading 354 , 357 , together with the associated rotor blades (not shown in more detail), constitutes a first blading region 360 . The intermediate-pressure part-turbine 303 has a central steam inflow region 333 . Assigned to the steam inflow region 333 , the turbine shaft 309 has a radially symmetrical shaft shield 363 , a cover plate, on the one hand for dividing the flow of steam between the two flows of the intermediate-pressure part-turbine 303 and also for preventing direct contact between the hot steam and the turbine shaft 309 . In the intermediate-pressure part-turbine 303 , the turbine shaft 309 has a second blading region 366 comprising the intermediate-pressure rotor blades 354 , 342 . The hot steam flowing through the second blading region 366 flows out of the intermediate-pressure part-turbine 303 from an outflow connection piece 369 to a low-pressure part-turbine (not shown) which is connected downstream in terms of flow.
[0072] The components of the steam turbine 300 , 303 likewise have protective layers and/or corrosion products 10 which are removed by the process according to the invention before the components can be refurbished. | Components comprising corrosion products are often reused, in which case the corrosion product has to be removed. According to the prior art, this takes a very long time since the reaction times with the corrosion product are often very long. According to the invention, the corrosion product is pretreated in order to produce a larger attackable surface area, so that the corrosion product can be removed more quickly. | 2 |
This application is a continuation of application Ser. No. 07/567,985, filed on Aug. 15, 1990, now abandoned.
BACKGROUND OF THE INVENTION
Over the last several years it has become apparent that the neurotransmitter serotonin (5-hydroxytryptamine--5-HT) is associated directly or indirectly with a number of physiological phenomena, including appetite, memory, thermoregulation, sleep, sexual behavior, anxiety, depression, and hallucogenic behavior [Glennon, R. A., J. Med. Chem. 30, 1 (1987)].
It has been recognized that there are multiple types of 5-HT receptors. These receptors have been classified as 5-HT 1 , 5-HT 2 , and 5-HT 3 receptors, with the former being further divided into the sub-classes 5-HT 1A , 5-HT 1B , 5-HT 1C , and 5-HT 1D .
Selected 2-amino-1,2,3,4-tetrahydronaphthalenes (2-aminotetralins) and 3-aminochromanes have been shown to exhibit binding affinity at the 5-HT 1A receptor.
Co-pending application Ser. No. 315,750 filed Feb. 27, 1989, now abandoned, describes certain 2-aminotetralins substituted in the 8-position by formyl, cyano, halo, hydroxymethyl, carboxamido, carboxyl, or alkoxycarbonyl. The compounds are described as exhibiting high binding affinity at the 5-HT 1A receptor. 2-aminotetralins in which the 8-position is substituted by, among others, formyl, are also described in EPO Patent Application No. 272,534. In addition, co-pending application Ser. No. 315,752 filed Feb. 27, 1989, now abandoned, describes other 2-aminotetralins substituted in the 8-position and 3-aminochromanes substituted in the 5-position by sulfides, sulfoxides, and sulfones. These compounds, as well, are described as having binding affinity at the 5-HT 1A receptor.
Another class of 2-aminotetralins are described in European Patent Application No. 343,830, published Nov. 29, 1989. These compounds have a piperazinyl or homopiperazinyl moiety in the 2-position and, distinct from the foregoing tetralins, do not exhibit affinity for serotonin receptors but rather inhibit the re-uptake of serotonin. We have now discovered a further class of compounds which, by reason of their 5-HT 1A agonist activity, are useful in the treatment, for example, of sexual dysfunction, anxiety, depression, obsessive-compulsive behavior, cognition disorders, emesis, drug abuse, hypertension, excess acid secretion, and eating disorders, such as anorexia.
SUMMARY OF THE INVENTION
The present invention provides novel ring-substituted 2-amino-1,2,3,4-tetrahydronaphthalenes and 3-aminochromanes which are selective agonists at the 5-HT 1A receptor.
More specifically, this invention is directed to a compound of the formula ##STR1## in which R is C 1 -C 4 alkyl, C 3 -C 4 alkenyl, or cyclopropylmethyl;
R 3 is hydrogen; or
R and R 3 taken together are a divalent group of the formula --CH 2 CH 2 CH 2 --;
R 1 is hydrogen, C 1 -C 4 alkyl, C 3 -C 4 alkenyl, cyclopropylmethyl, aryl(C 1 -C 4 -alkyl), --COR 4 , --(CH 2 ) n S(C 1 -C 4 alkyl) or --(CH 2 ) n CONR 5 R 6 ;
n is an integer from 1 to 4;
R 4 is hydrogen, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, or phenyl;
R 5 and R 6 are independently hydrogen, a C 1 -C 4 alkyl, or C 3 -C 7 cycloalkyl with the proviso that when one of R 5 or R 6 is cycloalkyl the other is hydrogen;
X is --CH 2 --, --O--, --S--, ##STR2## A is ##STR3## R 2 is C 1 -C 8 alkyl, substituted C 1 -C 8 alkyl, C 2 -C 4 alkenyl, aryl, substituted aryl, aryl(C 1 -C 4 -alkyl), substituted aryl(C 1 -C 4 alkyl), C 3 -C 7 cycloalkyl-substituted methyl, or C 3 -C 7 cycloalkyl;
and pharmaceutically acceptable acid addition salts thereof.
This invention also provides a pharmaceutical formulation which comprises, in association with a pharmaceutically acceptable carrier, diluent, or excipient, a compound of the formula ##STR4## in which R is C 1 -C 4 alkyl, C 3 -C 4 alkenyl or cyclopropylmethyl;
R 3 is hydrogen; or
R and R 3 taken together are a divalent group of the formula --CH 2 CH 2 CH 2 --;
R 1 is hydrogen, C 1 -C 4 alkyl, C 3 -C 4 alkenyl, cyclopropylmethyl, aryl(C 1 -C 4 -alkyl), --COR 4 , --(CH 2 ) n S(C 1 -C 4 alkyl) or --(CH 2 ) n CONR 5 R 6 ;
n is an integer from 1 to 4;
R 4 is hydrogen, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, or phenyl;
R 5 and R 6 are independently hydrogen, C 1 -C 4 alkyl, or C 3 -C 7 cycloalkyl with the proviso that when one of R 5 or R 6 is cycloalkyl the other is hydrogen; ##STR5## R 2 is C 1 -C 8 alkyl, substituted C 1 -C 8 alkyl, alkenyl, aryl, substituted aryl, aryl(C 1 -C 4 -alkyl), substituted aryl(C 1 -C 4 alkyl), C 3 -C 7 cycloalkyl-substituted methyl, or C 3 -C 7 cycloalkyl;
and pharmaceutically acceptable acid addition salts thereof.
A further embodiment of the invention is a method for effecting a biological response at the 5-HT 1A receptor. More particularly, further embodiments are methods for treating a variety of disorders in mammals which may be treated by stimulating 5-HT 1A receptors. Included among these disorders are anxiety, depression, sexual dysfunction, obsessive-compulsive behavior, hypertension, excess acid secretion, and eating disorders. Any of these methods employ a compound of the formula ##STR6## in which R is C 1 -C 4 alkyl, C 3 -C 4 alkenyl or cyclopropylmethyl;
R 3 is hydrogen; or
R and R 3 taken together are a divalent group of the formula --CH 2 CH 2 CH 2 --;
R 1 is hydrogen, C 1 -C 4 alkyl, C 3 -C 4 alkenyl, cyclopropylmethyl, aryl(C 1 -C 4 -alkyl), --COR 4 , --(CH 2 ) n S(C 1 -C 4 alkyl) or --(CH 2 ) n CONR 5 R 6 ;
n is an integer from 1 to 4;
R 4 is hydrogen, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, or phenyl;
R 5 and R 6 are independently hydrogen, C 1 -C 4 alkyl, or C 3 -C 7 cycloalkyl with the proviso that when one of R 5 or R 6 is cycloalkyl the other is hydrogen; ##STR7## R 2 is C 1 -C 8 alkyl, substituted C 1 -C 8 alkyl, C 2 -C 4 alkenyl, aryl, substituted aryl, aryl(C 1 -C 4 -alkyl), substituted aryl(C 1 -C 4 alkyl), C 3 -C 7 cycloalkyl-substituted methyl, or C 3 -C 7 cycloalkyl;
and pharmaceutically acceptable acid addition salts thereof.
DETAILED DESCRIPTION OF THE INVENTION
In the above formulas, the term "C 1 -C 4 alkyl" means a straight or branched alkyl chain having from one to four carbon atoms. Such C 1 -C 4 alkyl groups are methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, and t-butyl.
The term "C 1 -C 8 alkyl" means a straight or branched alkyl chain having from one to eight carbon atoms. Groups which are included in such term are methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, t-butyl, n-pentyl, 2-methylbutyl, 3-methylbutyl, n-hexyl, 4-methylpentyl, n-heptyl, 3-ethylpentyl, 2-methylhexyl, 2,3-dimethylpentyl, n-octyl, 3-propylpentyl, 6-methylheptyl, and the like.
The term "C 1 -C 4 alkoxy" means any of methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, isobutoxy, t-butoxy, and sec-butoxy.
The term "aryl" means an aromatic carbocyclic structure. Examples of such ring structures are phenyl, naphthyl, and the like.
The term "C 3 -C 7 cycloalkyl" means cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, and cycloheptyl.
The term "aryl (C 1 -C 4 alkyl)" means an aromatic carbocyclic structure joined to a C 1 -C 4 alkyl group. Examples of such groups are benzyl, phenylethyl, α-methylbenzyl, 3-phenylpropyl, α-naphthylmethyl, β-naphthylmethyl, 4-phenylbutyl, and the like.
The term "C 2 -C 4 alkenyl" means a straight or branched hydrocarbon chain having from two to four carbon atoms and containing one double bond. Groups which are included in such terms are vinyl, 1-methylvinyl, 2-methylvinyl, allyl, 2-butenyl, 3-butenyl, 1-butenyl, 1-methylallyl, 2-methylallyl, and the like.
For purposes herein, the term "C 3 --C 4 alkenyl" is specifically defined to mean any of allyl, 2-butenyl, 3-butenyl, and 2-methylallyl.
In addition, the C 1 -C 8 alkyl, the aryl, and the aryl (C 1 -C 4 alkyl) groups may be substituted by one or two moieties. Typical aryl and/or alkyl substituents are C 1 -C 3 alkoxy, halo, hydroxy, C 1 -C 3 thioalkyl, and the like. Moreover, the aryl and aryl (C 1 -C 4 alkyl) groups may also be substituted by a C 1 -C 3 alkyl or a trifluoromethyl group.
In the foregoing, the term "C 1 -C 3 alkyl" means any of methyl, ethyl, n-propyl, and isopropyl; the term "C 1 -C 3 alkoxy" means any of methoxy, ethoxy, n-propoxy, and isopropoxy; the term "halo" means any of fluoro, chloro, bromo, and iodo; and the term "C 1 -C 3 thioalkyl" means any of methylthio, ethylthio, n-propylthio, and isopropylthio.
Examples of substituted C 1 -C 8 alkyl are methoxymethyl, trifluoromethyl, 6-chlorohexyl, 2-bromopropyl, 2-ethoxy-4-iodobutyl, 3-hydroxypentyl, methylthiomethyl, and the like.
Examples of substituted aryl are p-bromophenyl, m-iodophenyl, p-tolyl, o-hydroxyphenyl, β-(4-hydroxy)naphthyl, p-(methylthio)phenyl, m-trifluoromethylphenyl, 2-chloro-4-methoxyphenyl, α-(5-chloro)-naphthyl, and the like.
Examples of substituted aryl (C 1 -C 4 alkyl) are p-chlorobenzyl, o-methoxybenzyl, m-(methylthio)-α-methylbenzyl, 3-(4'-trifluoromethylphenyl)-propyl, o-iodobenzyl, p-methylbenzyl, and the like.
While all of the compounds of the present invention are useful for treating a variety of disorders by virtue of their ability to activate the 5-HT 1A receptor in mammals, certain of the compounds are preferred.
Thus, although compounds in which A is ##STR8## have activity in their own right, their dominant purpose herein is as intermediates to those compounds in which A is ##STR9## therefore, the latter are preferred.
Moreover, R and R 1 preferably are both C 1 -C 4 alkyl, and, more preferably, both are n-propyl.
X preferably is --CH 2 --.
R 2 preferably is C 1 -C 8 alkyl, and, more preferably, C 1 -C 5 alkyl. Most preferably, R 2 is t-butyl.
The compounds of the present invention possess an asymmetric carbon represented by the carbon atom labeled with an asterisk in the following formula: ##STR10## As such, each of the compounds exists as its individual d- and 1-stereoisomers and also as the racemic mixture of such isomers. Accordingly, the compounds of the present invention include not only the dl-racemates but also their respective optically active d- and 1-isomers.
As mentioned hereinabove, the invention includes pharmaceutically acceptable acid addition salts of the compounds defined by the above formula in which A is ##STR11##
Since the compounds of this invention are amines, they are basic in nature and accordingly react with any of a number of inorganic and organic acids to form pharmaceutically acceptable acid addition salts. Since the free amines of the compounds of this invention are typically oils at room temperature, it is preferable to convert the free amines to their corresponding pharmaceutically acceptable acid addition salts for ease of handling and administration, since the latter are routinely solid at room temperature. Acids commonly employed to form such salts are inorganic acids such as hydrochloric acid, hydrobromic acid, hydroiodic acid, sulfuric acid, phosphoric acid, and the like, and organic acids such as maleic, fumaric, p-toluenesulfonic, methanesulfonic acid, oxalic acid, p-bromophenylsulfonic acid, carbonic acid, succinic acid, citric acid, benzoic acid, acetic acid, and the like. Examples of such pharmaceutically acceptable salts thus are the sulfate, pyrosulfate, bisulfate, sulfite, bisulfite, phosphate, monohydrogenphosphate, dihydrogenphosphate, metaphosphate, pyrophosphate, chloride, bromide, iodide, acetate, propionate, decanoate, caprylate, acrylate, formate, isobutyrate, caproate, heptanoate, propiolate, oxalate, malonate, succinate, suberate, sebacate, fumarate, maleate, butyne-1,4-dioate, hexyne-1,6-dioate, benzoate, chlorobenzoate, methylbenzoate, dinitrobenzoate, hydroxybenzoate, methoxybenzoate, phthalate, sulfonate, xylenesulfonate, phenylacetate, phenylpropionate, phenylbutyrate, citrate, lactate, γ-hydroxybutyrate, glycollate, tartrate, methanesulfonate, propanesulfonate, naphthalene-1-sulfonate, naphthalene-2-sulfonate, mandelate, and the like. Preferred pharmaceutically acceptable acid addition salts are those formed with mineral acids such as hydrochloric acid and hydrobromic acid, and those formed with organic acids such as maleic acid.
In addition, some of these salts may form solvates with water or organic solvents such as ethanol. Such solvates also are included as compounds of this invention.
The following compounds further illustrate compounds contemplated within the scope of this invention:
2-(Di-n-propylamino)-8-acetyl-1,2,3,4-tetrahydronaphthalene;
2-Ethylamino-8-benzoyl-1,2,3,4-tetrahydronaphthalene;
2-(N-Methyl-N-benzylamino)-8-isobutyryl-1,2,3,4-tetrahydronaphthalene;
2-Diallylamino-8-phenylacetyl-1,2,3,4-tetrahydronaphthalene;
2-Diethylamino-8-(p-methoxybenzoyl)-1,2,3,4-tetrahydronaphthalene;
2-(Di-n-propylamino)-8-trifluoroacetyl-1,2,3,4-tetrahydronaphthalene;
2-Benzylmethylamino-8-heptanoyl-1,2,3,4-tetrahydronaphthalene;
2-(Di-n-propylamino)-8-(α-methylpropionyl)-1,2,3,4-tetrahydronaphthalene;
2-Dimethylamino-8-cyclohexylcarbonyl-1,2,3,4-tetrahydronaphthalene;
2-(Di-cyclopropylmethylamino)-8-(β-chloropentanoyl)-1,2,3,4-tetrahydronaphthalene;
2-(Di-n-propylamino)-8-(p-chlorophenylacetyl)thio-1,2,3,4-tetrahydronaphthalene;
2-Ethylamino-8-propionyl-1,2,3,4-tetrahydronaphthalene;
2-n-Butylamino-8-(α,α-dimethylpropionyl)-1,2,3,4-tetrahydronaphthalene;
2-(Di-n-propylamino)-8-[β-(4'-methoxyphenyl)propionyl]-1,2,3,4-tetrahydronaphthalene;
2-(Di-n-propylamino)-8-(α,α-dimethylbutyryl)-1,2,3,4-tetrahydronaphthalene;
3-(Di-n-propylamino)-5-acetyl-chromane; and the like.
The compounds of the present invention may be prepared by procedures well known to those of ordinary skill in the art. The compounds in which X is --CH 2 -- and R 3 is hydrogen preferably are synthesized by preparation of an 8-bromo-2-tetralone. The 8-bromo-2-tetralone then is reductively aminated with the desired amine to produce the desired 2-amino-8-bromotetralin intermediate. The 8-bromo intermediate then is treated to produce the desired product directly or via the corresponding compound in which the group in the 8-position is R 2 CH(OH)--.
Schemes for these reactions are as follows: ##STR12##
As depicted above, the 8-bromo-2-tetralones represent intermediates which, when reductively aminated and treated, via lithiation, with the appropriate reagent, result in compounds of this invention. When, for example, the reaction involves the use of an aldehyde, the product which results, although having activity in its own right, is, in general, an intermediate of formula I (A is ═CHOH) to the preparation of the final product. When the reaction involves the use of an ester, the product is the final product itself (A is ═C═O).
The tetralones are available by any of a wide range of recognized methods. For example, they can be produced by a Friedel-Crafts reaction of an appropriately ring-substituted phenylacetyl chloride with ethylene in the presence of aluminum chloride.
The tetralone, once formed, can, by simple reductive amination using the selected amine, be converted to a 2-amino-8-bromo-1,2,3,4-tetrahydronaphthalene useful as an intermediate to a compound of this invention. The tetralone is first reacted with the amine to form the corresponding enamine after which the enamine is reduced with sodium borohydride to the tetrahydronaphthalene.
The 2-amino-8-bromo-1,2,3,4-tetrahydronaphthalene can be used to produce compounds of this invention by formation of a lithium intermediate via a lithiation reaction using an alkyllithium, preferably n-butyllithium. The reactive lithium intermediate then is treated with an appropriate carbonyl compound to produce either the ketone directly or a precursor of the ketone. Hence, treatment of the 8-lithio tetralin with a compound R 2 COZ, where Z is halo, alkoxy, hydroxy, aryloxy, --S--(C 1 -C 3 alkyl), --OCO 2 R', ##STR13## and the like, will, upon workup, yield the desired ketone.
Alternatively, treatment of the 8-lithiotetralin with carbon dioxide and then treatment of the resulting carboxylate with an organolithium reagent, e.g., methyllithium, provides the corresponding ketone. A further alternative synthesis entails reacting the 8-lithiotetralin with an appropriate aldehyde to yield an alcohol of formula I (A═CHOH) which is subsequently oxidized to the ketone. The aforementioned alcohol can also be prepared by addition of a suitable organometallic reagent (R 2 M in which M is Li, MgW, ZnW, and the like, W being an appropriate halide) to an 8-formyl-2-aminotetralin. The 8-formyl-2-aminotetralin is prepared by addition of the 8-lithio-2-aminotetralin to dimethylformamide with aqueous workup of the resulting product.
In another approach, the 8-bromo-2-tetralone can first be protected and the bromo substituent converted to the appropriate ketone as described above. The resulting 8-acyl-2-tetralone, after deprotection, can then be reductively aminated to a compound of this invention.
In the foregoing reactions, the 8-lithio tetralin may be replaced by the corresponding Grignard reagent to yield the desired product.
The compounds of this invention in which X is oxygen are available by reductive amination and bromo replacement as in the foregoing, but using 5-bromo-3-chromanone. The latter can be produced by a sequence of reactions beginning with m-bromophenol. Briefly, m-bromophenol is treated with allyl bromide in the presence of potassium carbonate to produce allyl 3-bromophenyl ether. The ether is converted to 2 -allyl-3-bromophenol upon heating it in the presence of N,N-dimethylaniline. The phenol, upon reaction with ethyl chloroacetate, is converted to the ethyl ester of 2-allyl-3-(carboxymethoxy)bromobenzene. Upon oxidation using ozone followed by reductive work up, the allyl group is converted to a formylmethyl substituent which is then further oxidized using Jones' Reagent to the carboxymethyl substituent, the resulting product being the ethyl ester of (2-carboxymethyl-3-bromo)phenoxyacetic acid. The partial ester is converted to the diethyl ester using ethanol and gaseous hydrogen chloride. In the presence of potassium t-butoxide, the diester is cyclized to a mixture of 4-ethoxycarbonyl-5-bromo-3-chromanone and 2-ethoxycarbonyl-5-bromo-3-chromanone. Upon heating in the presence of acid, the latter is converted to 5-bromo-3-chromanone.
An alternate and improved synthesis of the 5-bromo-3-chromanone involves a sequence of reactions beginning with the ethyl ester of (2-allyl-3-carboxymethoxy)bromobenzene. The bromobenzene is oxidized using ozone to form, upon work-up with dimethyl thioether, the ethyl ester of (2-formylmethyl-3-carboxymethoxy)bromobenzene. The formylmethyl substituent is further oxidized to carboxymethyl using Jones' Reagent, the resulting product being (2-bromo-6-ethoxycarbonylmethoxy)phenylacetic acid. The acid is esterified to the t-butyl ester using t-butyl acetate and sulfuric acid, after which the resulting diester is cyclized in the presence of potassium t-butoxide to 4-t-butoxycarbonyl-5-bromo-3-chromanone. The t-butoxycarbonyl group then is cleaved using trifluoroacetic acid with formation of the desired 5-bromo-3-chromanone.
The compounds of this invention in which X is sulfur are available by bromo replacement of the corresponding 2-amino-5-bromothiochromanes. The latter are available by a sequence of reactions beginning with m-bromothiophenol. The thiophenol is treated in base with β-chloropropionic acid to produce m-bromophenylthiopropionic acid. The acid then is cyclized with polyphosphoric acid or with thionyl chloride or phosgene and a Lewis acid to produce a mixture of 5-bromo-4-thiochromanone and 7-bromo-4-thiochromanone. The thiochromanone mixture is reduced using, for example, sodium borohydride, to produce 4-bromo-1,2-benzothiapyran which is then oxidized with an organic peroxide to the corresponding sulfoxide having an epoxy group in the 3,4 position. Upon treatment with a Lewis acid, 5-bromo-3-thiochromanone sulfoxide is formed which can be reduced to the corresponding thiochromanone using dimethyl sulfide in the presence of trifluroacetic anhydride, oxalyl chloride, thionyl chloride, and the like, or reductively aminated to the 3-amino-5-bromothiochromane sulfoxide by treatment with the appropriate amine and sodium borohydride. The latter is reduced to the desired 3-amino-5-bromothiochromane using trifluoroacetic anhydride.
Two additional alternative syntheses of the compounds of this invention are via each of two novel intermediates, both of which are part of this invention. The starting material in both sequences is the previously-described bromo compound in which X, R, R 1 , and R 3 are as herein defined.
In the first sequence the reaction proceeds via a trialkylstannyl intermediate of the formula ##STR14## in which R 7 is C 1 -C 4 alkyl.
The foregoing compounds of formula III are prepared by reacting the corresponding bromo compound with n-butyllithium and treating the resulting lithio derivative with chlorotri(C 1 -C 4 alkyl)stannane.
The stannyl intermediate then is reacted with an acyl chloride in the presence of a suitable catalyst such as dichlorobis(triphenylphosphine)palladium II or palladium dichloride. This reaction is described in Yamamoto and Yanagi, Chem. Pharm. Bull. 30(6), 2003 (1982), Milstein and Stille, J. Am. Chem. Soc. 100, 3636 (1978) and J. Org. Chem. 44, 1613 (1979).
The second additional sequence proceeds via an alkyne intermediate of the formula ##STR15## in which X, R, R 1 , and R 3 are as above and R 8 is hydrogen, C 1 -C 7 alkyl, C 1 -C 7 substituted alkyl, aryl, substituted aryl, aryl(C 1 -C 3 alkyl), or substituted aryl (C 1 -C 3 alkyl). The sequence is useful in preparing compounds of this invention in which R 2 is C 1 -C 8 alkyl, C 1 -C 8 substituted alkyl, aryl-(C 1 -C 4 alkyl), or substituted aryl(C 1 -C 4 alkyl).
The foregoing compounds of formula IV are prepared by reacting an iodo compound of the formula ##STR16## with a 1-alkyne in a suitable inert solvent and in the presence of a palladium catalyst such as tetrakis (triphenylphosphine)palladium or palladium dichloride.
The resulting alkyne is converted to a compound of this invention by hydration in the presence of a suitable catalyst. Suitable catalysts are, for example, protic acids such as HCl, HBr and H 2 SO 4 as well as mercury (II) salts.
The compounds of this invention also include those in which the groups R and R 3 taken together represent a --CH 2 CH 2 CH 2 -- group. These compounds can be prepared from the corresponding bromo-substituted tetralones, chromanones, or thiochromanones.
The foregoing bromo-substituted compound is reacted with pyrrolidine to form the corresponding 3-pyrrolidino-1,2-dihydronaphthalene, 3-pyrrolidinobenzpyran, or 3-pyrrolidinobenzthiopyran. The 3-pyrrolidino compound then is reacted with acrylamide to produce the corresponding cyclic amide bridging the 3,4-position and comprising the group --NH--CO--CH 2 --CH 2 --. The resulting product then is sequentially reduced, first using HSiEt 3 and trifluoroacetic acid to reduce the 3,4 double bond and then using B 2 H 6 or BH 3 .SMe 2 to reduce the cyclic amide carbonyl. The resulting product is a highly useful intermediate to the compounds of this invention. The intermediate is one in which X is --CH 2 --, --S--, or --O--, R 1 is hydrogen, and R and R 3 taken together represent a group of the formula --CH 2 CH 2 CH 2 --. Moreover, the intermediate contains a bromo substituent at the 8-position of the tetralin (X═--CH 2 --) or the 5-position of the chromane (X═O) or thiochromane (X═ S).
The foregoing intermediates can be further modified by conversion of the group R 1 from hydrogen to C 1 -C 4 alkyl, allyl, cyclopropylmethyl, or aryl(C 1 -C 4 alkyl) by reaction with the appropriate organic bromide or iodide.
Further, in those instances in which X is ##STR17## both are available from the corresponding thiochromanes by oxidation using NaIO 4 or a peroxyacid such as peroxyacetic acid, m-chloroperoxybenzoic acid, and the like, in acidic media.
The optically active isomers of the racemates of the invention are also considered part of this invention. Such optically active isomers may be prepared from their respective optically active precursors by the procedures described above, or by resolving the racemic mixtures. This resolution can be carried out in the presence of a resolving agent, by chromatography or by repeated crystallization. Particularly useful resolving agents are d- and 1-tartaric acids, d- and 1-ditoluoyltartaric acids, and the like.
One particularly useful method for producing optically active isomers of the compounds of this invention is via an 8-substituted-2-tetralone, a 5-substituted-3-chromanone, or a 5-substituted-3-thiochromanone. Any of these intermediates may be reductively alkylated with an optically active α-phenethylamine after which the resulting mixture of diastereomers is separated by recognized methodology, such as chromatography. Cleavage of the α-phenethyl moiety produces a correspondingly substituted, optically active 2-amino-1,2,3,4-tetrahydronaphthalene, 3-aminochromane, or 3-aminothiochromane.
The conditions necessary for removing the phenethyl moiety are relatively severe and can tend to disrupt the integrity of the core tetralin, chromane, or thiochromane molecule. It has been discovered that the cleavage can be carried out in a much more facile and efficient manner requiring only mild cleavage conditions when the particular α-phenethylamine which is used is p-nitro-α-phenethylamine.
Cleavage of the p-nitro-α-phenethyl moiety is achieved by reduction of the p-nitro group followed by acid-catalyzed solvolysis of the resulting p-amino-α-phenethyl moiety. Reduction of the nitro group can be accomplished by a wide range of reducing agents including, for example, titanium trichloride, lithium aluminum hydride, or zinc/acetic acid, or by catalytic hydrogenation. Solvolytic cleavage takes place when the monohydrochloride (or other monobasic salt) of the reduction product is treated with water or an alcohol at room temperature or, in some instances, at elevated temperatures. A particularly convenient condition for removing the p-nitro-α-phenethyl moiety is hydrogenation of the amine monohydrochloride in methanol over a platinum catalyst.
As indicated hereinabove, compounds highly useful as intermediates to the compounds of this invention are the corresponding 8-bromo compounds. It has been discovered that the 8-bromo compounds in their optically active form are not available using routine methodology whereas they can be prepared using the described method employing p-nitro-α-phenethylamine.
The compounds employed as initial starting materials in the synthesis of the compounds of this invention are well known and readily synthesized by standard procedures commonly employed by those of ordinary skill in the art. Moreover, each of the sequences described in the foregoing for producing compounds of this invention involves recognized reactions commonly employed by those of ordinary skill in the art.
The pharmaceutically acceptable acid addition salts of this invention are typically formed by reacting a 1,2,3,4-tetrahydronaphthalene, chromane, thiochromane sulfoxide, or thiochromane sulfone of this invention with an equimolar or excess amount of acid. The reactants are generally combined in a mutual solvent such as diethyl ether or benzene, and the salt normally precipitates out of solution within about one hour to 10 days, and can be isolated by filtration.
The following Examples further illustrate the compounds of the present invention and methods for their synthesis. The Examples are not intended to be limiting to the scope of the invention in any respect and should not be so construed.
EXAMPLE 1
Preparation of 2-Di-n-propylamino-8-pentanoyl-1,2,3,4-tetrahydronaphthalene, oxalate salt
n-Butyllithium (3.5 mmole, 3.0 ml, 1.2M in hexane) was added to a solution of 8-bromo-2-di-n-propylamino-1,2,3,4-tetrahydronaphthalene (1.0 g, 3.2 mmol) in THF (10 ml) at -78° C. The reaction was stirred at -78° C. for 45 min and then n-pentanal (0.41 ml, 3.9 mmole) was added. After stirring at -78° C. for 5 min, the reaction was warmed to room temperature and poured into dilute HCl solution. The resulting solution was washed once with ether and the ether layer discarded. The aqueous layer was made basic with NH 4 OH solution and extracted with methylenechloride. The extract was dried (Na 2 SO 4 ) and concentrated to give 0.95 g of the crude product.
Purification by silica gel flash chromatography using 1:1 ether:hexane with a trace of NH 4 OH gave 0.68 g of product MS(FD) m/e=317.
Pyridinium chlorochromate (0.9 g, 4.0 mmol) and 4 Å molecular sieves (30 g) were added to a solution of 2-di-n-propylamino-8-(1'-hydroxy-1-pentyl)-1,2,3,4-tetrahydronaphthalene (0.63 g=2.0 mmole) in methylene chloride (50 ml). The reaction was stirred at room temperature for 11/2 hr at which time the reaction was quenched by the addition of methanol (50 ml). Ether was added until the reaction became cloudy and this material was added to a shorted silica gel column and eluted with ether. The eluent was concentrated. Elution of the column was continued with 10% methanol in methylene chloride and the eluent concentrated to give a residue which was triturated with methanol and filtered through Celite. The filtrate was combined with the crude product from the ether elution and concentrated. Purification of this material on a flash silica gel column using 1:3 ether:hexane with a trace of NH 4 OH provided 240 mg of the title compound. MS(FD): m/e=315. The oxalate salt was formed and crystallized from ethylacetate/hexanes to give 165 mg of white crystals.
m.p. 107°-108.5° C.
Elemental Analysis:
Theory: C, 68.12; H, 8.70; N, 3.45;
Found: C, 67.85; H, 8.67; N, 3.41.
EXAMPLE 2
Preparation of 2-Di-n-propylamino-8-trifluoroacetyl-1,2,3,4-tetrahydronaphthalene, hydrobromide salt
2-Di-n-propylamino-8-bromo-1,2,3,4-tetrahydronaphthalene (1.0 g.; 3.2 mmole) was dissolved in 10 ml. of THF, and the mixture was cooled to -78° C. after which 2.2 ml. of n-butyllithium (1.6M. in hexane) was added. The reaction mixture was stirred at -78° C. for 40 minutes. Ethyl trifluoroacetate (0.42 ml;3.5 mmole) was added and the mixture allowed to warm to room temperature after which it was poured into water, the pH adjusted to 12, and the mixture extracted with methylene chloride. The extract was dried over sodium sulfate and evaporated to give 1.1 g. of a residue.
The residue was purified on a silica gel column which was eluted using a 3:1 mixture of hexane and ether containing a trace of ammonium hydroxide. Fractions containing the impure product were combined to give 240 mg. of a mixture which was further purified by treatment on a silica gel column. The appropriate fractions from this second chromatographic purification were combined with the pure fractions from the first chromatographic purification to obtain 240 mg. of product. The product was converted to the hydrobromide salt and the salt recrystallized from a mixture of ethyl acetate and hexane to give 150 mg. of the title compound as a tan solid, m.p. 142°-144° C.
Elemental Analysis:
Theory: C, 52.95; H, 6.17; N, 3.43;
Found: C, 53.19; H, 6.08; N, 3.35.
EXAMPLE 3
Preparation of 2-Di-n-propylamino-8-propionyl-1,2,3,4-tetrahydronaphthalene, oxalate salt
2-Di-n-propylamino-8-bromo-1,2,3,4-tetrahydronaphthalene (8.5 g.; 27.4 mmole) was dissolved in 80 ml. of THF and cooled to -78° C. after which 25.7 ml. of n-butyllithium (1.6M in hexane) were added. The mixture was stirred at -78° C. for one hour after which 2.4 ml. (32.9 mmole) of propionaldehyde were added. The mixture was warmed to room temperature and then poured into water, and extracted with methylene chloride. The extract was dried over sodium sulfate and evaporated to give 9.1 g of a yellow oil.
The oil was placed on a silica gel column and was eluted with a mixture of 3% methanol in methylene chloride containing a trace of ammonium hydroxide. The appropriate fractions were combined to give 6.5 g. (82.0%) of 2-di-n-propylamino-8-(1'-hydroxypropyl)-1,2,3,4-tetrahydronaphthalene as a clear oil.
The foregoing product was dissolved in 250 ml. of methylene chloride, and 17.0 g. (78.7 mmole) of pyridinium chlorochromate (PCC) were added along with 30 g 4A molecular sieves. The mixture was stirred for three hours at room temperature after which 250 ml. of ether and Celite were added. The mixture was poured onto a short silica gel column and eluted with ether. Methanol was added to dissolve the brown sludge which had precipitated upon addition of ether to the reaction. This material was added to the column and eluted with 10% methanol in methylene chloride. The eluent was concentrated to give a brown oil which was further purified by column chromatography employing 2:1 hexanes:ether and then pure ether as solvent. Fractions containing the product were combined and concentrated to give 4.7 g of the product. The oxalate salt of 2.5 g of this material was formed and recrystallized three times from ethanol/ether to give the product as a white solid. (1.5 g, m.p. 114.5°-115° C.).
Elemental Analysis:
Theory: C, 66.82; H, 8.29; N, 3.71;
Found: C, 67.07; H, 8.20; N, 4.00.
EXAMPLE 4
Preparation of 2-Di-n-propylamino-8-butanoyl-1,2,3,4-tetrahydronaphthalene, hydrobromide salt
2-Di-n-propylamino-8-bromo-1,2,3,4-tetrahydronaphthalene (5.0 g.; 16.1 mmole) was dissolved in 50 ml of THF, and the mixture was cooled to -78° C. after which 21.0 ml of n-butyllithium (0.92M in hexane) were added. The mixture was stirred for 30 minutes, and 1.85 ml (21.0 mmole) of butyraldehyde were added. The mixture was allowed to warm to room temperature and was stirred overnight after which it was poured into water and extracted with methylene chloride. The extract was dried over sodium sulfate and evaporated to give 6.4 g of a residue. The residue was placed on a silica gel column and was eluted with a mixture of 2% methanol in methylene chloride containing a trace of ammonium hydroxide. The appropriate fractions were combined to give 4.8 g of 2-di-n-propylamino-8-(1'-hydroxybutyl)-1,2,3,4-tetrahydronaphthalene as a thick oil.
The oil (4.0 g.; 13.2 mmole) was dissolved in 200 ml of methylene chloride and 4A molecular sieves (30 g) were added. The mixture was stirred, and 10.0 g (46.2 mmole) PCC were added. Stirring was continued for three hours at room temperature after which the mixture was poured onto a pad of silica gel and eluted sequentially with ether and 3% methanol in methylene chloride containing a trace of ammonium hydroxide to recover the product as a brown oil.
The oil was placed on a silica gel column and was eluted with a mixture of 3% methanol and methylene chloride containing a trace of ammonium hydroxide. The appropriate fractions were combined to obtain an oil which, when dissolved in ether, caused a brown precipitate to form. The precipitate was removed by filtration, and the filtrate was evaporated to give 3.0 g. of a light brown oil as the free base of the title compound.
One gram of the oil was converted to the hydrobromide salt and was recrystallized from a mixture of methanol and ethyl acetate to give 0.9 g of the title compound as tan crystals, m.p. 122°-123° C. Following a second recrystallization, 750 mg were recovered, m.p. 125°-126.5° C.
Elemental Analysis:
Theory: C, 62.82; H, 8.43; N, 3.66;
Found: C, 63.09; H, 8.22; N, 3.66.
EXAMPLE 5
Preparation of 2-Di-n-propylamino-8-(α-methylpropionyl)-1,2,3,4-tetrahydronaphthalene, hydrobromide salt
2-Di-n-propylamino-8-bromo-1,2,3,4-tetrahydronaphthalene (1.0 g; 3.2 mmole) was dissolved in 10 ml of THF and cooled to -78° C. after which 3.5 ml (1.0M in hexane) of n-butyllithium were added. To the resulting mixture after 30 minutes was added 0.41 ml (3.5 mmole) of methyl isobutyrate; the mixture was stirred at -10° C. for 30 minutes and then was poured into 10% aqueous hydrochloric acid, washed with ether, and the pH raised to 10. The mixture then was extracted with methylene chloride, and the extract was dried over sodium sulfate and evaporated to give 0.72 g of a residue.
The residue was placed on a silica gel column and was eluted sequentially with a 4:1 mixture of hexane and ether containing a trace of ammonium hydroxide and then a 3:1 mixture of hexane and ether containing a trace of ammonium hydroxide. The appropriate fractions were combined to give 190 mg of the free base of the title compound.
The compound was converted to its hydrobromide salt and was recrystallized from ethyl acetate to give 80 mg of the title compound as tan crystals, m.p. 175°-176.5° C.
Elemental Analysis:
Theory: C, 62.82; H, 8.43; N, 3.66;
Found: C, 62.54; H, 8.53; N, 3.44.
EXAMPLE 6
Preparation of 2-Di-n-propylamino-8-(β-methylbutyryl)-1,2,3,4-tetrahydronaphthalene, hydrobromide salt
2-Di-n-propylamino-8-bromo-1,2,3,4-tetrahydronaphthalene (1.0 g; 3.2 mmole) was dissolved in 10 ml of THF and cooled to -78° C. after which 3.5 ml of n-butyllithium (1.0M in hexane) were added. After 30 minutes, 0.53 ml (3.5 mmole) of ethyl isovalerate was added, and the mixture was warmed to -10° C. and maintained for 30 minutes. The mixture then was poured into dilute acid, washed with ether, and the pH adjusted to 10. The mixture was extracted with methylene chloride, and the extract was dried over sodium sulfate and evaporated to give 0.83 g of a residue.
The residue was placed on a silica gel column and was eluted sequentially a 4:1 mixture of hexane and ether containing a trace of ammonium hydroxide and then a 3:1 mixture of hexane and ether containing a trace of ammonium hydroxide. The appropriate fractions were combined to give 50 mg of the free base of the title compound.
The free base was converted to the hydrobromide salt which was recrystallized from a mixture of ethyl acetate and hexane to give 30 mg of the title compound as a tan powder, m.p. 131°-132° C.
Elemental Analysis:
Theory: C, 63.63; H, 8.64; N, 3.53;
Found: C, 63.35; H, 8.42; N, 3.83.
EXAMPLE 7
Preparation of 2-Di-n-propylamino-8-dimethylpropionyl-1,2,3,4-tetrahydronaphthalene, hydrobromide salt
2-Di-n-propylamino-8-bromo-1,2,3,4-tetrahydronaphthalene (1.0 g; 3.2 mmole) was dissolved in 20 ml of THF and cooled to -78° C. after which 4.7 ml of n-butyllithium (0.82M in hexane) was added. The mixture was stirred for 30 minutes at -78° C. after which 0.56 ml (4.2 mmole) of methyl trimethyl acetate was added. The mixture was allowed to warm to room temperature and then was poured into water and extracted with methylene chloride. The extract was dried over sodium sulfate and evaporated to give 1.6 g of a residue.
The residue was placed on a silica gel column and was eluted with a 3:1 mixture of hexane and ether containing a trace of ammonium hydroxide. The appropriate fractions were combined to give 140 mg of the free base of the title compound.
The free base was converted to the hydrobromide salt and was recrystallized from methanol/ethyl acetate to give 80 mg of the title compound, m.p. 157°-158° C.
Elemental Analysis:
Theory: C, 63.63; H, 8.65; N, 3.53;
Found: C, 63.39; H, 8.46; N, 3.43.
EXAMPLE 8
Preparation of 2-Di-n-propylamino-8-cyclohexanecarbonyl-1,2,3,4-tetrahydronaphthalene, oxalate salt
Method A
2-Di-n-propylamino-8-bromo-1,2,3,4-tetrahydronaphthalene (1.0 g; 3.2 mmole) was dissolved in 10 ml of THF and cooled to -78° C. after which 2.8 ml of n-butyllithium (1.27M in hexane) were added. The mixture was stirred at -78° C. for 45 minutes after which 0.59 ml (3.5 mmole) of ethyl cyclohexanecarboxylate was added. The mixture was warmed to room temperature and then was poured into a 10% hydrochloric acid solution, washed with ether, the pH adjusted to 10 with ammonium hydroxide, and extracted with methylene chloride. The extract was dried over sodium sulfate and evaporated to give 0.8 g of a residue.
The residue was placed on a silica gel column and was eluted with a 3:1 mixture of hexane and ether containing a trace of ammonium hydroxide. The appropriate fractions were combined to give 0.36 g of the title compound.
Method B
Butyllithium (1.2M in hexane, 3.0 ml, 3.5 mmole) was added to a solution of 8-bromo-2-di-n-propylamino-1,2,3,4-tetrahydronaphthylene (1.0 g, 3.2 mmole) in THF (10 ml) at -78° and stirred for 45 minutes. Cyclohexanecarboxaldehyde (0.47 ml, 3.9 mmole) was added. The reaction was stirred at -78° for five minutes, warmed to room temperature, poured into dilute HCl solution and washed with ether. The aqueous layer was made basic with NH 4 OH and extracted with methylene chloride. The extract was dried (Na 2 SO 4 ) and concentrated to give 1.1 g of the crude product. The crude product was dissolved in methylene chloride (50 ml) and molecular sieves and pyridinium chlorochromate (1.4 g, 6.4 mmole) added. The reaction was stirred at room temperature for two hours. Methanol (50 ml) was added and the reaction concentrated to provide a slurry. The slurry was dissolved in methylene chloride (50 ml) and enough ether was added to give a cloudy solution. This material was added to a pad of silica gel and eluted with ether.
The silica gel pad was eluted with 10% methanol in methylene chloride and the eluent concentrated to give an oily residue. This material was triturated with methanol and filtered through Celite. This filtrate was combined with the ether solution from above and concentrated. This material was dissolved in methylene chloride. Ether was added until the solution became cloudy and then filtered through florisil. The filtrate was concentrated to give 560 mg of an oil which was purified by silica gel flash chromatography using 3:1 hexane:ether containing a trace of NH 4 OH as solvent. Appropriate fractions were combined and concentrated to give 350 mg of the desired compound. The oxalate salt was formed and crystallized from ethyl acetate/hexane to give 370 mg of a white solid. m.p. 98.5°-100°.
Elemental Analysis:
Theory: C, 69.58; H, 8.64; N, 3.25;
Found: C, 69.28; H, 8.87; N, 3.00.
EXAMPLE 9
Preparation of 2-Di-n-propylamino-8-benzoyl-1,2,3,4-tetrahydronaphthalene, tosylate salt
2-Di-n-propylamino-8-bromo-1,2,3,4-tetrahydronaphthalene (1.0 g; 3.2 mmole) was dissolved in 20 ml of THF and cooled to -78° C. after which 3.0 ml of n-butyllithium (1.6M in hexane) was added. The mixture was stirred at -78° C. for one hour after which 0.5 ml (4.8 mmole) of benzaldehyde was added. Stirring was continued for 15 minutes, and the mixture was allowed to warm to room temperature and then was poured into water and extracted with methylene chloride. The extract was dried over sodium sulfate and evaporated to give 1.4 g of a yellow oil.
The oil was placed on a silica gel column and was eluted with a 1:1 mixture of hexane and ether containing a trace of ammonium hydroxide. The appropriate fractions were combined to give 0.9 g of 2-di-n-propylamino-8-(α-hydroxybenzyl)-1,2,3,4-tetrahydronaphthalene.
The foregoing product (0.83 g; 2.5 mmole) was dissolved in 50 ml of methylene chloride, and about 1 g of molecular sieves was added followed by 1.9 g (8.6 mmole) of PCC. The mixture was stirred for two hours after which it was diluted with ether and poured onto a silica gel column. The column was eluted with ether and then with a mixture of 10% methanol and methylene chloride. The fractions were combined, and the residue was dissolved in methanol and the solution was filtered through a pad of Celite. The filtrate was evaporated, and the residue was placed on a Florisil column which was eluted with a 2:1 mixture of hexane and ether. The appropriate fractions were combined to give 0.5 g of the free base of the title compound.
The free base was converted to the tosylate salt which was recrystallized from a mixture of acetone and ether to give 125 mg of the title compound as a white powder, m.p. 148.5°-149° C.
Elemental Analysis:
Theory: C, 70.97; H, 7.35; N, 2.76;
Found: C, 71.18; H, 7.27; N, 2.74.
EXAMPLE 10
Preparation of 2-Di-n-propylamino-8-(p-chlorobenzoyl)-1,2,3,4-tetrahydronaphthalene
2-Di-n-propylamino-8-bromo-1,2,3,4-tetrahydronaphthalene (1.0 g; 3.2 mmole) was dissolved in 10 ml of THF and cooled to -78° C. after which 3.5 ml of n-butyllithium (1.0M in hexane) were added. The mixture was stirred for one hour at -78° C. after which 680 mg (1.5 equivalents) of 4-chlorobenzaldehyde in THF were added. The mixture was stirred for 15 minutes at -78° C. and then was allowed to warm to room temperature. The mixture was poured into a 10% aqueous hydrochloric acid solution, washed with ether, the pH adjusted to 10 with ammonium hydroxide, and extracted with methylene chloride. The extract was dried over sodium sulfate and evaporated to give 1.5 g of a residue.
The residue was placed on a silica gel column and was eluted with a 1:1 mixture of hexane and ethyl acetate containing a trace of ammonium hydroxide. The appropriate fractions were combined to give 1.3 g of substantially pure 2-di-n-propylamino-8-(α-methyl-4'-chlorobenzyl)-1,2,3,4-tetrahydronaphthalene.
The foregoing product (3.2 mmole) was dissolved in 50 ml of methylene chloride, and 30 g of 4A molecular sieves were added followed by 1.4 g (6.4 mmole) of PCC. The mixture was stirred for one hour and then was diluted with ether and poured through a pad of silica gel and the silica gel rinsed with ether. The filtrate was evaporated. The silica gel was washed with a mixture of 10% methanol and methylene chloride, and the latter filtrate was evaporated and the residue dissolved in methanol and filtered twice. This filtrate was combined with the ether filtrate, and the resultant mixture was placed on a silica gel column and eluted with a 2:1 mixture of hexane and ether containing a trace of ammonium hydroxide. The appropriate fractions were combined to give 0.3 g of the title compound.
ms(FD): m/e=369.
EXAMPLE 11
Preparation of 2-Di-n-propylamino-8-(o-fluorobenzoyl)-1,2,3,4-tetrahydronaphthalene, p-toluenesulfonic acid salt
2-Di-n-propylamino-8-bromo-1,2,3,4-tetrahydronaphthalene (1.0 g; 3.22 mmole) dissolved in THF (25 ml) was cooled to -78° C., and 2.5 ml of n-butyllithium (1.27M in hexane) were added. After one hour, o-fluorobenzoyl chloride (0.38 ml, 3.22 mmol) was added. The mixture was stirred for 10 minutes at -78° C. after which the reaction was quenched by addition of water at -78° C. The reaction was poured into dilute HCl solution and extracted with methylene chloride. The aqueous layer was made basic with NaOH and extracted with methylene chloride. The basic extract was dried (Na 2 SO 4 ) and concentrated to give 200 mg of residue which by nmr did not contain product. The extract from the acidic material was dried (Na 2 SO 4 ) and concentrated to give 2.0 g of a residue. Purification of this material by flash silica gel chromatography using 1:1 ether:hexane containing a trace of ammonium hydroxide as solvent provided the free base of the title compound (340 mg). The salt of 130 mg of this material with p-toluene sulfonic acid was prepared and crystallized from ethyl acetate/ether to provide 118 mg of the title compound. m.p. 107°-109° C.
Elemental Analysis:
Theory: C, 68.55; H, 6.90; N, 2.66;
Found: C, 68.41; H, 7.02; N, 2.65.
EXAMPLE 12
Preparation of 2-Di-n-propylamino-8-(methoxyacetyl)-1,2,3,4-tetrahydronaphthalene oxalate
Method A
2-Di-n-propylamino-8-bromo-1,2,3,4-tetrahydronaphthalene (5.0 g; 16.1 mmole) was dissolved in 25 ml of THF and cooled to -78° C. after which 3.22 ml of n-butyllithium (1M in hexane) was added. The mixture was maintained at -78° C. for 1.5 hours. This solution was transferred via cannula to a solution of methyl methoxyacetate (7.5 ml, 160 mmol) in THF at -78° C. The reaction mixture was stirred at room temperature overnight, poured into NaHCO 2 solution and extracted with CH 2 Cl 2 . The extract was dried (Na 2 SO 4 ) and concentrated to give 6.8 g of crude product.
The material then was placed on a chromatographic column, and the product was eluted using 4% methanol in methylene chloride containing a trace of ammonium hydroxide. The appropriate fractions were combined to give 1.4 g of the title compound.
The oxalic acid salt was formed and three times recrystallized from ethyl acetate to give the salt as a white powder, m.p. 118° C.
Method B
a. 2-Di-n-propylamino-8-trimethylstannyl-1,2,3,4-tetrahydronaphthalene.
Butyllithium (1.2M in hexane; 2.8 ml; 3.4 mmol) was added to a solution of 8-bromo-2-di-n-propylamino-1,2,3,4-tetrahydronaphthalene (1 g; 3.22 mmol) in THF (50 ml) at -78° C. After 1.5 hr., a solution of trimethyltin chloride (1.3 g, 2.0 mmol) in THF (20 ml) was added. The reaction mixture was allowed to warm to room temperature, stirred overnight at room temperature, poured into water, and extracted with methylene chloride. The extract was dried (Na 2 SO 4 ) and concentrated to give the crude product. Purification by chromatography using 1:10 methanol:methylene chloride gave 1.2 g of the desired product which was used directly in the next step.
b. 2-Di-n-propylamino-8-methoxyacetyl-1,2,3,4-tetrahydronaphthalene.
Bis-triphenylphosphine palladium dichloride (120 mg) was added to a solution of 2-dipropylamino-8-trimethylstannyl-1,2,3,4-tetrahydronaphthalene (500 mg, 1.27 mmol) in benzene (20 ml). Methoxyacetyl chloride (1.5 ml; 1.77 g; 16.5 mmol) was added. The reaction mixture was stirred at room temperature overnight and then heated to reflux for 5 hr. The reaction mixture was poured into water and extracted with methylene chloride. The extract was dried (MgSO 4 ) and concentrated to give 800 mg of crude product. Purification by chromatography using 1:10 methanol: methylene chloride as solvent gave 380 mg of 2-di-n-propylamino-8-methoxyacetyl-1,2,3,4-tetrahydronaphthalene.
EXAMPLE 13
Preparation of 2-Di-n-propylamino-8-acetyl-1,2,3,4-tetrahydronaphthalene
Method A
A solution of n-butyllithium (1.6M in hexane, 15.1 ml, 24.2 mmole) was added to a solution of 8-bromo-2-di-n-propylamino-1,2,3,4-tetrahydronaphthalene (5.0 g, 16.1 mmole) in THF (50 ml) at -78° and the reaction stirred at -78° for one hour. Gaseous carbon dioxide was bubbled through the reaction at -78° until the deep violet color which forms dissipates. Methyllithium (1.4M in ether, 23 ml) was added. The reaction was stirred at -78° for 30 minutes and warmed to room temperature. The reaction was stirred for an additional ten minutes at room temperature at which time the pink color had been lost. An additional 10 ml of the methyllithium solution was added and the reaction became pink once again. After 15 minutes, the pink color was lost and an additional 10 ml of the methyllithium solution added. The reaction was poured onto ice, made acidic with hydrochloric acid and extracted with ether. The aqueous layer was made basic and extracted with methylenechloride. The basic extracts were dried (Na 2 SO 4 ) and concentrated to give 3.8 g of crude product. Purification by flash silica gel chromatography using 2:1 hexane:ether containing trace ammonium hydroxide provided the free base of the title compound as a yellow oil (2.7 g, 61%).
The maleate salt was prepared and crystallized from methanol/ethyl acetate/hexane to give the maleate salt. m.p. 115°-116°.
Elemental Analysis:
Theory: C, 67.84; H, 8.04; N, 3.60;
Found: C, 68.07; H, 8.02; N, 3.55.
Alternatively, the hydrochloride salt can be prepared. Crystallization from ethanol/ether provided the hydrochloride salt as colorless crystals. m.p. 124°-125° C.
Elemental Analysis:
Theory: C, 69.77; H, 9.11; N, 4.52;
Found: C, 69.91; H, 9.20; N, 4.53.
Method B
n-Butyllithium (1.6 M in hexane, 60.5 ml, 96.8 mmole) was added to a solution of 8-bromo-2-di-n-propylamino-1,2,3,4-tetrahydronaphthalene (20.0 g, 64.5 mmole) in THF (200 ml) at -78° and the reaction stirred at -78° for one hour. Acetaldehyde (4.3 ml, 77.4 mmole) was added and the reaction allowed to warm to room temperature. The reaction was poured into water, made basic with ammonium hydroxide and extracted with methylene chloride. The extract was dried (Na 2 SO 4 ) and concentrated to give 21.4 g of a yellow oil.
To a solution of this yellow oil in methylene chloride (800 ml) was added 4 Å molecular sieves (30 g) and pyridinium chlorochromate (27.8 g, 129 mmole). The reaction was stirred at room temperature for 11/2 hours. Methanol was added and the reaction filtered through a pad of Celite. The filtrate was concentrated and purified by chromatography over Florisil using 2:1 hexane:ether as solvent. The appropriate fractions were combined to give 6.8 g of the desired product. The solids from the filtration through Celite were suspended in 10% Methanol in methylene chloride and purified by Florisil column chromatography using 10% methanol in methylenechloride as solvent. The fractions containing product were combined and concentrated to give a residue which was taken up in a small volume of methylene chloride. Ether was added to this solution until the material became slightly cloudy. The solution was added to a pad of silica gel and eluted with ether. This material was combined with the product from the original filtrate and concentrated to give the methylketone as a light brown oil. (9.9 g).
As noted above, the compounds (Formula I) of this invention, especially those in which A is ##STR18## have binding affinity for the 5-HT 1A receptor. Therefore, another embodiment of the present invention is a method of effecting agonist action at the 5-HT 1A receptors which comprises administering to a mammal in need thereof a pharmaceutically effective amount of a compound of the invention.
The term "pharmaceutically effective amount", as used herein, represents an amount of a compound of the invention which is capable of binding to serotonin 1A receptors. The specific dose of compound administered according to this invention will, of course, be determined by the particular circumstances surrounding the case, including, for example, the compound administered, the route of administration, and the condition being treated. A typical daily dose generally will contain from about 0.01 mg/kg to about 20 mg/kg of the active compound of this invention. Preferred daily doses generally will be from about 0.05 to about 10 mg/kg, and ideally from about 0.1 to about 5 mg/kg.
The compounds can be administered by a variety of routes including oral, rectal, transdermal, subcutaneous, intravenous, intramuscular, and intranasal. A special feature of the compounds of this invention is that they are extremely selective in effecting agonist action at serotonin 1A receptors relative to other serotonin receptors.
A variety of physiologic functions have been shown to be subject to influence by brain serotonergic neural systems. As such, the compounds of this invention are believed to have the ability to treat in mammals a variety of 5-HT mediated states and disorders such as sexual disorders, eating disorders, depression, alcoholism, pain, senile dementia, anxiety, and smoking. Therefore, the present invention also provides methods of treating the above disorders at rates set forth above for agonist action in mammals at 5-HT receptors.
The following experiment was conducted to demonstrate the ability of the compounds of the present invention to effect agonist action at the serotonin 1A receptors. This general procedure is set forth in Wong et al., J. Neural Transm. 71:207-218 (1988).
Male Sprague-Dawley rats (110-150 g) from Harlan Industries (Cumberland, Ind.) were fed a Purina Chow ad libitum for at least 3 days before being used in the studies. Rats were killed by decapitation. The brains were rapidly removed, and the cerebral cortices were dissected out at 4° C.
Brain tissues were homogenized in 0.32M sucrose. After centrifugation at 1000×g for 10 min and then at 17000×g for 20 min, a crude synaptosomal fraction was sedimented. The pellet was suspended in 100 vol of 50 mM Tris-HCl, pH 7.4, incubated at 37° C. for 10 min, and centrifuged at 50000×g for 10 min. The process was repeated and the final pellet was suspended in ice-chilled 50 mM Tris-HCl, pH 7.4. By the radio-ligand binding method, sites specifically labeled by tritiated 8-hydroxy-2-dipropylamino-1,2,3,4-tetrahydronaphthalene ( 3 H-8-OH-DPAT) have been identified as 5-HT 1A receptors.
Binding of ( 3 H-8-OH-DPAT) was performed according to the previously described method [Wong et al., J. Neural Transm. 64:251-269 (1985)]. Briefly, synaptosomal membranes isolated from cerebral cortex were incubated at 37° C. for 10 min. in 2 ml of 50 mM Tris-HCl, pH 7.4; 10 μM pargyline; 0.6 mM ascorbic acid; 0.4 nM 3 H-8-OH-DPAT; and from 1 to 1000 nM of test compound. Binding was terminated by filtering samples under reduced pressure through glass fiber (GFB) filters. The filters were washed twice with 5 ml of ice cold buffer and placed in scintillation vials with 10 ml of PCS (Amersham/Searle) scintillation fluid. Radioactivity was measured with a liquid scintillation spectrometer. Unlabeled 8-OH-DPAT at 10 μM was also included in separate samples to establish non-specific binding. Specific binding of 3 H-8-OH-DPAT is defined as the difference of radioactivity bound in the absence and in the presence of 10 μM unlabeled 8-OH-DPAT.
The results of the evaluation of various compounds of the present invention are set forth below in Table I. In Table I, the first column provides the Example Number of the compound evaluated; the next 7 columns identify the structure of the compound evaluated when taken with the formula set forth in the heading; the next-succeeding column identifies the salt form of the compound evaluated; and the final column provides the amount of the test compound expressed in nanomolar concentration required to inhibit the binding of 3 H-8-OH-DPAT) by 50%, and is indicated in Table I as IC 50 .
TABLE I__________________________________________________________________________BINDING AT 5HT.sub.1a IN VITROCompound of IC.sub.50 (nM)Example No. R R.sub.1 A R.sub.2 R.sub.3 X Salt Form 5HT.sub.1a__________________________________________________________________________1 Pr Pr CO -n-butyl H CH.sub.2 oxalate 2.22 Pr Pr CO CF.sub.3 H CH.sub.2 hydrobromide 293 Pr Pr CO ethyl H CH.sub.2 oxalate 0.84 Pr Pr CO -n-propyl H CH.sub.2 hydrobromide 35 Pr Pr CO isopropyl H CH.sub.2 hydrobromide 0.46 Pr Pr CO isobutyl H CH.sub.2 hydrobromide 0.47 Pr Pr CO .sub.≅ t-butyl H CH.sub.2 hydrobromide 98 Pr Pr CO cyclohexyl H CH.sub.2 oxalate 0.59 Pr Pr CO phenyl H CH.sub.2 tosylate 3.711 Pr Pr CO -o-F-phenyl H CH.sub.2 tosylate 0.812 Pr Pr CO methoxymethyl H CH.sub.2 oxalate 5.813 Pr Pr CO methyl H CH.sub.2 hydrochloride 0.8__________________________________________________________________________
The compounds of this invention are preferably formulated prior to administration. Therefore, another embodiment of the present invention is a pharmaceutical formulation comprising a compound of the invention and a pharmaceutically acceptable carrier, diluent or excipient therefor.
The present pharmaceutical formulations are prepared by known procedures using well known and readily available ingredients. In making the compositions of the present invention, the active ingredient will usually be mixed with a carrier, or diluted by a carrier, or enclosed within a carrier which may be in the form of a capsule, sachet, paper or other container. When the carrier serves as a diluent, it may be a solid, semisolid or liquid material which acts as a vehicle, excipient or medium for the active ingredient. Thus, the compositions can be in the form of tablets, pills, powders, lozenges, sachets, cachets, elixirs, suspensions, emulsions, solutions, syrups, aerosols (as a solid or in a liquid medium), ointments containing, for example, up to 10% by weight of the active compound, soft and hard gelatin capsules, suppositories, sterile injectable solutions, sterile packaged powders, and the like.
Examples of suitable carriers, excipients, and diluents are lactose, dextrose, sucrose, sorbitol, mannitol, starches, gum acacia, calcium phosphate, alginates, tragacanth, gelatin, calcium silicate, microcrystalline cellulose, polyvinylpyrrolidone, cellulose, water syrup, methyl cellulose, methyl-hydroxybenzoates, propyl hydroxybenzoates, talc, magnesium stearate, and mineral oil. The formulations may additionally include lubricating agents, wetting agents, emulsifying agents, suspending agents, preserving agents, sweetening agents, flavoring agents, and the like. The compositions of the invention may be formulated so as to provide quick, sustained or delayed release of the active ingredient after administration to the patient by employing procedures well known in the art.
The compositions are preferably formulated in a unit dosage form, each dosage generally containing from about 0.1 to about 500 mg, and preferably from about 1 to about 250 mg, of the active ingredient. The term "unit dosage form" refers to physically discrete units suitable as unitary dosages for human subjects and other mammals, each unit containing a predetermined quantity of active material calculated to produce the desired therapeutic effect, in association with a suitable pharmaceutical carrier.
The following formulation examples are illustrative only and are not intended to limit the scope of the invention in any way.
Formulation 1
Hard gelatin capsules are prepared using the following ingredients:
______________________________________ Quantity (mg/capsule)______________________________________2-di- -n-propylamino-8-acetyl- 2501,2,3,4-tetrahydronaphthalenehydrochloridestarch, dried 200magnesium stearate 10Total 460 mg______________________________________
The above ingredients are mixed and filled into hard gelatin capsules in 460 mg quantities.
Formulation 2
A tablet is prepared using the ingredients below:
______________________________________ Quantity (mg/tablet)______________________________________2-di- -n-propylamino-8-propionyl- 2501,2,3,4-tetrahydronaphthalenehydrochloridecellulose, microcrystalline 400silicon dioxide, fumed 10stearic acid 5Total 665 mg______________________________________
The components are blended and compressed to form tablets each weighing 665 mg.
Formulation 3
An aerosol solution is prepared containing the following components:
______________________________________ Weight %______________________________________2-diisopropylamino-8-( -p-chlorobenzoyl) 0.251,2,3,4-tetrahydronaphthalenedihydrochlorideethanol 29.75Propellant 22 70.00(chlorodifluoromethane)Total 100.00______________________________________
The active compound is mixed with ethanol and the mixture added to a portion of the propellant 22, cooled to -30° C. and transferred to a filling device. The required amount is then fed to a stainless steel container and diluted with the remainder of the propellant. The valve units are then fitted to the container.
Formulation 4
Tablets, each containing 60 mg of active ingredient, are made as follows:
______________________________________2-methylethylamino-8-(α,αdimethylpropionyl)- 60 mg1,2,3,4-tetrahydronaphthalene maleatestarch 45 mgmicrocrystalline cellulose 35 mgpolyvinylpyrrolidone 4 mg(as 10% solution in water)sodium carboxymethyl starch 4.5 mgmagnesium stearate 0.5 mgtalc 1 mgTotal 150 mg______________________________________
The active ingredient, starch and cellulose are passed through a No. 45 mesh U.S. sieve and mixed thoroughly. The aqueous solution containing polyvinylpyrrolidone is mixed with the resultant powder, and the mixture then is passed through a No. 14 mesh U.S. sieve. The granules so produced are dried at 50° C. and passed through a No. 18 mesh U.S. sieve. The sodium carboxymethyl starch, magnesium stearate and talc, previously passed through a No. 60 mesh U.S. sieve, are then added to the granules which, after mixing, are compressed on a tablet machine to yield tablets each weighing 150 mg.
Formulation 5
Capsules, each containing 80 mg of active ingredient, are made as follows:
______________________________________2-propylamino-8-cyclohexanecarbonyl-1,2,3,4- 80 mgtetrahydronaphthalene hydrochloridestarch 59 mgmicrocrystalline cellulose 59 mgmagnesium stearate 2 mgTotal 200 mg______________________________________
The active ingredient, cellulose, starch, and magnesium stearate are blended, passed through a No. 45 mesh U.S. sieve, and filled into hard gelatin capsules in 200 mg quantities.
Formulation 6
Suppositories, each containing 225 mg of active ingredient, are made as follows:
______________________________________2-di- -n-propylamino-8-methoxy- 225 mgacetyl-1,2,3,4-tetrahydro-naphthalene hydrochloridesaturated fatty acid glycerides 2,000 mgTotal 2,225 mg______________________________________
The active ingredient is passed through a No. 60 mesh U.S. sieve and suspended in the saturated fatty acid glycerides previously melted using the minimum heat necessary. The mixture is then poured into a suppository mold of nominal 2 g capacity and allowed to cool.
Formulation 7
Suspensions, each containing 50 mg of active ingredient per 5 ml dose, are made as follows:
______________________________________2-diallylamino-8-trifluoroacetyl-1,2,3,4- 50 mgtetrahydronaphthalene hydrochloridesodium carboxymethyl cellulose 50 mgsyrup 1.25 mlbenzoic acid solution 0.10 mlflavor q.v.color q.v.purified water to total 5 ml______________________________________
The active ingredient is passed through a No. 45 mesh U.S. sieve and mixed with the sodium carboxymethyl cellulose and syrup to form a smooth paste. The benzoic acid solution, flavor and color are diluted with a portion of the water and added, with stirring. Sufficient water is then added to produce the required volume.
Formulation 8
An intravenous formulation may be prepared as follows:
______________________________________2-diethylamino-8-phenylacetyl-1,2,3,4- 100 mgtetrahydronaphthalene hydrochlorideisotonic saline 1000 ml______________________________________
The solution of the above ingredients generally is administered intravenously at a rate of 1 ml per minute to a subject suffering from depression. | The present invention provides novel ring-substituted 2-amino-1,2,3,4-tetrahydronaphthalenes, 3-aminochromanes, and 3-aminothiochromanes, including their corresponding sulfoxides and sulfones, which ring-substituted compounds exhibit agonist activity at the serotonin 1A receptor. | 2 |
The present utility application hereby formally claims priority of currently pending U.S. Provisional Patent application No. 61/630,592 filed Dec. 15, 2011 on “AUTOMATIC RETRACTABLE STEP APPARATUS UTILIZING OVER-CENTER LOCKING MECHANISM” filed by the same inventor listed herein, namely, Michael P Ziaylek and W Brian McGinty, and assigned to the same assignee, namely, Michael P Ziaylek. Said referenced provisional application is hereby formally incorporated by reference as an integral part of the present application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention deals with the field of automated powered deployable and retractable steps for facilitating entry and exit from the passenger compartment of motor vehicles and particularly for use with emergency vehicles such as fire trucks. This apparatus can be coordinated to open simultaneously with opening of one of the vehicle doors and to retract simultaneously with closing of the adjacent door. Such vehicles can have extremely limited space within which such automated step apparatus can be mounted due to the nature of such fire truck cab design. Many fire trucks have tilting cabs that tilt forwardly for the purpose of providing access to the vehicle engine for maintenance. This construction greatly limits the amount of space available for mounting and positioned of the step apparatus since it must not interfere with the cab tilting construction motion. The available area can be as small as 21″ horizontally and/or 9″ vertically. The present invention provides a construction which is small enough to fit within this restricted environment and yet still is constructed having a very strong and rigidly secured deployable step when in the deployed position. Such steps are subjected to significant impact and other forces when used for the purposes of facilitating entry into the passenger compartment of a truck by firemen whose bodies can be heavily encumbered with a significant amount of emergency equipment. As such, the strength of and rigidity of the deployable step apparatus needs to be very secure and it is somewhat problematical to devise such a rigid step when restricted by the limited dimension within which the overall apparatus must be capable of being positioned. As such, the present invention utilizes a uniquely configured over-center locking mechanism to achieve a firmly secure, rigid, automatically deployable auxiliary step for an emergency vehicle which is capable of being retracted and deployed within very limited vertical and horizontal dimensions.
2. Description of the Prior Art
Many patents have been granted on various types of automated retractable steps many of which are usable with vehicles such as shown in U.S. Pat. No. 438,021 patented Oct. 7, 1890 to E. P. Robbins on a “Movable Vehicle-Step”; and U.S. Pat. No. 2,118,557 patented May 24, 1938 to G. W. Hamilton and assigned one-fourth to Vinton H. Rowlett on a “Retractable Step For Vehicles”; and U.S. Pat. No. 2,146,668 patented Feb. 7, 1939 to B. C. Baade and assigned to Goodyear-Zeppelin Corporation on a “Retractable Car Step”; and U.S. Pat. No. 2,226,717 patented Dec. 31, 1940 to W. M. Haessler and assigned to American Car and Foundry Company on a “Combined Folding Step. Platform, And Skirt Arrangement”; and U.S. Pat. No. 2,492,068 patented Dec. 20, 1949 to E. L. Schofield et al and assigned to Superior Coach Corporation on a “Retractable Vehicle Step”; and U.S. Pat. No. 3,229,993 patented Jan. 18, 1966 to M. M. Riddle on a “Door Operated Vehicle Boarding Step”; and U.S. Pat. No. 3,329,443 patented Jul. 4, 1967 to E. Lowder et al on a “Swing-Out Step For Vehicle”; and U.S. Pat. No. 3,408,959 patented to A. R. Cripe et al on Nov. 5, 1968 and assigned to United Aircraft Corporation on a “Folding Staircase”; and U.S. Pat. No. 3,572,754 patented Mar. 30, 1971 to S. Fowler and assigned to General Motors Corporation on a “Vehicle Step Arrangement”; and U.S. Pat. No. 3,645,557 patented Feb. 29, 1972 to A. Aldropp et al on a “Foldable Retractable Step Assembly For Campers And Like Vehicles”; and U.S. Pat. No. 3,751,068 patented Aug. 7, 1973 to H. C. R. Green on a “Door-Operated Vehicle Boarding Step”; and U.S. Pat. No. 3,771,815 patented Nov. 13, 1973 to R. F. Bridges on an “Extensible Step”; and U.S. Pat. No. 3,807,758 patented Apr. 30, 1974 to G. E. Rogge on a “Retractable Step For A Motor Home”; and U.S. Pat. No. 3,833,240 patented Sep. 3, 1974 to R. C. Weiler on a “Retractable Step For Use With Trailers, Motor Homes, Or Other Vehicles”; and U.S. Pat. No. 3,861,713 patented Jan. 21, 1975 to D. P. McKee on a “Retractile Door Step For Motor Homes”; and U.S. Pat. No. 3,887,217 patented Jun. 3, 1975 to W. W. Thomas on a “Retractable Step For Vehicles”; and U.S. Pat. No. 4,017,093 patented Apr. 12, 1977 to A. Stecker, Sr. on a “Vehicle Step”; and U.S. Pat. No. 4,020,920 patented May 3, 1977 to J. D. Abbott on a “Retractable Transit Coach Step”; and U.S. Pat. No. 4,073,502 patented Feb. 14, 1978 to R. C. Frank et al on a “Retractable Step”; and U.S. Pat. No. 4,106,790 patented Aug. 15, 1978 to R. C. Weiler and assigned to Blackstone Manufacturing Co., Inc. on a “Vehicle Step”; and U.S. Pat. No. 4,110,673 patented Aug. 29, 1978 to E. J. Nagy et al and assigned to Kwikee Enterprises, Inc. on an “Extendable Vehicle Step And Step Motor Control System”; and U.S. Pat. No. 4,180,143 patented Dec. 25, 1979 to G. D. Clugston on a “Step For Vehicles”; and U.S. Pat. No. 4,185,849 patented Jan. 29, 1980 to W. J. Jaeger on a “Retractable Step For Motor Vehicle”; and U.S. Pat. No. 4,200,303 patented Apr. 29, 1980 to P. N. Kelly on a “Door-Operated Boarding Step For Trucks”; and U.S. Pat. No. 4,274,648 patented Jun. 23, 1981 to R. R. Robins on a “Vehicle Bumper Step”; and U.S. Pat. No. 4,312,515 patented Jan. 26, 1982 to R. J. Allori and assigned to International Harvester Company on a “Self-Locking Step Assembly For A Vehicle”; and U.S. Pat. No. 4,412,686 patented Nov. 1, 1983 to E. T. Fagrell and assigned to AB Volvo on a “Folding Step For Vehicles”; and U.S. Pat. No. 4,440,364 patented Apr. 3, 1984 to S. S. Cone et al on a “Retractable Aircraft Step”; and U.S. Pat. No. 4,623,160 patented Nov. 18, 1986 to J. W. Trudell on an “Extensible Step Assembly For Vehicles”; and U.S. Pat. No. 4,679,810 patented Jul. 14, 1987 to J. F. Kimball on a “Powered Step Assembly For Vehicles”; and U.S. Pat. No. 4,708,355 patented Nov. 24, 1987 to J. Tiede on a “Hideaway Vehicle Step”; and U.S. Pat. No. 4,930,797 patented Jun. 5, 1990 to L. R. Parrill on a “Safety Step System”; and U.S. Pat. No. 4,982,974 patented Jan. 8, 1991 to W. L. Guidry and assigned to Interco Tire Corporation on an “Adjustable High Vehicle Boarding Step”; and U.S. Pat. No. 5,085,450 patented Feb. 4, 1992 to L. DeHart, Sr. and assigned to The Dometic Corporation on a “Step Stall Prevention For Vehicle Steps”; and U.S. Pat. No. 5,228,707 patented Jul. 20, 1993 to C. T. Yoder and assigned to Carriage, Inc. on a “Retractable Vehicle Step”; and U.S. Pat. No. 5,342,073 patented Aug. 30, 1994 to R. L. Poole on a “Retractable Step For Motor Vehicles”; and U.S. Pat. No. 5,498,012 patented Mar. 12, 1996 to P. K. McDaniel et al and assigned to McDaniel Manufacturing Inc. on a “Convertible Vehicle Step”; and U.S. Pat. No. 5,538,269 patented Jul. 23, 1996 to P. K. McDaniel et al and assigned to McDaniel Manufacturing, Inc. on a “Convertible Vehicle Step”; and U.S. Pat. No. 5,547,040 patented Aug. 20, 1996 to P. E. Hanser et al and assigned to HWH Corporation on an “Automatic Step For Recreational Vehicles”; and U.S. Pat. No. 5,842,709 patented Dec. 1, 1998 to M. M. Maccabee and assigned to Kwikee Products Co., Inc. on a “Retractable, Swing Down Step Assembly”; and U.S. Pat. No. 5,957,237 patented Sep. 28, 1999 to R. H. Tigner and assigned to Specific Cruise Systems, Inc. on a “Motorized Collapsible Step”; and U.S. Pat. No. 6,135,472 patented Oct. 24, 2000 to K. Wilson et al and assigned to SportRack LLC on a “Motor Powered Running Board”; and U.S. Pat. No. 6,213,486 patented Apr. 10, 2001 to J. R. Kunz et al and assigned to Kwikee Products Co., Inc. on a “Step Assembly With Concealed Lower Tread”; and U.S. Pat. No. 6,641,158 patented Nov. 4, 2003 to H. Leitner and assigned to American Moto Products, Inc. on a “Retractable Vehicle Step”; and U.S. Pat. No. 6,655,706 patented Dec. 2, 2003 to J. Murrell and assigned to Hickory Springs Manufacturing Company on an “Extensible-Retractable RV Step And Method Of Assembling Same”; and U.S. Pat. No. 6,685,204 patented Feb. 3, 2004 to K. I. Hehr on a “Hitch-Mounted Extensible Step For Pickup Trucks And Other Vehicles Having Tailgates”; and U.S. Pat. No. 6,830,257 patented Dec. 14, 2004 to H. Leitner and assigned to American Moto Products, Inc. on a “Retractable Vehicle Step”; and U.S. Pat. No. 6,834,875 patented Dec. 28, 2004 to H. Leitner et al and assigned to American Moto Products, Inc. on a “Retractable Vehicle Step”; and U.S. Pat. No. 6,938,909 patented Sep. 6, 2005 to H. Leitner and assigned to 89908, Inc. on a “Retractable Vehicle Step”; and U.S. Pat. No. 6,942,233 patented Sep. 13, 2005 to H. Leitner et al and assigned to 89908, Inc. on a “Retractable Vehicle Step”; and U.S. Pat. No. 7,007,961 patented Mar. 7, 2006 to H. Leitner et al and assigned to 89908, Inc. on a “Retractable Vehicle Step”; and U.S. Pat. No. 7,055,839 patented Jun. 6, 2006 to H. Leitner and assigned to 89908, Inc. on a “Retractable Vehicle Step”; and U.S. Pat. No. 7,163,221 patented Jan. 16, 2007 to H. Leitner and assigned to 89908, Inc. on a “Retractable Vehicle Step With Anti-Strike/Anti-Pinch Sensor System”; and U.S. Pat. No. 7,168,722 patented Jan. 30, 2007 to L. D. Piotrowski et al on a “Pull-Out Step Assembly For A Pickup Truck”; and U.S. Pat. No. 7,219,911 patented May 22, 2007 to D. Sukonthapanich et al and assigned to Ventra Group Inc. on a “Retractable Vehicle Step Assembly”; and U.S. Pat. No. 7,367,574 patented May 6, 2008 to H. Leitner on “Drive Systems For Retractable Vehicle Step”; and U.S. Pat. No. 7,380,807 patented Jun. 3, 2008 to H. Leitner and assigned to 89908, Inc. on a “Retractable Vehicle Step”; and U.S. Pat. No. 7,398,985 patented Jul. 15, 2008 to H. Leitner et al and assigned to 89908, Inc. on a “Retractable Vehicle Step”; and U.S. Pat. No. 7,413,204 patented Aug. 19, 2008 to H. Leitner and assigned to 89908, Inc. on a “Retractable Vehicle Step”; and U.S. Pat. No. 7,469,916 patented Dec. 30, 2008 to B. E. Watson and assigned to Magma International Inc. on an “Automated Deployable Running Board”; and U.S. Pat. No. 7,503,572 patented Mar. 17, 2009 to B. K. Park et al on a “Retractable Vehicle Step”; and U.S. Pat. No. 7,566,064 patented Jul. 28, 2009 to H. Leitner et al and assigned to 88908, Inc. on a “Retractable Vehicle Step”; and U.S. Pat. No. 7,584,975 patented Sep. 8, 2009 to H. Leitner and assigned to 89908, Inc. on a “Retractable Vehicle Step”; and U.S. Pat. No. 7,677,584 patented Mar. 16, 2010 to R. W. Raley et al and assigned to Actuant Corporation on a “Motorized Collapsible Step”; and U.S. Pat. No. 7,823,896 patented Nov. 2, 2010 to M. VanBelle et al and assigned to Ford Global Technologies and Multimatic, Inc. on an “Articulated Step System For Automotive Vehicle”; and U.S. Pat. No. 7,841,609 patented Nov. 30, 2010 to H. Okada et al and assigned to Aisin Seiki Kabushiki Kaisha on a “Step Device For Vehicle”; and U.S. Pat. No. 7,934,737 patented May 3, 2011 to H. Okada et al and assigned to Aisin Seiki Kabushiki Kaisha on a “Step Device For Vehicle”; and U.S. Pat. No. 7,967,311 patented Jun. 28, 2011 to D. E. Phillips on a “Multi Position Step”.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide an automated retractable step apparatus which utilizes an over-center locking mechanism which can be mounted in restricted dimensional areas adjacent any vehicle passenger compartment door.
It is an object of the present invention to provide an automated retractable step apparatus which can be usable with emergency vehicles, especially in constructions having cabs that tilt to provide engine access
It is an object of the present invention to provide an automated retractable step apparatus which allows the step to deploy approximately six inches below storage position in order to facilitate entry and exit from the vehicle passenger compartment.
It is an object of the present invention to provide an automated retractable step apparatus which can be conveniently powered by a 12 Volt electric actuator.
It is an object of the present invention to provide an automated retractable step apparatus which can be wired to a door interlock assembly to automatically move to the deployed position responsive to the opening of an adjacent door and to retract responsive to the door closing.
It is an object of the present invention to provide an automated retractable step apparatus which requires minimal maintenance costs and which may be retrofitted onto existing apparatus and which can sustain static loads of up to 500 pounds.
It is an object of the present invention to provide an automated retractable step apparatus which powers movement of a 20″ by 5″ stepping surface between an upper retracted position and a lower deployed position.
BRIEF DESCRIPTION OF THE DRAWINGS
While the invention is particularly pointed out and distinctly described herein, a preferred embodiment is set forth in the following detailed description which may be best understood when read in connection with the accompanying drawings, in which:
FIG. 1 is an upper front perspective illustration of an embodiment of the automated retractable step apparatus of the present invention shown in the deployed position;
FIG. 2 is a left side plan view of the embodiment shown in FIG. 1 shown in the deployed position;
FIG. 3 is a left side plan view of the embodiment shown in FIG. 2 shown in the retracted position;
FIG. 4 is a three-quarter perspective view of the embodiment shown in FIG. 1 viewed from the left in the deployed position;
FIG. 5 is an illustration of the embodiment shown in FIG. 4 in the retracted position;
FIG. 6 is a exploded bottom perspective view of the embodiment shown in FIG. 1 illustrating the details of the powering and locking linkage positioned below the main housing plate of the apparatus of the present invention shown in the deployed position;
FIG. 7 is a three-quarter perspective view of the embodiment of the apparatus shown in FIG. 1 of the present invention shown from the left and from beneath fully deployed;
FIG. 8 is a bottom perspective view of an embodiment of the apparatus of the present invention in the retracted position;
FIG. 9 is three-quarter perspective view of the embodiment of the apparatus shown in FIG. 1 of the present invention shown from the right from beneath fully deployed;
FIG. 10 is an illustration of an embodiment of the present invention shown from the right and beneath shown at an intermediate position between the retracted position and the deployed position;
FIG. 11 is a side plan view of an embodiment of the first outer locking lever of the present invention;
FIG. 12 is a side plan view of an embodiment of the second outer locking lever of the present invention; and
FIG. 13 is a side plan view of an embodiment of the inner locking lever of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention discloses an automatic retractable step apparatus usable with a vehicle which is movable between a deployed position 6 as shown best in FIGS. 1 , 2 , 4 , 6 , 7 and 9 and also is movable to a retracted position 8 as shown best in FIGS. 3 , 5 and 8 . FIG. 10 shows the apparatus at an intermediate position between fully deployed and fully retracted. The overall size of the construction of the apparatus will be preferably less than 21″ in width and, preferably less than 9″ in vertical height such that it does not inhibit in any way the operation of the vehicle such as the tilting mechanism for providing engine access for a conventional emergency vehicle such as a fire truck or the like. The construction of the retractable step apparatus includes a main housing bracket 9 which includes a main housing plate 10 which generally extends horizontally and will preferably include side mounting sections 11 which can include a plurality of holes to facilitate mounting with respect to the truck construction. The side mounting sections 11 will often be formed as ears or perpendicular sections extending away from the main section of the housing plate 10 at an angle thereto.
The construction of the main housing plate includes an upper surface 14 preferably mountable in abutment with respect to the truck construction and a lower surface 12 oppositely positioned relative to the upper surface and facing downwardly therefrom to which the operating mechanism of the automatically retractable construction can be attached.
A step plate 16 is included which is movable between a retracted position 8 immediately adjacent to and below the lower surface 12 of the main housing plate 10 and a deployed position 6 extending downwardly and forwardly relative to the lower surface 12 of the main housing plate 10 to facilitate entry and exit from the vehicle passenger compartment. A driven arm assembly 18 controls and powers the swinging movement of the step plate 16 between the deployed position 6 and the retracted position 8 .
The construction of the driven arm assembly 18 will preferably include a first driven arm member 20 pivotally secured to the lower surface 12 of the main housing plate 10 generally positioned extending downwardly from the main housing plate 10 and a second driven arm member 22 which is also pivotally mounted with respect to both the step plate 16 and the lower surface 12 of the main housing plate 10 and also is positioned extending downwardly therefrom at a location spatially disposed from said first driven arm member 20 . To control coordinating movement between the first driven arm member 20 and the second driven arm member 22 a driven arm cross member 24 which is shown in the Figures herein as being in the shape of a rod will be fixedly secured to the first driven arm member 20 and second driven arm member 22 to assure simultaneous movement of the driven arm members 20 and 22 together. The driven arm assembly 18 is also attached to a drive mechanism for facilitating powering of movement of the step plate 16 between the deployed position 6 and the retracted position 8 , respectively.
Another arm assembly will be included for controlling and guide movement of the step between the deployed and retracted positions which is not powered. This free arm assembly 26 which will include a first free arm member 28 pivotally secured with respect to the step plate 16 and the lower surface 12 of the main housing plate 10 . Similarly the free arm assembly 26 will include a second free arm member 30 which is pivotally secured with respect to the step plate 16 and the lower surface 12 of the main housing plate 10 at a position spatially disposed from said first free arm member 26 . A free arm cross member 32 will be fixedly secured to the first free arm member 28 and the second free arm member 30 preferably at opposite ends thereof to assure simultaneous coordinated movement of these two free arm members whenever the step plate 16 is driven between the deployed position 6 and the retracted position 8 . The free arm assembly 26 does not power movement of the step plate 16 but does serve to guide, strengthen and control the positioning of the step plate 16 particularly when located in the deployed position 6 . Powering of movement of the step plate 16 between the deployed position 6 and the retracted position 8 is provided solely by driving of the driven arm assembly 18 .
At least one stop assembly 34 is preferably included in the apparatus of the present invention to limit the movement of the free arm assembly 26 toward the deployed position 6 thereof. This stop assembly is mounted with respect to the lower surface 12 of the main housing plate 10 . Preferably a housing stop boss 36 extends downwardly from the lower surface 12 and defines a housing stop hole 38 extending therethrough extending generally parallel to the lower surface 12 . A stop pin member 40 extends through the housing stop hole 38 . A resilient biasing means 42 such as a stop spring means preferably in the form of a coil spring extends around the stop pin 40 and a stop collar 44 in the form a washer will be positioned extending around the stop pin 40 with the stop spring means 42 positioned between the stop collar 44 and the portion of the housing stop boss 36 which surrounds the housing stop hole 38 . In this manner as one of the free arm members of the free arm assembly 26 moves the step plate 16 toward the deployed position 6 the free arm will come into abutment with the stop assembly which define the location of the fully deployed position and will limit any undesirable excessive movement beyond the deployed position. In the configuration shown in this embodiment of the stop assembly the stop pin member 40 is freely movable axially through the housing stop hole 38 . As such, as one of the free arm members 28 or 30 of the free arm assembly 26 come into abutment with the stop pin member 40 it will move axially within the housing stop hole 38 thereby compressing the stop spring means 42 . This movement will ease the final portion of movement of the free arm assembly 26 toward the deployed position 6 and cushion the stopping thereof so that it will not be abrupt. Once the stop spring means 42 is completely compressed the free arm assembly 26 will have stopped movement of the step plate 16 in the desired final location for the deployed position 6 . This position can be adjusted by adjustment of positioning of components of the stop assembly.
The apparatus of the prevent invention includes a housing pivot bracket 46 which is generally U-shaped and is secured to the lower surface 12 of the main housing plate 10 . The housing pivot bracket 46 will preferably define a housing bracket aperture 47 extending therewithin preferably in a direction oriented perpendicularly with respect to the lower surface 12 and therebelow. Housing bracket pin 48 is designed to extend through the housing bracket aperture. The housing bracket pin 48 can be threaded and be in the form of a bolt with a nut to facilitate pivotally movable securement relative to the housing bracket aperture 47 .
The linkage for driving of the step plate between the deployed position 6 and the retracted position 8 includes an output arm 54 mounted extending generally parallel to the lower surface 12 of the main housing plate 10 . This output arm 54 will preferably define an output arm aperture 56 therewithin. Preferably output arm aperture 56 and housing bracket aperture 47 are vertically registered with respect to one another such that the housing bracket pin or stud 48 can extend through both the housing bracket aperture 47 and the output arm aperture 56 simultaneously for facilitating securement with pivotal relative movement between the output arm 54 and the main housing plate 10 .
The apparatus for driving movement of the step plate 16 for the present invention includes a longitudinal drive means 50 preferably pivotally secured with respect to the lower surface 12 of the main housing plate 10 and including a drive output rod 52 which is movable to extend outwardly or be retracted inwardly therewithin Longitudinal drive means preferably comprises an electrically powered mechanism. In the apparatus of the present invention longitudinal extension of the longitudinal drive means 50 will cause movement of the step plate 16 toward the retracted position whereas retracting of the drive output rod 52 toward a position within the longitudinal drive means 50 will urge movement of the step plate 16 toward the deployed position 6 . In this preferred embodiment the drive output rod 52 is pivotally attached with respect to one end of the output arm 54 to facilitate driving pivotal movement thereof relative to the housing pivot bracket 46 .
A drive control linkage provides connection of the drive means 50 to the step plate 16 . Drive control linkage includes an intermediate link 58 pivotally secured to the output arm 54 preferably at a position oppositely located from the point of connection of pivotal securement thereof with respect to the drive output rod 52 with the output arm aperture 56 and positioned therebetween. Intermediate link 58 is pivotally secured to an intermediate coupling member 60 at the opposite end thereon from the point of pivotal securement with respect to the output arm 54 . The intermediate coupling member 60 is pivotally secured with respect to an inner locking to an inner locking lever 82 . Inner locking lever 82 defines an inner locking lever central aperture 83 therein which is adapted to receive a linking pin 80 extending therethrough. Inner locking lever 82 includes an inner locking lever abutment surface 84 which can be urged into abutment with the outer surface of the driven arm cross member 24 to limit movement of the stop plate 16 toward the deployed position 6 and facilitate over-center securement of the step plate 16 so positioned. As the step plate 16 is urged to move toward the deployed position 6 . the inner locking lever 82 and, in particular, the inner locking lever abutment surface 84 , will bear against driven arm cross member 24 to terminate powered movement of the step plate 16 toward the deployed position 6 and facilitate temporary locking therein.
Inner locking lever 82 also defines an inner locking lever outer aperture 85 extending therethrough spatially disposed from said inner locking lever central aperture 83 to facilitate pivotally movement attachment thereof relative to the intermediate coupling member 60 .
The locking mechanism of the present invention further includes a housing drive boss assembly 64 . The housing drive boss assembly 64 will include a first housing drive control boss member 66 defining a first housing drive control boss hole 68 extending therethrough in a direction extending generally parallel to the lower surface 12 of the main housing plate 10 . The housing drive boss assembly 64 also includes a second housing drive control boss member 70 with a second housing drive control boss hole 72 defined therein. Preferably the second housing drive control boss hole 72 will be oriented extending approximately parallel to the lower surface 12 of the main housing plate 10 in direct axial registration with respect to the first housing drive control boss hole 68 . A housing drive pin 62 is positionable extending axially through the first housing drive control boss hole 68 and the second housing drive control boss hole 72 . This housing drive pin 62 so positioned will provide a means for pivotally moveably mounting of the outer locking lever assembly 74 .
The outer locking lever assembly 74 will include a first outer locking lever 76 which defines a first outer locking lever linking pin aperture 104 at an intermediate location therein and a first outer locking lever housing drive pin aperture 106 adjacent one end thereof. In a similar manner a second outer locking lever 78 will be included in the outer locking assembly 74 which defines a second outer locking lever linking pin aperture 108 at an intermediate location therein and a second outer locking lever housing drive pin aperture 110 adjacent one end thereof. With this construction the linking pin 80 can extend through the first outer locking lever linking pin aperture 104 of the first outer locking lever 76 and also through the second outer locking linking pin aperture 108 of the second outer locking lever 78 . The linking pin 80 will also extend through the inner locking lever central aperture 83 of inner lock lever 82 with lever 82 positioned between the first outer locking lever 76 and the second outer locking lever 78 .
The mounting of the outer locking lever assembly 74 with respect to the main housing plate 10 is achieved by positioning the housing drive pin 62 in a position extending through the first outer locking lever housing drive pin aperture 106 of first outer locking lever 76 and also through the second outer locking lever housing drive pin aperture 110 of the second outer locking lever 78 . In this manner both the first outer locking lever 76 and the second outer locking lever 78 will each be pivotally secured with respect to main housing plate 10 and will each be pivotally secured with respect to the linking pin 80 at positions on each opposite side of the inner locking lever 82 . Linking pin 80 will extend through the inner locking lever central aperture 83 of the inner locking lever to so position the linking pin 80 between the first outer locking lever 76 and the second outer locking lever 78 with all three lever pivotally moveable secured with respect thereto.
It should be appreciated that there are three main axes for providing the capability of pivotal movement within the locking mechanism of the apparatus of the present invention including the axis of the housing drive pin 62 and the axis of the driven arm cross member 24 and the axis of the linking pin 80 positioned generally therebetween.
Control of movement of the linking pin 80 with respect to the housing drive pin 62 is achieved because each of the first outer locking lever 76 and the second outer locking lever 78 are pivotally secured with respect to both pins 62 and 80 . Relative movement between the linking pin 80 and the driven arm cross member 24 is achieved by a driven cross member drive link assembly 98 . This driven cross member drive link assembly 98 includes a first driven cross member link 100 and a second driven cross member link 102 . Each of these links are pivotally secured with respect to the driven arm cross member 24 and also with respect to the linking pin 80 to achieve coordinated movement therebetween. Preferably the first driven cross member link 100 is positioned between the first outer locking lever 76 and the inner locking lever 82 . On the opposite side thereof, preferably, the second driven cross member link 102 is positioned between the inner locking lever 82 and the second outer locking lever 78 .
One of the important characteristics of this invention is to appreciate that the inner locking lever abutment surface 84 of inner locking lever 82 and the first outer locking lever abutment surface 77 of first outer locking lever 76 and the second outer lever abutment surface 79 of second outer locking lever 78 will simultaneously be moved into contact with the driven arm cross member 24 which operates as the stop and locking mechanism for holding the main housing plate 10 in the fully deployed position 6 .
It is very important further to consider that the movement of the linking pin 80 when the locking mechanism of the apparatus of this invention is brought to the fully deployed position 6 is to a slightly over center position. That over center position is achieved by defining a plane extending between the axis of the housing drive pin 62 and the axis of the driven arm cross member 24 and allowing the longitudinal axis of the locking pin 80 to move completely through and beyond this defined plane immediately prior to the step plate 16 arriving at the fully deployed position 6 . The over center positioning of lining pin 80 achieves a firm and secure locking capability not otherwise possible with an apparatus of this limited size and construction.
Another important consideration for the apparatus of the present invention is maintaining the linkage of the driving and locking mechanism at a predefined spacing below the lower surface 12 of the main housing plate 10 because it is confined within such a narrow area. The construction of the apparatus of the present invention operate within limited space restrictions and thus portions of the linkage operate in close tolerances relative to the adjacent lower surface 12 of main housing plate 10 For this purpose a linkage position control assembly 86 is included for carefully and accurately controlling linkage movement and positioning at all times. Linkage position control assembly 86 preferably includes a position control stud 88 which extends through the coupling member 60 and through a position control slot 90 defined in the main housing plate 10 extending completely therethrough from the lower surface 12 to the upper surface 14 . A lower position control washer 92 is secured to the position control stud 88 in direct abutment with respect to the lower surface 12 of the main housing plate 10 . Similarly but oppositely, an upper position control washer 94 is secured to the position control stud 88 at a location in abutment with the upper surface 14 of the main housing plate 10 . In this manner the positioning of the intermediate coupling member 60 and the portions of the linkage directly or indirectly secured thereto will be maintained in a close spatial displacement from the lower surface 12 of the main housing plate 10 . This construction achieves the operational strength desired by the apparatus of the present invention while allows operation within a very narrow confined dimension. The position control stud 88 can be a conventional bolt with the head positioned above the upper position control washer 94 above the upper surface 14 and with the lower threaded portion extending through and below the intermediate coupling member 60 with a position control nut 96 secured to the undersurface thereof for achieving effective operation of the linkage position control assembly 86 .
One of the unique advantages of the present invention is the use of the over-center mechanism which allows the overall structure and, particularly, the longitudinal drive means 50 and the associated drive output rod 52 , to have lower total strength requirements since the over-center construction affords basic structural strength in the inherent design thereof. This enhanced strength is, thusly, provide by the design of the drive means 50 and output rod 52 rather than by making the locking mechanism of more heavy-duty parts. Because of this design, the cost of production and material cost are minimized without sacrificing strength. Strength is an important issue in this device because there are large tensile forces exerted through the structural components because a fireman stepping on the step when deployed is often done in a very quick and sudden manner with heavy loads being carried. As such a strong design is needed and present design achieves this result from the over-center movement capability rather than from merely making the components from more heavy duty parts. The use of the lighter duty drive means 50 and output rod 52 allows the use of a smaller actuator for savings in cost as well as in overall size and weight.
Also space considerations in this design are extremely important because this device usually extends downwardly when in the stored position and downwardly and outwardly when in the deployed position from a location immediately below a passenger entry location such as a truck door. Thus, achieving the desire ground clearance for any similarly positioned auto or truck part is an important consideration. This advantage is particularly important for emergency vehicles such as fire trucks which are required to be capable of moving quickly and easily over moderately sized curbs and in other street and/or ground areas that may not be perfectly level. It is important that no part of the truck substructure contact the substrate on which the vehicle is being driven even when used in such demanding situations. All such vehicles need to be fully capable of moving through various angles of approach and department and navigating fairly steep grades often encountered in driveway entrances or highly crowned roads. All devices positioned beneath such emergency-type vehicles need to be fully capable of serious off-road travel without bottoming out.
While particular embodiments of this invention have been shown in the drawings and described above, it will be apparent that many changes may be made in the form, arrangement and positioning of the various elements of the combination. In consideration thereof, it should be understood that preferred embodiments of this invention disclosed herein are intended to be illustrative only and not intended to limit the scope of the invention. | An automatically deployable step apparatus particularly usable with vehicle such as a fire truck having a passenger compartment at substantial distance from the surrounding environmental surface which provides powered movement between a deployed position and a retracted position and can be mounted in a relatively small restricted area in order to avoid interference with a truck cab which tilted to provide engine access, said apparatus utilizing a unique over-center locking mechanism to provide secure locking of the step in the deployed position while maintaining an apparatus having limited overall dimensions. A unique linkage system is provided for facilitating accurately powered automated movement. | 1 |
The present invention relates to a method for controlling root growth comprising applying, to exposed plant roots, an effective amount of paraquat ion. It is based, at least in part, on the discovery that paraquat ion, a herbicide previously used primarily to destroy plant tissue by blocking photosynthesis, is also toxic to root tissue when locally applied. Such methods are particularly useful in reducing the amount of roots present in sewer pipes.
BACKGROUND OF THE INVENTION
A number of chemical products have hitherto been used to control vegetative root intrusion in pipeline systems. The most frequently used active ingredients in such products are copper sulfate, corrosive acids or bases, 2,6 dichlorobenzonitrile (hereafter “Dichlobenil”) and sodium methyldithiocarbamate (hereafter “Metam”). Each of these products, however, suffer from a number of disadvantages which render their use problematic.
For example, copper sulfate is not detoxified by wastewater treatment plants and, because it is a systemic herbicide, can damage above-ground vegetation. Corrosive acids and bases, such as sulfuric acid, hydrochloric acid, caustic soda, and sulfamic acid, use heat as the primary mechanism of root destruction, and as such are effective only at the point of application and do little to prevent regrowth. Dichlobenil acts upon growth points in root systems and therefore provides residual control by deterring regrowth, but has limited effectiveness, so that it is commonly formulated with the active agent Metam. Combinations of Metam and Dichlobenil were found to be so effective, they replaced other types of active ingredients in the industry. However, several problems associated with Metam were identified which created a motivation to find other suitable herbicides for root control. First, Metam is a carcinogen. Second, in concentrations typically used for root control, Metam may be toxic to microorganisms at biological wastewater treatment plants, where it may be particularly toxic to nitrifying bacteria. Third, Metam is a marine pollutant, and therefore is not amenable to storm drain applications unless costly precautions are taken to ensure against a release of Metam into fresh water sources such as streams, ponds and lakes.
U.S. Pat. No. 5,919,731 discloses the use of diquat as an effective agent against root growth in sewer pipes. Previously, diquat had been known as an herbicide which killed foliage by photosynthesis, and which was inactivated by organic materials. The mechanism by which diquat kills roots in sewers, where there is little or no photosynthesis occurring, and where there is an abundance of organic material, has not been determined. Although toxicity has been postulated to be associated with diquat's desiccant activity, this has not been confirmed. Toxicity issues associated with Metam are obviated by using diquat as a root control agent, because diquat's toxicity is limited due to its inactivation by organic matter.
Paraquat is chemically related to diquat, both being dipyridyl compounds. It is known in the art to share some, but not all, of the biological activities of diquat. For example, paraquat, like diquat, is an herbicide which acts by inhibiting photosynthesis and is inactivated by organic substances. However, the toxicology of paraquat and diquat are different. In animals, the primary target for paraquat toxicity is the lungs (Bismuth et al., 1982, J. Toxicol. Clin. Toxicol. 19:461-474), whereas diquat is severely toxic to the nervous system and does not produce significant pulmonary damage (Saeed et al., 2001, Postgrad. Med. 77(907):329-332; Lam et al., 1980, Toxicol. 18:111-123; Vanholder et al., 1981, Am. J. Med. 70:1267-1271).
Because the herbicidal mechanism shared by diquat and paraquat is not believed to operate in root control, it was not known, prior to the present invention, whether paraquat would be an effective root control agent. The fact that the primary toxic effects of diquat and paraquat in animals involve different organ systems contributed to this uncertainty, because it suggests that some tissues susceptible to damage by diquat are resistant to paraquat toxicity.
SUMMARY OF THE INVENTION
The present invention relates to the use of paraquat and its derivatives as root control agents. It is based, at least in part, on the results of green house testing in which application of paraquat as a dense foam to tree roots resulted in the destruction of the test roots without causing damage to the upper portion of the trees.
In a first set of embodiments of the invention, paraquat is applied to exposed roots as a foam comprising paraquat, where paraquat may be the sole root control agent or may be combined with additional root control agents, including, but not limited to, diquat and/or Dichlobenil.
In a second set of embodiments, paraquat may be applied, as the sole root control agent or combined with one or more additional root control agent, to exposed roots as a spray. In specific, non-limiting embodiments, the spray may be administered via a hydraulic sewer cleaning machine (commercially known as a “Sewer Jet” or “Hydraulic Sewer Cleaning Machine). Such an apparatus pumps water through a hose at high pressure through a nozzle having ports facing rearwards, thereby propelling the Sewer Jet hose down a pipeline, while flushing debris from the pipe.
Accordingly, the present invention provides for methods and compositions for using paraquat as a root control agent. This root control activity may be used to reduce, relieve and or/inhibit obstruction of conduits such as sewers, or in other contexts where roots enter an open space.
DESCRIPTION OF THE FIGURES
FIG. 1 . Schematic diagram of Sewer Jet, wherein a water storage tank ( 1 ) is linked to a high pressure pump ( 2 ) via a suction line ( 4 ), and the high pressure pump is able to pump water through a pressure line ( 5 ) to a hose reel ( 3 ) connected to a high pressure hydraulic sewer cleaner hose ( 6 ) having a jet nozzle ( 7 ). A solution of root control agent is introduced into the system from a holding tank ( 8 ) connected to the suction line ( 4 ) via a three-way valve ( 9 ).
FIG. 2 . Expanded view of the jet nozzle referred to in FIG. 1 . The nozzle is located at the free end of the high pressure hydraulic sewer cleaning hose ( 6 ). It is comprised of a center body ( 10 ) that spins in a direction perpendicular to the direction in which the hose is traveling. The center body has one or more side water port ( 11 ) that ejects water ( 12 ) in a direction that is approximately perpendicular to the direction that the hose is traveling. At the distal end of the nozzle is a stationary portion ( 13 ) having multiple rearward facing ports ( 14 ) which eject water ( 15 ) so as to propel the nozzle and hose forward, in the direction of the large arrow.
FIG. 3 shows the effect of paraquat on root growth in comparison to diquat and the untreated control. (D=diquat; P=paraquat; C=control).
FIG. 4 demonstrates the effect of diquat in comparison to Rootex, a rooting hormone. (D=diquat; R=Rootex).
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides for compositions and methods for destroying plant root tissue, comprising applying, to the tissue, an effective amount of paraquat ion, the technical name of which is 1,1′-dimethyl-4,4′-bipyridium ion, and which has the chemical structure:
(the term “paraquat” as used herein refers to the ion). Paraquat is typically provided as 1,1′-dimethyl-4,4′-bipyridium dichloride, for example, and not by way of limitation, as sold by Syngenta Inc., under the commercial name Gramoxone Max® as 43.8 percent paraquat and 56.2 percent inert ingredients wherein 3 pounds of paraquat ion per gallon are found in a solution having 4.143 pounds of the dichloride salt per gallon.
According to the invention, a composition comprising an effective amount of paraquat may be applied to a root to control the growth of the root. Growth control may be achieved by destruction of all or a portion of the root tissue. Preferably, after an effective amount of paraquat is applied to a root mass, the amount of living root present decreases by at least 75 percent within a period of 25 days. Preferably, an effective amount of paraquat is toxic within 25 days when applied to a root which is 3 mm in diameter.
Paraquat may be applied, according to the invention, as a solution for application by either pressure spray or foam, or any other method known in the art. In specific non-limiting embodiments of the invention, the solution comprises between 0.00219 and 0.876 percent paraquat, preferably between 0.00438 and 0.438 percent paraquat, and more preferably between 0.0219 and 0.219 percent paraquat. Paraquat solutions may be prepared, in nonlimiting examples of the invention, by diluting between 0.005 to 2.0 gallons of paraquat stock aqueous solution (e.g., Gramoxone Max®, having a concentration of 43.8 percent per gallon, referred to herein as a paraquat stock solution, and intended for further dilution prior to application) per 100 gallons of mixed solution; preferably by diluting between 0.01 to 1.0 gallons of the foregoing paraquat stock solution (43.8 percent) per 100 gallons of mixed solution; and more preferably by diluting 0.05 to 0.5 gallons of paraquat stock solution (43.8 percent) per 100 gallons of mixed solution.
Such solutions, comprising paraquat, may further comprise other agents, such as diquat, Dichlobenil, Metam and/or ammonium sulfate, at effective concentrations. In a specific, non-limiting embodiment, a solution may be prepared comprising paraquat at a concentration of between about 0.0438 and 0.876 percent and diquat at a concentration of between about 0.0373 and 0.746 percent.
Such solutions may also comprise adjuvants which act as carriers, facilitate the removal of organic substances, improve the ability of the active ingredients to adhere or penetrate root tissue, or otherwise improve the efficacy of the treatment, including, but not limited to, detergents, degreasers, emulsifiers, foaming agents, surfactants, wetting agents, penetrants, spreaders, and sticking agents.
In a first set of embodiments, paraquat solution may be applied to exposed roots as a foam, using standard equipment. The most common method of foaming herbicides in sewers, is to mix the herbicide in solution with water and foaming agent. Suitable foaming agents include, but are not limited to, liquid-type sulfonates such as sodium methyl 2-sulfolaurate, disodium 2-sulfolaurate, sodium alkylbenzene sulfonate (linear), calcium alkylbenzene sulfonate (branched), amine alkylbenzene sulfonate (branched) and amine alkyl aryl sulfonate blend; liquid sulfonic acids such as alkylbenzene sulfonic acid (branched) and alkylbenzene sulfonic acid (linear); liquid alkyl ether sulfates such as ammonium ether sulfate and sodium ether sulfate; liquid olean sulfonates such as sodium alpha olefin sulfonate; liquid amphoterics such as cocoamidopropyl betaine; liquid alkyl sulfates such as ammonium lauryl sulfate, sodium lauryl sulfate and DEA lauryl sulfate; liquid betaines such as cocamidopropyl betaine; liquid sarcosinates such as sodium lauroyl sarcosinate, sulfosuccinates liquid, disodium laureth sulfosuccinate, sodium lauryl sulfoacetate; and liquid alkyl polyglycosides such as short chain alkyl polyglycosides. For example, but not by way of limitation, an application hose may be placed within the sewer from one manhole, or access point, to another. Compressed air may be injected into the stream of mixed solution as it is being pumped, in order to create a foam. The foam may then be ejected under pressure, filling the sewer as the hose is retrieved.
In preferred embodiments of the invention, paraquat may be used with a cationic, neutral or non-ionic foaming agent. Paraquat is typically not compatible with anionic foaming agents. However, the use of moderately ionic (i.e., 50% or less of the foaming agent components are anionic and the remainder are neutral or cationic) is possible, provided that application takes place promptly after mixing paraquat and foaming agent in solution.
The objective of foam application techniques is generally to fill a pipe with foam as completely as possible as the application hose is being retrieved. The filling capability may be optimized by altering the rate at which the application hose is retrieved. In order to fill a pipe with foam, the application hose may be retrieved at a rate (feet per minute) equal to the gallons of foam generated per minute divided by the volume (gallons per foot of length) of pipe.
As a first specific, nonlimiting example of the invention, typical foaming compounds are associated with an expansion ratio of 20 to 1 when applied via standard sewer foaming equipment. This equipment is normally run at a rate which utilizes 4.5 gallons of solution per minute, which therefore produces 90 gallons of foam per minute (4.5 gallons×20). The volume of an 8 inch diameter pipe is approximately 2.6 gallons per foot of length. At an application rate of 90 gallons of foam per minute in an 8 inch diameter pipe, the hose should be retrieved at a rate of approximately 35 feet per minute (90 gallons/minute÷2.6 gallons per foot=35 feet per minute).
As a second specific nonlimiting example, if a foaming compound provides a lower expansion ratio, e.g., 15 to 1, and the foam application equipment is pumping solution at a lower rate, e.g., 3.5 gallons per minute, then the application hose ejects approximately 53 gallons of foam per minute (3.5×15=53). If the pipe to be treated is 10″ in diameter, the volume of said pipe is approximately 4 gallons per foot. The hose retrieval rate in this example would be approximately 13 feet per minute (53 gallons per minute÷4 gallons per foot=13.25).
The flow in large diameter pipes (e.g., 15″ and greater) will often overpower the foam such that it cannot fill the pipe and remain in place. This job condition may be handled by applying a 3″ to 4″ coating of foam along the entire inside circumference of the pipe. The volume of foam required to coat a pipe may be calculated by determining the volume of the pipe to be treated (per foot), and subtracting from that the volume of a pipe 6 to 8 inches smaller in diameter (per foot).
In a second set of nonlimiting embodiments, paraquat solution may be applied to exposed roots as a spray, for example as applied by a hydraulic sewer cleaning machine (henceforth referred to as a “Sewer Jet”) as depicted in FIGS. 1 and 2 or other spraying device. A Sewer Jet should be operated using parameters (e.g. pressures and retrieval rates) recommended by the manufacturer. It is advisable to recirculate water within the jet truck in order to ensure an even distribution of paraquat. Several brands and styles of sewer jetting equipment are available, including but not limited to Aquatech, Vac-Con, Vactor, Myers, Clean Earth Machine, and SRECO.
It may be preferable to mix paraquat into an ancillary tank, rather than the primary water tank of the Sewer Jet (see FIG. 1 ). In this way, fresh water from the primary water tank is used to jet the hose up the pipe, and the paraquat solution in the secondary tank is pumped as the hose is retrieved, by switching off the fresh water tank and switching on the solution tank. Heavy roots and other obstacles may impede the progress of the hose when jetting up a line. This can cause wasteful over-application of chemical in those areas. The applicator should be cautioned to ensure that the Sewer Jet hose has been purged of fresh water and is dispensing paraquat solution before beginning to retrieve the hose.
In preferred embodiments of the invention, a Sewer Jet is equipped with a spinning nozzle, which provides better coverage of the spray solution within the pipe. Typical Sewer Jet nozzles are rearward facing and propel the Sewer Jet hose down a pipe line. The spinning nozzle variant has a side port that jets water in a direction approximately perpendicular to the pipe wall. The jetting action from this side port causes the nozzle body to spin, thereby causing the direction of the spray to rotate, thereby widely distributing sprayed liquid over the inner surface of the pipe. In further preferred embodiments of the invention, a Sewer Jet is equipped with a spray port designed to fog or atomize the spray solution, which minimizes droplet size, and reduces run-off. Fogging sewer jet nozzles and spinning sewer jet nozzles are common stock items for most sewer jet manufacturers.
In view of the toxicity of paraquat, it is imperative that the applicator wear a respirator and additional safety equipment to protect, among other things, from pulmonary and transcutaneous exposure. The use of hot water or steam in conjunction with application of parauat may be dangerous.
EXAMPLE
Destruction of Root Tissue by Paraquat
Materials and Methods
Individual branch cuttings of black willow ( Salix nigra ) were collected and grown in containers according to methods described in Groninger and Bohanek 2000, J. of Plant Growth Regulation 19:453-456. The cuttings were rooted in 262 ml tubes containing a 1:1 mixture of peat moss and white washed play sand. Tubes were perforated with a 2 cm 2 hole in the bottom and four 1.4 cm 2 holes on the side, 2 cm from the bottom of the tube. Cuttings were grown under greenhouse conditions in racks containing 12 tubes each with one cutting per tube. To facilitate root growth outside of the tube, the racks were placed in aluminum pans and positioned so that the base of each tube was suspended in dilute nutrient solution. Water was added as needed and a 20-20-20-NPK fertilizer was provided at a rate of 0.04 g/cutting per week into the pan. Root growth was further facilitated by maintaining the root zone in darkness by covering gaps between the edge of the rack and the pan with aluminum foil. When cuttings had been growing for approximately four months, intermingling exposed roots from adjacent cuttings were separated from one another and fine roots were allowed to regrow. Treatment were initiated when shoots averaged 0.8 meters in height with healthy foliage. At the time of treatment, each cutting produced profuse growth of roots 0.3 cm in diameter or less.
Roots of the cuttings were exposed to paraquat, diquat, Rootex, a rooting hormone, and a control. Paraquat (Gramoxone Max®, Syngenta, containing 43.8% paraquat) was applied to roots cuttings at two rates, 2.0 and 4.0 ml/L. Diquat (Reward®, Syngenta, containing 37.3% diquat) was applied at 4.0 ml/L. Each treatment of the four treatments were applied in 1.0 L water solution with a 2% alkyl polyglycoside-based foaming agent, AU-340 (Adjuvants Unlimited, Tulsa, Okla.) using a foam generator to simulate a standard application of chemicals in controlling tree roots in sewer lines. Roots were placed in contact with foam solution for 20 minutes. Dense root growth at the time of treatment prevented the movement of foam into the tube containing the cutting. Upon removal of foam solution, cuttings and their exposed roots were returned to pretreatment nutrient conditions with residual foam permitted to maintain contact with exposed roots.
Evaluation of roots was conducted twenty-five days following treatment. Roots were visually inspected, harvested, separated into living and dead groups, dried and weighed for dry mass determination.
Results
Untreated controls displayed abundant root growth and no evidence of dead roots (FIG. 3 ). Rootex-treated controls exhibited abundant root growth (FIG. 4 ). No living roots were observed in the diquat or paraquat treated roots (FIG. 3 ).
Table 1 demonstrates that there is no root growth in diquat or paraquat treated roots.
TABLE 1
Dry Weight of Roots Twenty-five Days following Treatment
(Each value represents the average of 24 willows cuttings.)
Live Roots
Dead Roots
Treatment
(g/willow cutting)
(g/willow cutting)
Control
5.7
0
Diquat* (4.0 ml/L)
0
0.9
Paraquat** (2.0 ml/L)
0
0.7
Paraquat** (4.0 ml/L)
0
2.2
*dilution of a 37.3% diquat stock
**dilution of a 43.8% paraquat stock
These results show that paraquat is effective for controlling the growth of tree roots, and may be more toxic to roots than diquat.
Various publications are cited herein, the contents of which are hereby incorporated by reference in their entireties. | The present invention relates to the use of paraquat as a root control agent. It is based, at least in part, on the results of green house testing in which application of paraquat ion as a dense foam to tree roots resulted in the destruction of the test roots without causing damage to the upper portion of the trees. The inactivation of paraquat by organic materials, under these circumstances, becomes an advantage, as it prevents toxic levels of paraquat from traveling downstream from the point of application | 0 |
[0001] This invention claims priority from provisional application 60/492,548 filed Aug. 4, 2003.
BACKGROUND
[0002] 1. Field of the Present Invention
[0003] The present invention generally relates to the field of agricultural implements used for field preparation and configuration, and more particularly to an improved folding furrow roller for seed bed preparation, configuration, and planting that may be selectively deployed between an extended state for seed bed preparation, configuration, and planting and a folded state for storage and legal transport over public roads.
[0004] 2. History of Related Art
[0005] Agricultural implements for preparing fields and configuring seed beds are well known in the art. Many of these agricultural implements employ earth working tools which are mounted on horizontally disposed frames to permit the implements to work wide swaths of earth. One example of such an implement is a furrow roller which utilizes plowshares and heavy rollers connected to the frames to prepare and configure seed beds. As the furrow roller is drawn through the field, the plowshares dig irrigation furrows that produce raised earthen mounds between the furrows, and the rollers smooth and compact these raised earthen mounds so as to create uniform raised seed beds separated by uniform irrigation furrows.
[0006] Working as wide a swath of earth as possible reduces the number of passes by the implement and the overall field preparation and configuration time. Consequently, the overall width of many of the agricultural implements has increased over time. The increased width, however, makes transport along public roads and highways difficult. In order to facilitate the transport and storage of these implements, the implement frames typically have been designed to utilize a main frame having one or more wing frames or members. These wing frames are typically connected to laterally opposite sides of the main frame so that the wing frames may be raised from positions that are substantially coplanar with the main frame (extended-working positions) to positions wherein the wing frames generally overlie or are generally perpendicular to the main frame (folded-transport or storage positions).
[0007] While the utilization of wing frames facilitates both objectives of working wide swaths of earth and transporting the implement along public roads and highways, the increased width of the implement while in the extended-working position together with the weight of the applicable earth working tools imposes significant axial and torsional forces that negatively impact the operational functionality of the implement. Accordingly, it would be beneficial to have an implement with wing frames that can support the applicable earth working tools and also manage the axial and torsional forces that are encountered when the wing frames are in the extended-working position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The structure and operation of the invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings in which:
[0009] FIG. 1 is a top frontal isometric view of the preferred embodiment of the present invention depicting the plowshares and rollers with the foldable wing members deployed in the extended-working position for operation;
[0010] FIG. 2 is top plan view of the preferred embodiment of the present invention with the wing members deployed in the extended-working position for operation;
[0011] FIG. 3 is a top frontal isometric view of the preferred embodiment of the present invention with the wing members in the folded-transport or storage position used for storage and transport;
[0012] FIG. 4 is a sectional elevation view from FIG. 2 showing a gauge wheel assembly according to an embodiment of the present invention;
[0013] FIG. 5 is a partial isometric top view from FIG. 3 showing a roller lock and a scraper plate according to an embodiment of the present invention;
[0014] FIG. 6 is a partial enlarged isometric view of a cylinder and a cylinder lock according to an embodiment of the present invention;
[0015] FIG. 7 is an isometric view of a cylinder lock from FIG. 6 ; and
[0016] FIG. 8 is frontal view of an embodiment of the present invention showing a seeder and showing the wing members in the folded-transport or storage position used for storage and transport.
[0017] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description presented herein are not intended to limit the invention to the particular embodiment disclosed. On the contrary, the invention is limited only by the claim language.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Generally speaking, the present invention contemplates a folding furrow roller that has wing members that may be selectively deployed from a folded-transport or storage position to an extended-working position that increases the overall width of the furrow roller, and that is capable of managing the axial and torsional forces that are encountered when the wing members are in the extended-working position so as to permit the folding furrow roller to efficiently prepare, configure, and plant fields with the result being fields that have uniform furrows and elevated seed beds. Throughout the description and the drawings, elements which are the same will be accorded the same reference numerals.
[0019] FIG. 1 is a top frontal isometric view of the preferred embodiment of the present invention. Folding furrow roller 50 is designed to be towed by a suitable motorized vehicle, such as a farm tractor (not shown), over a field 52 for preparation and configuration for planting. Arrow 10 depicts the operational direction of folding furrow roller 50 . Folding furrow roller 50 includes a rigid center frame member 54 and one or more outboard, foldable wing members 56 and 57 that may be selectively rotated between the extended-working position illustrated in FIG. 1 and a folded-transport or storage position illustrated in FIG. 3 . In a preferred embodiment, folding furrow roller 50 includes both foldable wing members 56 and 57 . Foldable wing members 56 and 57 may be selectively locked in either the extended-working position illustrated in FIG. 1 or the folded-transport or storage position illustrated in FIG. 3 for safety and stability. Center frame member 54 and foldable wing members 56 and 57 support and contain cylindrical rollers 54 A, 56 A, and 57 A, respectively.
[0020] Folding wing members 56 and 57 are connected to center frame member 54 and controlled by arms 72 . In one embodiment of the present invention, a pair of angularly inclined arms 72 are disposed on opposite top ends of both the front and rear of center frame member 54 and pivotally extend at an acute angle toward wing members 56 and 57 . Each of arms 72 pivotally terminate on the front and rear edges of bordering ends of wing members 56 and 57 , respectively, and are configured to manipulate wing members 56 and 57 between the extended-working position and the folded-transport or storage position. In a preferred embodiment of the present invention, arms 72 include hydraulic cylinders suitable for extending and folding wing members 56 and 57 . Hydraulic cylinders of this type are commonly available from various manufacturers. One suitable model of such cylinders is a 4 inch by 8 inch hydraulic cylinder manufactured by Monarch Industries of Winnipeg, Canada.
[0021] Folding furrow roller 50 includes a plurality of downwardly projecting plowshares 59 that are moveably attached to rigid beams 58 A, 58 B, and 58 C. Rigid beams 58 B, 58 A, and 58 C are attached to the front of wing member 56 , the front of center frame member 54 , and the front of wing member 57 , respectively. As folding furrow roller 50 is drawn about field 52 , plowshares 59 engage the ground and dig irrigation furrows that produce raised earthen mounds between the furrows. Gauge wheel assemblies 62 are connected to rigid beams 58 A and 58 C and provide additional support for folding furrow roller 50 as it is towed through field 52 .
[0022] The raised earthen mounds created by the soil pushed up from the furrows dug by plowshares 59 become the seed beds for the desired crops. Cylindrical rollers 54 A, 56 A, and 57 A smooth and compact the seed beds in a uniform manner. Because cylindrical rollers 54 A, 56 A, and 57 A are behind plowshares 59 , the irrigation furrows and the seed beds are not only created concurrently, but the seed beds are also concurrently smoothed and compacted in a uniform manner when folding furrow roller 50 is towed about field 52 .
[0023] FIG. 2 is top plan view of the preferred embodiment of the present invention with wing members 56 and 57 deployed in the extended-working position for operation, and depicts each of the elements of folding furrow roller 50 shown in FIG. 1 . Wing members 56 and 57 are not required to be the same length. Further, while center frame member 54 may be the same length as either of wing members 56 or 57 , center frame member 54 is not required to be the same length as either of wing members 56 or 57 . In a preferred embodiment of the present invention, wing members 56 and 57 are the same length and center frame member 54 is longer than wing members 56 and 57 . In one embodiment of the present invention, wing members 56 and 57 are between 99 and 100 inches in length and center frame member 54 is 180 inches in length. In yet another embodiment of the present invention, wing members 56 and 57 are between 128 and 129 inches in length and center frame member 54 is between 228 and 229 inches in length.
[0024] FIG. 3 is a top frontal isometric view of the preferred embodiment of the present invention with wing members 56 and 57 depicted in a folded-transport or storage position that may be used for transport and storage of folding furrow roller 50 . FIG. 3 depicts each of the elements of folding furrow roller 50 shown in FIG. 1 . In the preferred embodiment of folding furrow roller 50 , center frame member 54 and wing members 56 and 57 are rigid rectangular welded tubular steel frames. In one embodiment of the preferred invention, the tubular steel frames from which center frame member 54 and wing members 56 and 57 are constructed are {fraction (5/16)} inch thick steel and have an outer dimension of 5 inches by 7 inches. It will be appreciated that cylindrical rollers 54 A, 56 A, and 57 A may be constructed of any material such as steel or rugged plastic suitable for rolling over and uniformly compressing the applicable seed beds and connected to center frame member 54 and wing members 56 and 57 by way of stub shafts commonly known to those with ordinary skill in the relevant art. In one embodiment of the present invention, cylindrical rollers 54 A, 56 A, and 57 A are constructed of steel pipe closed on the ends with welded steel discs. In the preferred embodiment of the present invention, concentrically through each of cylindrical rollers 54 A, 56 A, and 57 A is an interior steel axle (not shown) having a diameter of 2.25 inches, both ends of which terminate in a pillow block 74 , a bearing support commonly understood by those with ordinary skill in the relevant art. In an alternative embodiment, center frame member 54 and wing members 56 and 57 may contain two or more cylindrical rollers.
[0025] Hitch connectors 75 A, 75 B, and 75 C include suitable pin holes and are connected to the front side of center frame member 54 and rigid beam 58 B and permit folding furrow roller 50 to be connected by way of a standard three-point hitch, a connection device commonly known to those with ordinary skill in the farm implement industry, to a suitable motorized vehicle, such as a farm tractor (not shown). The typical distance from the pin hole of top hitch connector 75 C to the center of cylindrical roller 54 A (hereinafter, the “centerline measurement”) is 50 inches or more. In a preferred embodiment of the present invention, the centerline measurement is less than 50 inches so as to substantially improve the ability of the applicable motorized towing device to lift folding furrow roller 50 and disengage folding furrow roller 50 from the ground particularly when wing members 56 and 57 are in a deployed extended-working position. In one embodiment of the present invention, the centerline measurement is 34 inches.
[0026] FIG. 4 is a sectional elevation view from FIG. 2 showing gauge wheel assembly 62 according to an embodiment of the present invention. In a preferred embodiment, additional support for folding furrow roller 50 is provided by a pair of gauge wheel assemblies 62 disposed substantially at each end of wing members 56 and 57 . Adjusting means 61 permits variable vertical and angular positioning of each of plowshares 59 . In a preferred embodiment of the present invention, adjusting means 61 includes a beam 62 vertically slideable in a fixed sleeve 70 and a plate 71 angularly moveable on slideable beam 62 , both mechanisms commonly understood by those with ordinary skill in the relevant art. Gauge wheel assembly 62 may include a tire 64 , wheel 65 , and axle 66 , and is attached to wing member 56 with commonly understood struts that may include adjustable linkages 67 . In addition to support for wing members 56 and 57 , in a preferred embodiment, gauge wheel assembly 62 provides, in cooperation with the three-point hitch connection, a means of affecting and gauging the vertical displacement of center frame member 54 and wing members 56 and 57 (and thereby, each of the corresponding cylindrical rollers—with cylindrical roller 56 A and its corresponding pillow block 74 depicted here) when wing members 56 and 57 are parallel and locked to center frame member 54 in their deployed extended-working position. Although not shown, it should be apparent to those skilled in the art that one or more gauge wheel assemblies may also be connected to center frame member 54 so as to provide additional support for folding furrow roller 50 . In another embodiment of the present invention, gauge wheel assemblies are disposed substantially at each end of center frame member 54 .
[0027] FIG. 5 is a partial isometric top view from FIG. 3 . In a preferred embodiment of the present invention, scraper plate 63 is attached to center frame member 54 parallel and close enough to cylindrical roller 54 A so as to perform a cleaning function. As cylindrical roller 54 A rolls over the elevated seed beds created by plowshares 59 ( FIG. 1 ), soil frequently accumulates on the outer surface of cylindrical roller 54 A. Scraper plate 63 extends the entire length of cylindrical roller 54 A and is bolted in place through one or more slots 68 in center frame member 54 so as to provide adjustability in the proximity of scraper plate 63 to cylindrical roller 54 A, and thereby permit scraper plate 63 to be adjusted for a variety of soil adhesion conditions and to the optimum position for wiping soil or mud from cylindrical roller 54 A while folding furrow roller 50 is towed through a field. In a preferred embodiment of the present invention, scraper plate 63 is constructed from 0.25 inch by 4.0 inch flat metal with a 0.5 inch by 1.5 inch hardened plow steel wear strip welded to the bottom of the flat metal. Although not shown, it should be apparent to those skilled in the art that the foregoing description with respect to scraper plate 63 may be applied to each of cylindrical rollers 56 A and 57 A as well as to cylindrical roller 54 A.
[0028] At any convenient location, pivot mount 80 is attached so that L-shaped locking lug 81 may pivot and be capable of engaging a slot 82 in cylindrical roller 54 A configured to receive L-shaped locking lug 81 , and thereby, prevent rotation of cylindrical roller 54 A. Pivot mount 80 is particularly useful when folding furrow roller 50 is in a folded-transport or storage position for storage or transport. Locking lug 81 may be pinned or cabled or otherwise configured so as to be prevented from engaging slot 82 during operation of folding furrow roller 50 . In a preferred embodiment of the present invention, pivot mount 80 is attached to hinge plate 54 E of center frame member 54 . Although not shown, it should be apparent to those skilled in the art that the foregoing description with respect to pivot mount 80 , locking lug 81 , and slot 82 may be applied to each of wing members 56 and 57 and each of cylindrical rollers 56 A and 57 A as well as to center frame member 54 and cylindrical roller 54 A.
[0029] Wing members 56 and 57 are pivotally connected to center frame member 54 by way of hinge plates or other suitable connection devices. In a preferred embodiment of the present invention, pair of hinge plates 54 D and 54 E are located on opposite top ends of center frame member 54 (on each of the front and rear edges of these top ends of center frame member 54 ), and wing member 57 has a pair of hinge plates 57 D and 57 E on the top end of wing member 57 located adjacent to center frame member 54 configured so as to pivotally connect to center frame member 54 . Each pair of hinge plates 54 D and 54 E is configured to receive each corresponding pair of hinge plates 57 D and 57 E. In a preferred embodiment of the present invention, hinge plates 54 D and 54 E are on the outside edges of hinge plates 57 D and 57 E, respectively. Each pair of hinge plates 54 D, 54 E, 57 D, and 57 E are configured to be pivotally connected to one another using stub shafts or other suitable connection means well known to those with ordinary skill in the relevant art. In one embodiment of the present invention, each pair of hinge plates 54 D, 54 E, 57 D, and 57 E is pivotally connected to each other by way of hinge pin 57 F which traverses the entire distance from hinge plate 54 D on the front edge of center frame member 54 to hinge plate 54 D on the rear edge of center frame member 54 so as to provide maximum resistance to axial and torsional forces that may be encountered by wing member 57 . In a preferred embodiment of the present invention, hinge pin 57 F is a solid steel shaft having a diameter of at least 2 inches. Also in a preferred embodiment of the present invention, arms 72 include hydraulic cylinders. With respect to the one of these hydraulic cylinders, one end is connected to hinge plate 57 D on the front edge of wing member 57 and the other end is connected to the front edge of center member 54 . With respect to another of these hydraulic cylinders, one end is connected to hinge plate 57 D on the rear edge of wing member 57 and the other end is connected to the rear edge of center member 54 . The connection of arms 72 to each of hinge plates 57 D provides the improved benefit of allowing arms 72 to pull from points close to the pivot points of wing frame 57 , and thereby, avoid the need for long connecting arms that are subject to torsional and potentially damaging bending forces. Although not shown, it should be apparent to those skilled in the art that the foregoing description with respect to the connection of wing member 57 to center frame member 54 and the connection of arms 72 to each of hinge plates 57 D may be applied to the pivotal connection of wing member 56 to the opposite end of center frame member 54 .
[0030] FIG. 6 is a partial enlarged isometric view of arm 72 (which is depicted as hydraulic cylinder) connected to hinge plate 57 D and a cylinder lock 121 according to an embodiment of the present invention. Cylinder lock 121 permits hydraulic cylinder 72 to be selectively locked after wing members 56 and 57 are rotated into their extended-working position or their folded-transport or storage position.
[0031] FIG. 7 is an isometric view of cylinder lock 121 from FIG. 6 . Cylinder lock 121 is a U-shaped steel block having an open region 122 configured to receive an exposed ram of hydraulic cylinder 72 having a through-hole that lines up with a hole in each leg of the U-shaped-block of cylinder lock 121 so that a removable retainer pin 124 , normally held by a retainer cable 125 which is connected to cylinder lock 121 penetrates, through the exposed ram of hydraulic cylinder 72 and the opposing legs of lock 121 to lock hydraulic cylinder 72 in the desired position. Cylinder lock 121 may be used to lock wing members 56 and 57 in a deployed extended-working position. Further, cylinder lock 121 may be configured to lock wing members 56 and 57 in a folded transport or storage position. When not in use, cylinder lock 121 may be pinned to any convenient member of folding furrow roller 50 capable of fitting in open region 122 and having a hole capable of receiving pin 124 .
[0032] FIG. 8 is frontal view of an embodiment of the present invention with wing members 56 and 57 in the folded-transport or storage position. Seeder bins 90 A, 90 B, and 90 C are selectively mounted above cylindrical rollers 54 A, 56 A, and 57 A, respectively, by way of mounting arms 91 A, 91 B, and 91 C, and are configured to hold seed. Feeder tubes 92 are connected to seeder bins 90 A, 90 B, and 90 C, respectively, and configured for lateral adjustment so as to be centered between each of plow shares 59 . In a preferred embodiment of the present invention, feeder tubes 92 are positioned so as to be substantially perpendicular to seeder bins 90 A, 90 B, and 90 C and substantially parallel to each of plow shares 59 . In one embodiment of the present invention, seeder bins 90 A, 90 B, and 90 C are configured so as to distribute their respective weight (particularly when loaded with seed) evenly and directly over cylindrical rollers 54 A, 56 A, and 57 A, and thereby aid with the smoothing and compaction of the seed beds. In another embodiment of the present invention seeder bins 90 A, 90 B, and 90 C are configured to be connected to the rear of center frame member 54 and foldable wing members 56 and 57 . In yet another embodiment of the present invention, a single seeder bin may be connected to the rear of furrow roller 50 . As furrow roller 50 is drawn through the field, plowshares 59 dig irrigation furrows that produce raised earthen mounds between the furrows, seeds from seeder bins 90 A, 90 B, and 90 C flow through feeder tubes 92 are deposited into the raised earthen mounds produced by plowshares 59 , and cylindrical rollers 54 A, 56 A, and 57 A smooth and compact these raised earthen mounds so as to create uniform, raised, and planted seed beds separated by uniform irrigation furrows concurrently in one operation.
[0033] It will be apparent to those with ordinary skill in the relevant art having the benefit of this disclosure that the present invention provides a foldable furrow roller with deployable wing members that is highly stabilized when deployed, but capable of easy reconfiguration for stable use, and for easy and legal transport. It is understood that the forms of the invention shown and described in the detailed description and the drawings are to be taken merely as presently preferred examples and that the invention is limited only by the language of the claims. While the present invention has been described in terms of one preferred embodiment and a few variations thereof, it will be apparent to those skilled in the art that form and detail modifications may be made to those embodiments without departing from the spirit or scope of the invention. | A folding furrow roller that facilitates planting operations and optimization of irrigation and drainage with efficient preparation, configuration, and planting of seed beds. A centrally located fixed drum roller supports a pair of hinged outboard drum roller wings that for maximum implement width are deployed in alignment with the main section during operation. The wings are hydraulically folded into a compact upright position for legal transport over public roads. The implement is constructed so as to provide strength and durability comparable to single-section furrow rollers. | 0 |
FIELD OF THE INVENTION
The invention generally relates to flash-spinning polymeric film-fibril strands. More particularly, the invention concerns an improvement in such a process which permits flash-spinning of the strands from C 1-4 alcohol-based spin liquids which, if released to the atmosphere, would not detrimentally affect the earth's ozone layer.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 3,081,519 (Blades et al.) describes a flash-spinning process for producing plexifilamentary film-fibril strands from fiber-forming polymers. A solution of the polymer in a liquid, which is a non-solvent for the polymer at or below its normal boiling point, is extruded at a temperature above the normal boiling point of the liquid and at autogenous or higher pressure into a medium of lower temperature and substantially lower pressure. This flash-spinning causes the liquid to vaporize and thereby cool the exudate which forms a plexifilamentary film-fibril strand of the polymer. Preferred polymers include crystalline polyhydrocarbons such as polyethylene and polypropylene.
According to Blades et al., in both U.S. Pat. No. 3,081,519 and U.S. Pat. No. 3,227,784, a suitable liquid for the flash spinning desirably (a) has a boiling point that is at least 25 C. below the melting point of the polymer; (b) is substantially unreactive with the polymer at the extrusion temperature; (c) should be a solvent for the polymer under the pressure and temperature set forth in the patent (i.e., these extrusion temperatures and pressures are respectively in the ranges of 165 to 225 C. and 545 to 1490 psia); (d) should dissolve less than 1% of the polymer at or below its normal boiling point; and should form a solution that will undergo rapid phase separation upon extrusion to form a polymer phase that contains insufficient solvent to plasticize the polymer. Depending on the particular polymer employed, the following liquids are useful in the flash-spinning process: aromatic hydrocarbons such as benzene, toluene, etc.; aliphatic hydrocarbons such as butane, pentane, hexane, heptane, octane, and their isomers and homologs; alicyclic hydrocarbons such as cyclohexane; unsaturated hydrocarbons; halogenated hydrocarbons such as trichlorofluoromethane, methylene chloride, carbon tetrachloride, chloroform, ethyl chloride, methyl chloride; alcohols; esters; ethers; ketones; nitriles; amides; fluorocarbons; sulfur dioxide; carbon disulfide; nitromethane; water; and mixtures of the above liquids. The patents illustrate certain principles helpful in establishing optimum spinning conditions to obtain plexifilamentary strands. Blades et al. state that the flash-spinning solution additionally may contain a dissolved gas, such as nitrogen, carbon dioxide, helium, hydrogen, methane, propane, butane, ethylene, propylene, or butene, to assist nucleation by increasing the "internal pressure" and lowering the surface tension of the solution. Preferred for improving plexifilamentary fibrillation are the less soluble gases, i.e., those that are dissolved to a less than 7% concentration in the polymer solution under the spinning conditions. Common additives, such as antioxidants, UV stabilizers, dyes, pigments and the like also can be added to the solution prior to extrusion.
U.S Pat. 3,227,794 (Anderson et al.) discloses a diagram similar to that of Blades et al. for selecting conditions for spinning plexifilamentary strands. A graph is presented of spinning temperature versus cloud-point pressure for solutions of 10 to 16 weight percent of linear polyethylene in trichlorofluoromethane. Anderson et al. describe in detail the preparation of a solution of 14 weight percent high density linear polyethylene in trichlorofluoromethane at a temperature of about 185 C. and a pressure of about 1640 psig which is then flash-spun from a let-down chamber at a spin temperature of 185 C. and a spin pressure of 1050 psig. Very similar temperatures, pressures and concentrations have been employed in commercial flash-spinning of polyethylene into plexifilamentary film-fibril strands, which were then converted into sheet structures.
Although trichlorofluoromethane has been a very useful solvent for flash-spinning plexifilamentary film-fibril strands of polyethylene, and has been the dominant solvent used in commercial manufacture of polyethylene plexifilamentary strands, the escape of such a halocarbon into the atmosphere has been implicated as a source of depletion of the earth's ozone layer. A general discussion of the ozone-depletion problem is presented, for example, by P. S. Zurer, "Search Intensifies for Alternatives to Ozone-Depleting Halocarbons", Chemical & Engineering News. pages 17-20 (Feb. 8, 1988).
Clearly, what is needed is a flash-spinning process which uses a spin liquid which does not have the deficiencies inherent in the prior art. It is therefore an object of this invention to provide an improved process for flash-spinning plexifilamentary film-fibril strands of a fiber-forming polymer, wherein the spin liquid used for flash-spinning is not a depletion hazard to the earth's ozone layer. Other objects and advantages of the present invention will become apparent to those skilled in the art upon reference to the detailed description of the invention which hereinafter follows.
SUMMARY OF THE INVENTION
In accordance with the invention, there is provided a process for flash-spinning plexifilamentary film-fibril strands of a fiber-forming polyolefin. Preferably, the polyolefin is selected from the group consisting of polyethylene, polypropylene and polymethylpentene.
In one embodiment, the invention comprises a process for flash-spinning plexifilamentary film-fibril strands wherein a polyolefin is dissolved in a spin liquid to form a spin mixture containing 1 to 35 percent of polyolefin by weight of the spin mixture at a temperature in the range of 130 to 300 C. and a mixing pressure that is greater than the autogeneous pressure of the spin mixture, preferably greater than the cloud point pressure of the spin mixture, which spin mixture is flash-spun into a region of substantially lower temperature and pressure. The improvement comprises the spin liquid comprising an alcohol spin liquid containing from 1 to 4 carbon atoms. Preferably, the C 1-4 alcohol spin liquid is selected from the group consisting of methanol, ethanol, 1-propanol, 2-propanol, tertiary butanol and mixtures thereof.
In a preferred mode of the first embodiment, the invention comprises a process for flash-spinning plexifilamentary film-fibril strands wherein polyethylene is dissolved in a spin liquid to form a spin mixture containing 1 to 35 percent of polyethylene by weight of the spin mixture at a temperature in the range of 130 to 300 C. and a mixing pressure that is greater than the autogeneous pressure of the spin mixture, preferably greater than the cloud-point pressure of the spin mixture, which spin mixture is flash-spun into a region of substantially lower temperature and pressure. The improvement comprises the spin liquid being selected from the group consisting of 1-propanol, 2-propanol and mixtures thereof.
In another preferred mode of the first embodiment, the invention comprises a process for flash-spinning plexifilamentary film-fibril strands wherein polypropylene is dissolved in a spin liquid to form a spin mixture containing 1 to 35 percent of polypropylene by weight of the spin mixture at a temperature in the range of 130 to 300 C. and a mixing pressure that is greater than the autogeneous pressure of the spin mixture, preferably greater than the cloud-point pressure of the spin mixture, which spin mixture is flash-spun into a region of substantially lower temperature and pressure. The improvement comprises the spin liquid being selected from the group consisting of ethanol, 1-propanol, 2-propanol and mixtures thereof.
In another embodiment, the invention comprises a process for flash-spinning plexifilamentary film-fibril strands wherein a polyolefin is dissolved in a spin liquid to form a spin mixture containing 1 to 35 percent of polyolefin by weight of the spin mixture at a temperature in the range of 130 to 300 C. and a mixing pressure that is greater than the autogeneous pressure of the spin mixture, preferably greater than the cloud-point pressure of the spin mixture, which spin mixture is flash-spun into a region of substantially lower temperature and pressure. The improvement comprises the spin liquid comprising an alcohol/co-solvent spin liquid wherein the alcohol contains from 1 to 4 carbon atoms and the co-solvent is capable of lowering the cloud-point pressure of the resulting spin mixture by at least 200 psig at the polyolefin concentration and the spin temperature used for flash-spinning. The co-solvent is a strong solvent for the polyolefin and is present in an amount up to 50 percent by weight of the total alcohol/co-solvent spin liquid present. Preferably, the C 1-4 alcohol spin liquid is selected from the group consisting of methanol, ethanol, 1-propanol, 2-propanol, tertiary butanol and mixtures thereof while the co-solvent comprises a hydrocarbon having from 4 to 7 carbon atoms. Preferably, the hydrocarbon co-solvent is selected from the group consisting of butane, pentane, hexane, cyclobutane, cyclopentane, cyclohexane, their isomers and mixtures thereof.
In yet another embodiment, the invention comprises a process for flash-spinning plexifilamentary film-fibril strands wherein a polyolefin is dissolved in a spin liquid to form a spin mixture containing 1 to 35 percent of polyolefin by weight of the spin mixture at a temperature in the range of 130 to 300 C. and a mixing pressure that is greater than the autogeneous pressure of the spin mixture, preferably greater than the cloud-point pressure of the spin mixture, which spin mixture is flash-spun into a region of substantially lower temperature and pressure. The improvement comprises the spin liquid comprising an alcohol/co-solvent spin liquid wherein the alcohol contains from 1 to 4 carbon atoms and the co-solvent is capable of raising the cloud-point pressure of the resulting spin mixture by at least 200 psig at the polyolefin concentration and the spin temperature used for flash-spinning. The co-solvent is a non-solvent for the polyolefin and is present in an amount up to 50 percent by weight of the total alcohol/co-solvent spin liquid present. Preferably, the C 1-4 alcohol spin liquid is selected from the group consisting of methanol, ethanol, 1-propanol, 2-propanol, tertiary butanol and mixtures thereof. Preferably, the co-solvent spin liquid is selected from the group consisting of inert gases such as nitrogen and carbon dioxide; water; polar solvents such as ketones and ethers; perfluorinated hydrocarbons; hydrofluorocarbons (HFC's); hydrochlorofluorocarbons (HCFC's); and mixtures thereof.
The invention also provides a novel flash-spinning spin mixture for forming plexifilamentary film-fibril strands comprising 1 to 35 weight percent of a fiber-forming polyolefin, preferably polyethylene, polypropylene or polymethylpentene, and 65 to 99 weight percent of a spin liquid, the spin liquid comprising an alcohol spin liquid selected from the group consisting of methanol, ethanol, 1-propanol, 2-propanol, tertiary butanol and mixtures thereof.
In another embodiment the invention provides a novel flash-spinning spin mixture for forming plexifilamentary film-fibril strands comprising 1 to 35 weight percent of a fiber-forming polyolefin, preferably polyethylene, polypropylene or polymethylpentene, and 65 to 99 weight percent of a spin liquid, the spin liquid comprising no less than 50 weight percent of an alcohol spin liquid selected from the group consisting of methanol, ethanol, 1-propanol, 2-propanol, tertiary butanol and mixtures thereof, and no more than 50 weight percent of a co-solvent spin liquid comprising a hydrocarbon containing from 4 to 7 carbon atoms. Preferably, the hydrocarbon is selected from the group consisting of butane, pentane, hexane, cyclobutane, cyclopentane, cyclohexane, their isomers and mixtures thereof.
In yet another embodiment, the invention provides a novel flash-spinning spin mixture for forming plexifilamentary film-fibril strands comprising 1 to 35 weight percent of a fiber-forming polyolefin, preferably polyethylene, polypropylene or polymethylpentene, and 65 to 99 weight percent of a spin liquid, the spin liquid comprising no less than 50 weight percent of an alcohol spin liquid selected from the group consisting of methanol, ethanol, 1-propanol, 2-propanol, tertiary butanol and mixtures thereof, and no more than 50 weight percent of a co-solvent spin liquid selected from the group consisting of inert gases such as nitrogen and carbon dioxide; water; polar solvents such as ketones and ethers; perfluorinated hydrocarbons; hydroflurocarbons (HFC's); hydrochlorofluorocarbons (HCFC's); and mixtures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The following figures are provided to illustrate the cloud-point pressures curves of selected spin mixtures at varying spin liquid concentrations and spin temperatures:
FIG. 1 is a cloud-point pressure curve for 30 weight percent high density polyethylene in various 100 wt. % alcohol spin liquids.
FIG. 2 is a cloud-point pressure curve for various weight percentages of high density polyethylene in a 1-propanol spin liquid.
FIG. 3 is a cloud-point pressure curve for 22 weight percent high density polyethylene in various concentrations of an ethanol/cyclohexane spin liquid.
FIG. 4 is a cloud-point pressure curve for 22 weight percent polypropylene in various alcohol spin liquids.
FIG. 5 is a cloud-point pressure curve for 22 weight percent polymethylpentene in an ethanol spin liquid.
FIG. 6 is a cloud-point pressure curve for various weight percentages of polypropylene in a 90 wt. % 1-propanol/10 wt. % water spin liquid.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The term "polyolefin" as used herein, is intended to mean any of a series of largely saturated open chain polymeric hydrocarbons composed only of carbon and hydrogen. Typical polyolefins include, but are not limited to, polyethylene, polypropylene, and polymethylpentene. Conveniently, polyethylene and polypropylene are the preferred polyolefins for use in the process of the present invention.
"Ethanol" as used herein is intended to mean not only pure ethanol but also denatured ethanol (e.g., ethyl alcohol containing small amounts of methanol, benzene, toluene, etc.). It will be understood that there are many different types of denatured ethanol. One of the most common types is "2-B alcohol", which contains one-half gallon of benzene or one-half gallon of rubber hydrocarbon solvent per 100 gallons of ethyl alcohol.
"Polyethylene" as used herein is intended to embrace not only homopolymers of ethylene, but also copolymers wherein at least 85% of the recurring units are ethylene units. One preferred polyethylene is a linear high density polyethylene which has an upper limit of melting range of about 130 to 135 C., a density in the range of 0.94 to 0.98 g/cm 3 and a melt index (as defined by ASTM D-1238-57T, Condition E) of between 0.1 to 100, preferably less than 4.
The term "polypropylene" is intended to embrace not only homopolymers of propylene but also copolymers wherein at least 85% of the recurring units are propylene units.
The term "plexifilamentary film-fibril strands" as used herein, means a strand which is characterized as a three-dimensional integral network of a multitude of thin, ribbon-like, film-fibril elements of random length and of less than about 4 microns average thickness, generally coextensively aligned with the longitudinal axis of the strand. The film-fibril elements intermittently unite and separate at irregular intervals in various places throughout the length, width and thickness of the strand to form the three-dimensional network. Such strands are described in further detail in U.S. Pat. No. 3,081,519 (Blades et al.) and in U.S. Pat. No. 3,227,794 (Anderson et al.), the contents of which are incorporated herein.
The term "cloud-point pressure" as used herein, means the pressure at which a single phase liquid solution starts to phase separate into a polyolefin-rich/spin liquid-rich two phase liquid dispersion.
The term "co-solvent spin liquid" as used herein, means a miscible spin liquid that is added to an alcohol spin liquid containing a dissolved polyolefin to either raise or lower the cloud-point pressure of the resulting spin mixture (i.e., the co-solvent, alcohol spin liquid and polyolefin) by 200 psig, preferably by 500 psig or even more, at the polyolefin concentration and the spin temperature used for flash-spinning.
To raise the cloud-point pressure the co-solvent spin liquid must be a "non-solvent" for the polyolefin, or at least a poorer solvent than the alcohol spin liquid. (In other words, the solvent power of the co-solvent spin liquid used must be such that if the polyolefin to be flash-spun were to be dissolved in the co-solvent spin liquid alone, the polyolefin would not dissolve in the co-solvent spin liquid, or the resultant solution would have a cloud-point pressure greater than about 7000 psig). Preferably, in this application the co-solvent spin liquid is an inert gas such as carbon dioxide or nitrogen; water; a polar solvent such as a ketone or an ether; a perfluorinated hydrocarbon; a hydrofluorocarbon (HFC); a hydrochlorofluorocarbon (HCFC); and mixtures thereof. The co-solvent spin liquid must be present in an amount no greater than 50 weight percent of the total weight of the co-solvent spin liquid and the alcohol spin liquid. It will be understood that the co-solvent spin liquid can be made up of one co-solvent or mixtures of co-solvents.
To lower the cloud-point pressure the co-solvent spin liquid must be a "strong solvent" for the polyolefin, or at least a better solvent than the alcohol spin liquid. (In other words, the solvent power of the co-solvent spin liquid used must be such that if the polyolefin to be flash-spun were to be dissolved in the co-solvent spin liquid alone, the polyolefin would easily dissolve in the co-solvent spin liquid, or the resultant solution would have a lower cloud-point pressure than it would have without addition of the co-solvent. Preferably, in this application the co-solvent spin liquid is a hydrocarbon having from 4 to 7 carbon atoms (e.g., butane, pentane, hexane, cyclobutane, cyclopentane, cyclohexane, their isomers, and mixtures thereof). The co-solvent spin liquid must be present in an amount no greater than 50 weight percent of the total weight of the co-solvent spin liquid and the alcohol spin liquid. It will be understood that the co-solvent spin liquid can be made up of one co-solvent or mixtures of co-solvents.
The present invention provides an improvement in the known process for producing plexifilamentary film-fibril strands of fiber-forming polyolefins from a spin liquid that contains the fiber-forming polyolefin. In the known processes, which were described in the above-mentioned U.S. patents, a fiber-forming polyolefin, e.g. linear polyethylene, is typically dissolved in a spin liquid that includes a halocarbon to form a spin solution containing about 10 to 20 percent of the linear polyethylene by weight of the solution and then is flash-spun at a temperature in the range of 130 to 230 C. and a pressure that is greater than the autogenous pressure of the spin liquid into a region of substantially lower temperature and pressure.
The key improvement of the present invention requires that the spin liquid comprise a C 1-4 alcohol or a C 1-4 alcohol/co-solvent spin liquid that has no or greatly reduced ozone depletion potential. In this invention, well-fibrillated plexifilamentary film-fibril strands can be successfully produced using a C 1-4 alcohol spin liquid or a C 1-4 alcohol spin liquid combined with a co-solvent spin liquid. It will be understood that the C 1-4 alcohol spin liquid can comprise a single C 1-4 alcohol or mixtures thereof. As noted above, the purpose of adding the co-solvent spin liquid to the C 1-4 alcohol spin liquid is to either raise or lower the cloud-point pressure of the resulting spin mixture, as the case may be.
FIGS. 1-6 illustrate cloud-point pressure curves for a selected number of 100 wt. % C 1-4 alcohol spin liquids and a selected number of C 1-4 alcohol/co-solvent spin liquids in accordance with the invention. The Figures provide the cloud-point pressure for particular spin liquids as a function of spin temperature in degrees C.
The following Table lists the known normal atmospheric boiling point (Tbp), critical temperature (Tcr), critical pressure (Pcr), heat of vaporization (H of V), density (gm/cc) and molecular weights (MW) for CFC-11 and for several selected co-solvents spin liquids and alcohol spin liquids useful in the invention. In the Table, the parenthetic designation is an abbreviation for the chemical formula of certain well known halocarbons (e.g., trichlorofluoromethane=CFC-11).
__________________________________________________________________________Spin Liquid Properties Tbp Tcr Pcr H of V Density C. C. psia cal/gm gm/cc MW__________________________________________________________________________(CFC-11) 23.80 198.0 639.5 43.3 1.480 137.368Isobutane -11.75 135.1 529.3 -- 0.557 58.124Butane -0.45 152.1 551.0 87.5 0.600 58.124Cyclobutane 12.55 186.9 723.6 -- 0.694 56.1082-methyl butane 27.85 187.3 491.6 -- 0.620 72.1512,2 dimethyl 9.45 160.6 464.0 -- 0.591 72.151propanePentane 36.10 196.6 488.7 91.0 0.630 72.151Methyl 39-42 -- -- -- 0.693 70.135cyclobutaneCyclopentane 49.25 238.6 654.0 -- 0.745 70.1352,2-dimethylbutane 49.65 215.7 446.6 -- 0.649 86.1782,3-dimethylbutane 57.95 226.9 453.9 -- 0.662 86.1782-methylpentane 60.25 224.4 436.5 -- 0.653 86.1783-methylpentane 63.25 231.4 452.4 -- 0.664 86.178Hexane 68.80 234.4 436.5 -- 0.660 86.178Methyl 71.85 259.6 548.1 -- 0.754 84.162cyclopentaneCyclohexane 80.70 280.3 590.1 -- 0.780 84.1622-methyl hexane 90.05 257.2 395.8 -- 0.679 100.2053-methyl hexane 91.85 262.1 407.4 -- 0.687 100.205Heptane 98.50 267.2 397.3 -- 0.684 100.205Methanol 64.60 239.5 1173 263.0 0.790 32.042Ethanol 78.30 240.8 890.3 204.0 0.789 46.069Propanol 97.15 263.7 749.7 -- 0.804 60.096Isopropanol 82.25 235.2 690.2 -- 0.786 60.0962-butanone 79.55 263.7 610.5 -- 0.805 72.107tert-butyl 82.35 233.1 575.7 -- 0.787 74.123alcoholCarbon dioxide Sublimes 31.0 1070.1 -- -- 44.010Nitrogen -195.8 -147 491.6 -- -- 28.013Water 100.0 374.2 3207.4 556.9 1.000 18.015Methylene 39.85 236.9 913.5 -- 1.317 84.933Chloride(HFC-125) -48.50 -- -- -- -- 120.00(HFC-134a) -26.50 113.3 652.0 52.4 1.190 --(HFC-152a) -24.70 -- -- 78.7 0.970 --__________________________________________________________________________
The following Table lists the weight ratio (Wt. Ratio) and known normal atmospheric boiling point (Tbp) for a few selected azeotropes useful in the invention. It will be understood that this list in non-limiting and that other alcohol/co-solvent azeotropes are useful in the invention.
______________________________________AzeotropesCo-solvent AlcoholSpin Liquid Spin Liquid Wt. Ratio Tbp (C.)______________________________________n-heptane* Methanol 48.5/51.5 59.1n-heptane* 2-propanol 49.5/50.5 76.4Methyl Methanol 46/54 59.2cyclohexane*Methyl 2-propanol 47/53 77.6cyclohexane*Water** 2-propanol 12.2/87.8 79.5Water** 1-propanol 28.3/71.7 87.7Water*** Ethanol 4/96 78.2______________________________________ *Taken from "Physical and Azeotropic Data" by G. Claxton, National Benzol and Allied Products Association (N.B.A.), 1958. **Taken from Industrial Solvents Handbook, 3rd Edition, Ed. E. W. Flick, Noyes Data Corporation (1985). ***Taken from CRC Handbook of Chemistry and Physics, 72nd Edition, Ed. D. R. Lide, CRC (1991).
In forming a spin mixture of fiber-forming polyolefin in the C 1-4 alcohol or C 1-4 alcohol/co-solvent spin liquids of the invention, a mixture of the fiber-forming polyolefin and spin liquid is raised to a mixing/spinning temperature in the range of 130 to 300 C. Mixing pressures less than the cloud-point pressure can be used as long as good mechanical mixing is provided to maintain a fine two phase dispersion (e.g., spin liquid-rich phase dispersed in polyolefin-rich phase). The mixtures described above are held under the required mixing pressure until a solution or a fine dispersion of the fiber-forming polyolefin is formed in the spin liquid. Usually, maximum pressures of less than 10,000 psig are satisfactory. After the fiber-forming polyolefin has dissolved, the pressure may be reduced somewhat and the spin mixture is then flash-spun to form the desired well fibrillated, plexifilamentary film-fibril strand structure.
It has been determined that for polypropylene and polymethylpentene that the mixing and spinning pressures should typically be greater than about 500 psig. It has also been determined for polyethylene that the mixing and spinning pressures should typically be greater than about 1,000 psig.
The concentration of fiber-forming polyolefin in the C 1-4 alcohol or C 1-4 alcohol/co-solvent spin liquid usually is in the range of 1-35 percent of the total weight of the spin liquid and the fiber-forming polyolefin. Higher polyolefin concentrations can be used (i.e., 30-35 wt. %) than are possible with hydrocarbon spin liquids (halogenated or non-halogenated) because of the alcohol's higher heat of vaporization and quenching power.
Conventional polyolefin or polymer additives can be incorporated into the spin mixtures by known techniques. These additives can function as ultraviolet-light stabilizers, antioxidants, fillers, dyes, and the like.
The various characteristics and properties mentioned in the preceding discussion and in the Tables and Examples which follow were determined by the following procedures:
Test Methods
Fibrillation level (FIB LEVEL) or quality of the plexifilamentary film-fibril strands produced in the Examples was rated subjectively. A rating of "5" indicates that the strand had better fibrillation than is usually achieved in the commercial production of spunbonded sheet made from flash-spun polyethylene strands. A rating of "4" indicates that the strand was as good as commercially flash-spun strands. A rating of "3" indicates that the strands were not quite as good as commercially flash-spun strands. A "2" rating indicates a very poorly fibrillated, inadequate strand. A "1" rating indicates no strand formation. A rating of "3" is the minimum considered satisfactory for use in the process of the present invention. The commercial strand product is produced from solutions of about 12.5% linear polyethylene in trichlorofluoromethane substantially as set forth in U.S. Pat. No. 4,554,207 (Lee), column 4, line 63, through column 5, line 10, which disclosure is hereby incorporated by reference.
Surface area of the plexifilamentary film-fibril strand product is another measure of the degree and fineness of fibrillation of the flash-spun product. Surface area is measured by the BET nitrogen absorption method of S. Brunauer, P. H. Emmett and E. Teller, J. Am. Chem Soc., V. 60 p 309-319 (1938) and is reported as m 2 /gm.
Tenacity of the flash-spun strand is determined with an Instron tensile-testing machine. The strands are conditioned and tested at 70 F. and 65% relative humidity. The sample is then twisted to 10 turns per inch and mounted in the jaws of the Instron Tester. A 1-inch gauge length and an elongation rate of 60% per minute are used. The tenacity (T) at break is recorded in grams per denier (GPD).
Denier (DEN) of the strand is determined from the weight of a 15 cm sample length of strand.
Elongation (E%) of the flash-spun strand is measured as elongation at break and is reported as a percentage.
The invention is illustrated in the non-limiting Examples which follow with a batch process in equipment of relatively small size. Such batch processes can be scaled-up and converted to continuous flash-spinning processes that can be performed, for example, in the type of equipment disclosed by Anderson and Romano, U.S. Pat. No. 3,227,794. Parts and percentages are by weight unless otherwise indicated.
EXAMPLES
Description of Apparatus and Operating Procedures
The apparatus used in the following Examples consists of two high pressure cylindrical chambers, each equipped with a piston which is adapted to apply pressure to the contents of the vessel. The cylinders have an inside diameter of 1.0 inch (2.54×10 -2 m) and each has an internal capacity of 50 cubic centimeters. The cylinders are connected to each other at one end through a 3/32 inch (2.3×10 -3 m) diameter channel and a mixing chamber containing a series of open mesh screens used as a static mixer. Mixing is accomplished by forcing the contents of the vessel back and forth between the two cylinders through the static mixer. A spinneret assembly with a quick-acting means for opening the orifice is attached to the channel through a tee. The spinneret assembly consists of a lead hole of 0.25 inch (6.3×10 -3 m) diameter and about 2.0 inch (5.08× 10 -2 m) length, and a spinneret orifice of 0.030 inch (7.62×10 -4 m) diameter and 0.030 inches length. The pistons are driven by high pressure water supplied by a hydraulic system.
In operation, the apparatus is charged with polyethylene or polypropylene pellets and spin liquids. High pressure water (e.g. 1800 psi (12410 kPa)) is introduced to drive the piston to compress the charge. The contents then are heated to mixing temperature and when the desired temperature is reached, pressure is increased to the final mixing pressure. The contents are held at the mixing temperature for about an hour or longer during which time a differential pressure of about 50 psi (345 kPa) or higher is alternatively established between the two cylinders to repeatedly force the contents through the mixing channel from one cylinder to the other to provide mixing and affect formation of a spin mixture. The pressure letdown chambers, as disclosed in Anderson et al., were not used in these spinning Examples. Instead, the accumulator pressure was set to that desired for spinning at the end of the mixing cycle to simulate the letdown chamber effect. Next, the valve between the spin cell and the accumulator is opened, and then the spinneret orifice is opened immediately thereafter in rapid succession. The resultant flash-spun product is collected in a stainless steel open mesh screen basket. Because of the relatively small amount of material and high pressure used, most of the spins in these Examples lasted only a fraction of a second (e.g., 0.1 to 0.5 seconds).
It usually takes about two to five seconds to open the spinneret orifice after opening the valve between the spin cell and the accumulator. When letdown chambers are used, the residence time in the chamber is usually 0.2 to 0.8 seconds. However, it has been determined that residence time does not have too much effect on fiber morphology and/or properties as long as it is greater than about 0.1 second but less than about 30 seconds. When the valve between the spin cell and the accumulator is opened, the pressure inside the spin cell drops immediately from the mixing pressure to the accumulator pressure. The spin cell pressure drops again when the spinneret orifice is opened because of the pressure drop in the line. The pressure is measured during spinning just before the spinneret with a pressure transducer using a computer and is entered as the spin pressure in the Examples. It is usually lower than the set accumulator pressure by about 100 to 500 psig. Therefore, the quality of the two phase dispersion in the spin cell depends on both the accumulator pressure and the spin pressure, and the time at those pressures. Sometimes the accumulator pressure is set at a pressure higher than the cloud point pressure. In this case, the quality of the two phase dispersion in the spin cell will be determined primarily by the spin pressure reached after the spinneret orifice is opened.
The morphology of plexifilamentary strands obtained by this process is greatly influenced by the level of pressure used for spinning. When the spin pressure is much greater than the cloud-point pressure of the spin mixture, "yarn-like" strands are usually obtained. Conversely, as the spin pressure is gradually decreased, the average distance between the tie points becomes very short while the strands become progressively finer. When the spin pressure approaches the cloud-point pressure of the spin mixture, very fine strands are obtained, but the distance between the tie points become very short and the resultant product looks somewhat like a porous membrane. As the spin pressure is further reduced below the cloud-point pressure, the distance between the tie points starts to become longer. Well fibrillated plexifilaments, which are most suitable for sheet formation, are usually obtained when spin pressures slightly below the cloud point pressure are used. The use of pressures which are too much lower than the cloud-point pressure of the spin mixture generally leads to a relatively coarse plexifilamentary structure. The effect of spin pressure on fiber morphology also depends somewhat on the type of the polymer/spin liquid system to be spun. In some cases, well fibrillated plexifilaments can be obtained even at spin pressures slightly higher than the cloud-point pressure of the spin mixture. Therefore, the effect of spin pressure discussed herein is intended merely as a guide in selecting the initial spinning conditions to be used and not as a general rule.
For cloud-point pressure determination, the spinneret assembly is replaced with a view cell assembly containing a 1/2 inch (1.23×10 -2 m) diameter high pressure sight glass, through which the contents of the cell can be viewed as they flow through the channel. The window was lighted by means of a fiber optic light guide, while the content at the window itself was displayed on a television screen through a closed circuit television camera. A pressure measuring device and a temperature measuring device located in close proximity to the window provided the pressure and temperature details of the content at the window respectively. The temperature and pressure of the contents at the window were continuously monitored by a computer. When a clear, homogeneous polymer-spin liquid mixture was established after a period of mixing, the temperature was held constant, and the differential pressure applied to the pistons was reduced to 0 psi (0 kPa), so that the pistons stopped moving. Then the pressure applied to the contents was gradually decreased until a second phase formed in the contents at the window. This second phase can be observed through the window in the form of cloudiness of the once clear, homogeneous polymer-spin liquid mixture. At the inception of this cloudiness in the content, the pressure and temperature as measured by the respective measuring devices near the window were recorded by the computer. This pressure is the phase separation pressure or the cloud-point pressure at that temperature for that polymer-spin liquid mixture. Once these data are recorded, mixing was again resumed, while the content was heated to the temperature where the next phase separation pressure has to be measured. As noted above, cloud-point pressures for selected polyolefin/spin liquid spin mixtures are plotted in FIGS. 1-6 at varying co-solvent spin liquid concentrations and spin temperatures.
The following Tables set forth the particular parameters tested and the samples used:
Table 1: High density polyethylene spun from 100% alcohol (e.g., 1-propanol and 2-propanol).
Table 2: High density polyethylene spun from an alcohol (e.g., ethanol) mixed with different co-solvent spin liquids (e.g., pentane and cyclohexane) to lower cloud-point pressure.
Table 3: High density polypropylene spun from 100% alcohol (e.g., ethanol and 2-propanol).
Table 4: High density polypropylene spun from a mixture of alcohols (e.g., ethanol mixed with 2-propanol).
Table 5: High density polypropylene spun from an alcohol (e.g., 1-propanol) mixed with a co-solvent spin liquid (e.g., water) to raise cloud-point pressure.
In the Tables, PE 7026A refers to a high density polyethylene (0.7 melt index) called Alathon 7026A commercially available from Occidental Chemical Corporation of Houston, Tex. PP 6823 refers to a high molecular weight polypropylene (0.4 melt flow rate) called Profax 6823 commercially available from Himont, Inc. of Wilmington, Del. PP 6523 refers to a high molecular weight polypropylene (4 melt flow rate) called Profax 6523 commercially available from Himont, Inc. of Wilmington, Del. CP350K refers to a medium molecular weight polypropylene (35 melt flow rate) commercially available from U.S. Steel of Pittsburgh, Pa.
In the Tables, MIX T stands for mixing temperature in degrees C, MIX P stands for mixing pressure in psig, SPIN T stands for spinning temperature in degrees C, ACCUM P stands for accumulator pressure in psig, SPIN P stands for spinning pressure in psig, T(GPD) stands for tenacity in grams per denier as measured at 1 inch (2.54×10 -2 m) gauge length 10 turns per inch (2.54×10 -2 m), E stands for elongation at break in %, and SA (M 2 /GM) stands for surface area in square meters per gram. FIB LEVEL stands for the fibrillation level in descriptive terms. CONC stands for the weight percent of polyolefin based on the total amount of polyolefin and spin liquid present. SOLVENT stands for the alcohol spin liquid. CO-SOLVENT stands for the co-solvent spin liquid added and its weight percent based on the total amount of co-solvent spin liquid and alcohol spin liquid present.
All values in the Tables were obtained using a spinneret orifice having a length of 0.030 inches and a diameter of 0.030 inches.
TABLE 1__________________________________________________________________________POLYETHYLENE FIBERS SPUN FROM 100% ALCOHOLSSAMPLE NO 1 P11085-136 2-P11128-8 3 P11085-114 4 P11128-6 5 P11085-148__________________________________________________________________________POLYMER PE 7026A PE 7026A PE 7026A PE 7026A PE 7026ACONC (WGT %) 20 22.5 22.5 22.5 22.5SOLVENT 1-PROPANOL 1-PROPANOL 1-PROPANOL 1-PROPANOL 1-PROPANOLCO-SOLVENT NONE NONE NONE NONE NONEMIX T (C.) 250 250 250 250 250MIX P (PSIG) ˜5000 5000 ˜5000 5000 ˜5000SPIN T (C.) 250 250 250 250 250ACCUM P (PSIG) 4500 2750 3000 3250 3750SPIN P (PSIG) 4050 2300 2500 2800 --DEN 358 429 382 370 397T (GPD) 3.1 3.25 3.35 3.86 3.79E (%) 95 76 58 62 62FIB LEVEL 4 4 4 4 4SA (M.sup.2 /GM)__________________________________________________________________________ SAMPLE NO 6 P11085-150 7 P11085-126 8 11085-106__________________________________________________________________________ POLYMER PE 7026A PE 7026A PE 7026A CONC (WGT %) 22.5 25 30 SOLVENT 1-PROPANOL 1-PROPANOL 2-PROPANOL CO-SOLVENT NONE NONE NONE MIX T (C.) 250 250 240 MIX P (PSIG) ˜5000 ˜5000 ˜5000 SPIN T (C.) 250 250 240 ACCUM P (PSIG) 4250 2750 ˜5000 SPIN P (PSIG) 3650 2150 4200 DEN 449 479 871 T (GPD) 3.51 3.58 1.27 E (%) 73 103 61 FIB LEVEL 4 4 3.75 SA (M.sup.2 /GM)__________________________________________________________________________
TABLE 2__________________________________________________________________________POLYETHYLENE SPUN FROM VARIOUS ETHANOL BASED MIXED SPIN LIQUIDSSAMPLE NO 1 P11030-52 2 P11087-20 3 P11087-21 4 P11087-22__________________________________________________________________________POLYMER PE 7026A PE 7026A PE 7026A PE 7026ACONC (WGT %) 22 22 22 22SOLVENT 50% ETHANOL 60% ETHANOL 60% ETHANOL 60% ETHANOLCO-SOLVENT 50% PENTANE 40% CYCLOHEXANE 40% CYCLOHEXANE 40% CYCLOHEXANEMIX T (C.) 210 240 240 240MIX P (PSIG) 5500 3250 3100 3300SPIN T (C.) 210 240 240 240ACCUM P (PSIG) -- 1800 1600 1400SPIN P (PSIG) 2000 1625 1420 1280DEN 321 223 242 206T (GPD) 2.99 2.77 4.92 3.84E (%) 97 118 84 91FIB LEVEL 3.75 4 4 4SA (M.sup.2 /GM)__________________________________________________________________________
TABLE 3__________________________________________________________________________POLYPROPLENE SPUN FROM 100% ALCOHOLSSAMPLE NO 1 P11169-56 2 P11169-34 3 P11169-64 4 P11169-48 5 P11128-78 6 P11169-86 7__________________________________________________________________________ P11169-146POLYMER PP 6823 PP 6823 PP 6823 PP 6823 PP 6823 PP 6823 PP 6823CONC (WGT %) 14 14 18 18 22 22 26SOLVENT ETHANOL ETHANOL ETHANOL ETHANOL ETHANOL ETHANOL ETHANOLCO-SOLVENT NONE NONE NONE NONE NONE NONE NONEMIX T (C.) 260 260 280 260 250 280 240MIX P (PSIG) 4000 4000 4000 4000 3500 4000 4000SPIN T (C.) 260 260 280 260 250 280 240ACCUM P (PSIG) 2700 2800 2600 2700 2400 2600 2500SPIN P (PSIG) 2500 2550 2400 2450 1900 2350 2200DEN 290 246 282 342 364 331 665T (GPD) 1.47 1.84 2.12 2.25 2.19 2.05 1.52E (%) 77 77 66 63 68 69 61FIB LEVEL 4 4 4 4 4 4 4SA (M.sup.2 /GM) 16 19 --__________________________________________________________________________ SAMPLE NO 8 11169-138 9 P11212-16 10 P11188-42 11 P11212-10 12__________________________________________________________________________ P11128-136 POLYMER PP 6823 PP 6523 PP 6523 CP350K PP 6823 CONC (WGT %) 30 18 22 18 22 SOLVENT ETHANOL ETHANOL ETHANOL ETHANOL 2-PROPANOL CO-SOLVENT NONE NONE NONE NONE NONE MIX T (C.) 240 260 260 260 250 MIX P (PSIG) 4000 4000 4000 4000 3000 SPIN T (C.) 240 260 260 260 250 ACCUM P (PSIG) 2300 2700 2700 2700 1200 SPIN P (PSIG) 1900 2400 2450 2470 1100 DEN 759 405 360 424 311 T (GPD) 0.89 1.32 1.46 0.49 1.53 E (%) 64 74 58 77 72 FIB LEVEL 3.75 4 4 4 4 SA (M.sup.2 /GM)__________________________________________________________________________
TABLE 4______________________________________POLYPROPYLENE SPUN FROMA MIXTURE OF ALCOHOLSSAMPLE NO 1 P11169-18______________________________________POLYMER PP 6823CONC (WGT %) 22SOLVENT 50% ETHANOLCO-SOLVENT 50% 2-PROPANOLMIX T (C.) 250MIX P (PSIG) 3000SPIN T (C.) 250ACCUM P (PSIG) 1500SPIN P (PSIG) 1370DEN 303T (GPD) 2.12E (%) 70FIB LEVEL 4SA (M.sup.2 /GM)______________________________________
TABLE 5__________________________________________________________________________POLYPROPYLENE SPUN FROM 1-PROPANOL AND WATERSAMPLE NO 1 P11322-54 2 P11322-58 3 P11322-52 4 P11322-56 5 P11322-46__________________________________________________________________________POLYMER PP 6523 PP 6523 PP 6523 PP 6523 PP 6523CONC (WGT %) 12 14.5 17 19.5 22SOLVENT 90% 1-PROPANOL 90% 1-PROPANOL 90% 1-PROPANOL 90% 1-PROPANOL 90% 1-PROPANOLCO-SOLVENT 10% WATER 10% WATER 10% WATER 10% WATER 10% WATERMIX T (C.) 260 260 260 260 260MIX P (PSIG) 2500 2500 2500 2500 2500SPIN T (C.) 260 260 260 260 260ACCUM P (PSIG) 1100 1100 1100 1100 1100SPIN P (PSIG) 1050 1030 1020 1020 1060DEN 238 205 220 226 241T (GPD) 0.79 1.55 1.44 1.56 0.91E (%) 56 70 68 68 65FIB LEVEL 4 4 4 4 4SA (M.sup.2 /GM)__________________________________________________________________________
Although particular embodiments of the present invention have been described in the foregoing description, it will be understood by those skilled in the art that the invention is capable of numerous modifications, substitutions and rearrangements without departing from the spirit or essential attributes of the invention. Reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention. | A process is provided for flash-spinning plexifilamentary film-fibril strands of a fiber-forming polyolefin from a C 1-4 alcohol or a C 1-4 alcohol/co-solvent spin liquid that, if released to the atmosphere, presents no or a greatly reduced ozone depletion hazard, as compared to the halocarbon spin liquids currently-used commercially for making such strands. The resulting flash-spun plexifilamentary film-fibril strands are well fibrillated and are of a quality equivalent to commercially available strands. The invention also covers the spin liquids useful in the inventive process. | 3 |
PRIOR APPLICATION
This application is a continuation-in-part application from my prior application Ser. No. 07/662,922, filed Mar. 1, 1991, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of The Invention
This invention relates to chlor-alkali cells. More particularly, it refers to a cell for separating chlorine in gaseous form and sodium from salt without the presence of a membrane between the anolyte and catholyte.
2. Description of The Prior Art.
Although various membraneless gas generating apparatus are known such as the one for oxygen production shown in U.S. Pat. No. 1,255,096 and chlorine production shown in 4,256,551, these apparatus suffer from intermittent gas production. Additionally, in U.S. Pat. No. 4,256,551, close control must be maintained of the temperature of the brine in the system and there is no mechanism for automatically adding water and salt.
U.S. Pat. Nos. 4,363,713 and 4,419,207 describe a halogen generator submerged in water. A space between the anode and cathode is filled with salt. The salt bed and an upward water and brine flow maintains separation between the catholyte and anolyte. The generator must be periodically removed from the water to resupply the salt.
An apparatus is needed that will furnish a continuous supply of chlorine to a swimming pool as needed without constant manual attention.
SUMMARY OF THE INVENTION
I have invented an apparatus that will continuously supply a halogen gas such as chlorine to a swimming pool or other body of water without the need for constant attention by the operator.
My apparatus controls the operating level of a liquid anolyte, catholyte and their interface by a combination of overflow pipe routed to a caustic catchment basin and a hydrometer float, or an electronic sensor designed to activate a water source to permit the addition of water as the caustic concentration increases to an unacceptable level. The hydrometer float actuates and positions a plate redirecting a continuous flow of water to the catholyte reservoir. The electronic sensor activates a valve to allow water to flow to the catholyte reservoir. Salt is stored above the liquid level and is consumed upon demand by the system, thereby providing a constant volume of salt in the liquid portion of the system. Chlorine gas coming off at the anode is carried to a collecting chamber where it is drawn off for use.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which:
FIG. 1 is a side sectional view in elevation of the apparatus.
FIG. 2 is a schematic view of the method for continuously feeding chlorine to a pool.
FIG. 3 is a side sectional view in elevation of standard operating level for the catholyte reservoir.
FIG. 4 is a side sectional view in elevation of a low level of catholyte with the level control float moving a plate deflecting water to the catholyte reservoir.
FIG. 5 is a top plan view along lines 5--5 of FIG. 1.
FIG. 6 is a side sectional elevational view of the apparatus with an electronic sensor to detect changes in caustic level.
FIG. 7 is a schematic view of the electronic sensor system.
DETAILED DESCRIPTION OF THE INVENTION
Throughout the following detailed description, the same reference numerals refer to the same elements in all figures.
My halogen gas generating apparatus 10 shown in FIG. 1 has a cell 12 containing an anode 14 and a cathode 16 in close vertical proximity to each other. A hood 18 is located above the anode 14. The hood 18 is integral with a vertically extending gas separator column 20. Cathode 16 is located above the lower lip of the hood. Column 20 also serves as a brine pump to return depleted brine to the salt bed or brine solution 26. A conduit 22 returns weak brine produced at the anode from a bore 21 in a lower portion of the gas separator column 20 to the brine solution 26. The description hereinafter refers to chlorine gas produced by this apparatus, but it is understood that other halogen gases ca be produced by changing the salt content.
Chlorine gas 28 bubbles up through the gas separator column 20 to a tube 30 having a gas tight connection 31 to the top 32 of gas separator column 20. Tube 30 leads to a catchment basin container 34 where the chlorine gas may mix with liquid caustic 36 overflowing into the catchment basin container 34 from the cell 12. The container has a tube 38 which leads to a liquid to be sanitized, such as a swimming pool. Alternatively, tube 38 can lead directly to a tank for storage or direct use of the chlorine gas 28.
A hydrometer body 40 is floatably disposed within the caustic 36 and moves in an upward direction as the density of the caustic 36 increases. This upward movement causes plate 41 supported by rod 43 to redirect a water stream from nozzle 46 and allow water to deflect through hole 45 into the caustic 36. A float 42 is attached to a plate 44. As the float 42 moves downward in response to decreased caustic level from 80 to 78, the plate 44 moves downwards and allows the water input 46 to be deflected into the caustic 36. Water flows continuously through tubes 67 and 68 when the hydrometer body 40 is in its down position and the plate 44 is in its up position.
In an alternative embodiment, an electronic control, senses cell resistance either through an electrode sensor 88 shown in FIG. 6, located in the wall of cell 12 or increased current through an ampmeter 90. A comparator circuit measures the cell resistance and activates a valve 128 to allow water to flow into the caustic 36 through pipe 100 when the caustic concentration increases to an unacceptable level.
A circuit for the electronic sensor is set forth in FIG. 7. This preferred circuit is connected to the cathode 16 and anode 14 through wires 84 and 82 respectively, with an ampmeter 90 sustaining a voltage drop when the caustic concentration increases. A shielded probe 88 mounted in the cell wall 12 warns the circuit if the caustic solution drops below line 78 as shown in FIG. 6. This prevents the system from continuing to operate when danger of explosion is possible. Resistors R1, R2, R3 and R4 in the circuit shown in FIG. 7 are selected so non inverting operational amplifier input is high until caustic concentration increases causing voltage drop across ampmeter 90 to increase to the point that minus input becomes higher than plus input. The operational amplifier comparator 92 will then switch its output low, turning on the darlington transistor pair 94, allowing current to flow through solenoid valve coil 96 to operate valve 128 and allow water to flow through a pipe 100 into the caustic solution.
An iron core transformer 102 concentrates magnetic flux from the primary coil 104 for the secondary coil 106. A switch 108 activates the power supply and timing circuit R5, R6 and C1 which fires diac 126 activating a light emitting diode 110 in an optical isolator circuit 112A and B, triggering SCR 114 or 116. Isolation diodes 118 and 120 prevent the circuit from self-triggering. Diodes 122 and 124 act as power rectifiers to power comparator circuit 92 and its bias networks.
Other methods of density control could include a manual sampling of the caustic every few hours to determine density and making appropriate water input adjustments. A timer control could be used if water input and cell power were held constant.
A container 48 is vertically disposed in the cell 12 so that its first end 50 is located below the upper level 76 of the brine solution 26. The upper level of the brine solution is also the caustic brine interface 76. The second end 52 of the container 48 allows for insertion of solid granular salt 54 which is stored within the container 48 and is used gradually upon utilization of the brine. An indicator rod 56 protruding through a hole 58 in lid 60 of the container 48 provides a means for visually determining the amount of salt in the container 48. In the schematic shown in FIG. 2 a completely enclosed system is shown whereby the halogen solution moves through tube 38, through a venturi 62 from whence it is directed through additional tubes 64 to a swimming pool 66. The control stream collector line 68 permits the water to return directly to the system via venturi 63 when it is not deflected into the caustic 36. A pump 70 moves water from the swimming pool 66, passes it through a standard filter 72, and then to piping 67 back to the cell 12 or through a venturi and pipe 64 back to the pool as seen in FIG. 2. An alternate pipe 69 leads to another venturi 63 which directs the flow to pipe 65 back to pipe 64.
The hydrometer body 40 is seen in more detail in FIGS. 3 and 4. The hydrometer is similar to the one set forth in U. S. Pat. No. 4,899,774 and the teaching in that patent is herein incorporated by reference. The hydrometer body 40 floats in the caustic solution 36 as seen in FIGS. 3 and 4 in its normal position when there is a preferred caustic density of about 1.01. If the density of the caustic rises above 1.01 it will cause the hydrometer body 40 to rise and cause its circular head plate 41 to block the flow of water through opening 46, thereby causing the water to flow downwardly through opening 45 into the caustic 36 to lower its density.
If the level of the caustic 36 falls too low as seen in FIG. 4, then float 42 lowers to allow plate 44 to deflect the water flowing through nozzle 46 so that it will flow downwardly into the caustic 36 to raise its level to that seen in FIG. 3, whereupon the plate 44 is raised by float 42 and the water flows through the system out through conduit 68 without entering the cell caustic solution.
The apparatus described above provides a chlorine gas producing chlor-alkali cell with a current efficiency which approaches the theoretical current requirements of 200 ampere-hour per pound of chlorine gas produced. Electrical current is provided to the system through wires 82 and 84. The cell requires no control instrumentation or valves involving routine maintenance adjustment or skill to set up or care for. Furthermore, the system is not sensitive to salt purity or contamination, thus making it a practical water purification device in areas where pure salt is not available.
The salt compartment 48 and caustic cell compartment 12 can be of any desired cross section or configuration. The salt 54 flows freely into the caustic chamber lower brine region 26 where it is dissolved and electrically decomposed at the anode 14.
The chlorine gas 28 produced at the anode 14 rises as it bubbles in the gas catcher 18 or separator column 20. The depleted brine is separated and returned to the brine region 26 via conduit 22. The salt 54 moves into the brine region 26 by gravity flow from chamber 48.
The anolyte (brine)-catholyte interface 76 is well defined in this system and appears at its highest level below the bottom of cathode 16. The catholyte 36 is maintained above the denser brine under normal steady-state operation.
The cathode 16 is positioned above the anode plate 14 at a distance of about 0 to 5 cm and preferably about 1 to 2 cm. The cathode is made preferably from stainless steel or titanium. The anode is made preferably from carbon, graphite, or platinum, or iridium coated titanium.
The maximum level 80 of caustic is controlled by the upper lip of collector chamber 34. The minimum caustic level 78 is controlled by float 42. Mixing of water introduced into the caustic is caused by the stirring action of the hydrogen gas by bubbles formed at the cathode 16.
Conduit 30 may be directed to a receiving body for the chlorine gas or to the collecting chamber 34 as seen in FIG. 1 so that catholyte, water and gas are mixed and conducted to the point of use. For such a configuration to be effective, a slight vacuum placed at the destination end of conduit 30 will serve to prevent loss of chlorine.
Equivalent equipment can be used to modify the apparatus and method described above without departing from the invention. | This chlorine gas generating apparatus controls the operating level of a liquid anolyte, catholyte and liquid interface by a combination of overflow pipe routed to a caustic catchment basin and a float or electronic sensor designed to add water as caustic concentration increases to an unacceptable level. Salt is stored above the liquid level and is consumed upon demand by the system so that a constant volume of salt is maintained in the liquid portion of the cell. Chlorine gas is directed to a catchment basin where it is collected and then delivered to a pool or other area to be sanitized. | 2 |
This application is the US National Stage Filing of PCR/FR98/02639 field on Dec. 7, 1998.
BACKGROUND OF THE INVENTION
The present invention relates to a device intended for the qualitative or quantitative dosing of at least one particular component in a product-sample, preferably making it possible to implement immunological dosing, as well as to a process and a kit which are intended for implementing the device.
Numerous methods have been developed for identifying, detecting or quantifying analytes in chemical or biological samples.
These methods are mostly based on the formation of complexes by affinity reaction between members of a specific binding pair.
These reactions, of ligand/receptor type, result for example from interactions between an antigen and a specific antibody, from hybridization between two complementary nucleic acid sequences or from a phenomenon of recognition between the binding site of a protein, for example an enzyme, hormone or other biological entity, and its ligand, substrate or receptor.
The formation of an affinity complex makes it possible to reveal the presence of the sought-after analyte in the sample. This analyte may possibly be quantified, if it is possible to separate the complexed forms from those remaining in the free state, or to measure the degree of occupancy of the specific ligands of the analyte.
This type of method of detecting and quantifying an analyte present in a sample, sometimes in trace amounts, is of great interest to research or analysis laboratories, especially clinical or biological analysis laboratories.
However, for routine use, the methods must be able to be applied simultaneously to a large number of samples. Furthermore, for one and the same sample, it is often necessary to carry out several tests.
Therefore, in most cases, the manual protocols of routine analysis involve several reactions and successive manipulation steps. These multiple tests are carried out on samples in series, in very large centers in which several tens of thousands of samples—may be tested per day. Such multiple tests may therefore impose constraints and require relatively lengthy performance times. Additionally, the successive manipulations which they require may give rise to errors in the results.
The problem of the automation of this type of test therefore rapidly arises, and various devices have thus been devised in order to achieve automation, or, at the very least, a simplification of the successive steps indicated above.
These devices remain however for the most part relatively complex or adapted to the detection of a particular type of analyte (cell or molecule) or else only allow qualitative analyses to be carried out. Such devices are described in particular in the documents EP 0339277 and EP 0426729.
In particular, the document EP 339 277 describes a device for performing successive analytical reactions for dosing an analyte in a liquid assay sample involving analytical reactions between the analyte and analytical reagents which interact with the analyte to produce an analyte-dependent detectable response.
This device comprises a closed receptacle having a horizontal axis of rotation. This closed receptacle is delimited externally by a cylindrical wall and internally comprises two concentric spoon-shaped walls which define between themselves a sample inlet zone. Between said spoon-shaped walls and the cylindrical peripheral wall there are defined several reaction zones into which the specific analytical reagents are incorporated.
According to this document, the sample is introduced by an entry pathway into the inlet chamber defined between the spoon-shaped walls and opening toward the reaction zones. By pivoting said receptacle in a swinging movement about its horizontal axis, the liquid sample is transported by gravity into the reaction zones where it interacts with the reagents and then transported to an examination zone situated at the center of the receptacle.
Such a device is designed chiefly to avoid any centrifugation of the product when carrying out dosing.
The document JP HEI-5 215 750 also discloses a device for detecting and analyzing cellular populations, which comprises a horizontal circular dish mounted rotatably about a vertical axis. This open dish is covered with antibodies.
It is rotated about its vertical axis so that the sample introduced at its center is distributed under the action of a centrifugal force over said dish.
The subsequent washing steps are carried out in the same way by introducing the rinsing liquid at the center of the dish, the liquid being discharged toward the periphery of the dish during the rotation of the latter, while rinsing the surface on which the component to be dosed is fixed. In order to recover the rinsing liquid, there is provided a receptacle placed beneath the dish.
Finally, the document WO 94 25 159 discloses a device for the qualitative and/or quantitative dosing of a particular component in a sample of products, which comprises a substantially circular container mounted rotatably on a shaft for driving via a central housing, and in which test chambers are made which extend along radii of the container and which have a density gradient. In the central part of the container, there is provided an annular centrifugation chamber which is in communication with each test chamber.
This annular centrifugation chamber can be divided into two parts which communicate with each other via an upper opening.
The wall delimiting the first part of the centrifugation chamber is inclined so that the products are transferred from the first part to the second part by overflowing from the delimiting wall, via the communication orifice. Likewise, the wall delimiting the second part of the centrifugation chamber exhibits an inclined slope so that the mixture is transferred into each test chamber by overflowing via the communication orifice between the second part of the centrifugation chamber and said test chambers.
The slope of the wall delimiting the second part of the centrifugation chamber is greater than the slope of the wall delimiting the first part so that during centrifugation, the product passes firstly from the first part of the centrifugation chamber situated close to the axis of rotation of the container, to the second part of the centrifugation chamber before being transferred to the test chambers.
SUMMARY OF THE INVENTION
The invention proposes a novel arrangement of a dosing device which is of simple design and easy to use and which can be manipulated individually with a minimum number of manipulations so as to carry out dosing, allowing dosings to be carried out in proximity to the place of withdrawal of the product sample containing the particular component to be dosed, such a device exhibiting an optimized arrangement and furthermore making it possible to carry out assays in series from small quantities of samples.
More particularly, according to the invention, there is proposed a device for the qualitative and/or quantitative dosing of at least one particular component in a product sample by labeling and fixing, said device comprising a container and a cover which are assembled to form a closed receptacle.
This device is characterized in that said closed receptacle has a vertical axis, in that the container and the cover carry coaxial cylindrical walls which, while the container and cover are being assembled, position themselves pairwise one against the other thereby delimiting at least three concentric annular chambers inside the receptacle, namely from the axis an inlet chamber intended for receiving the sample and as appropriate allowing the labeling of the component, a chamber for fixing and reading said labeled component and a discharge chamber, in that the coaxial cylindrical walls forming separations between the successive annular chambers each comprise at least one opening, and in that the assembled cover and container are able to turn with respect to one another about the vertical axis and the openings of the coaxial cylindrical walls of the container and of the cover are placed at determined angular positions, in such a way that by displacement of one with respect to the other of the cylindrical walls of each pair, the openings of each pair of walls are able to be positioned opposite one another or in an angularly offset manner, so as to put into communication or isolate from one another the successive annular chambers.
According to a preferred arrangement of the device in accordance with the invention, said openings provided in the coaxial cylindrical walls of the container and of the cover are positioned in such a way that the openings of a pair of cylindrical walls are opposite one another so as to put into communication two successive annular chambers, the openings of the other pairs of cylindrical walls are positioned in an angularly offset manner so that the other annular chambers are isolated.
According to other advantageous characteristics of the device in accordance with the invention, on the cover and on the container if comprises means of indexed positioning of these latter. The cover comprises a nipple on the external face of one of these coaxial cylindrical walls which are situated outside the other cylindrical walls so as to form the external peripheral edge of the receptacle, said nipple forming a grip or a sill for turning the cover about the vertical axis with respect to the container. The device according to the invention comprises a central through-orifice isolated from the immediately adjacent annular chamber and intended to be threaded onto a vertical shaft for rotational driving for setting said receptacle into rotation.
In the bottom of the cover or in the bottom of the container, there may be provided an entry orifice to the inlet chamber.
According to a variant of the device in accordance with the invention, provision may be made for the receptacle to comprise several concentric fixing and reading chambers between the inlet chamber and the discharge chamber.
The device according to the invention exhibits an optimized ergonomic shape. More particularly, its receptacle exhibits the shape of a disk.
Advantageously, the container of the device according to the invention is made from a transparent material so as to allow reading of the labeled fixed components in the fixing and reading chamber through the walls of said receptacle. The cover may be opacified or be treated in such a way as to avoid parasitic radiations, it being possible for the reading to be performed with the aid of a CCD camera.
The device according to the present invention preferably comprises in the fixing chamber at least one receptor of the component to be dosed, said receptor being fixed in the chamber. It should be understood according to the present invention that the terms receptor and ligand will be used to designate in a generic manner two elements which are bound by strong interactions, and it can therefore relate equally to an antigen/antibody pair or to a nucleic acid/complementary nucleic acid pair or else to a true ligand and receptor or other strong interactions.
The techniques making it possible to fix proteins (antigens, antibodies for example) or nucleic acids on plastic or even glass surfaces are well known to the person skilled in the art, these dealing with technologies currently used in particular to fix components of this same type in the standard microtiter plates which are used for example in ELISA or else which may be adapted as a function of the type of polymer involved.
Preferably the receptor will be fixed on the bottom of the container, if possible in the form of a monolayer so as to allow easier reading. Indeed, when the means of reading is a CCD camera, the radiation will pass through the bottom of the container and will or will not be modified by the presence of a labeled component and will then be recovered after a second pass through the bottom of the container.
The technique involved is in a general manner akin to so-called sandwich immunological dosing processes, that is to say the element to be detected reacts with the receptor for example the antibody and is itself labeled by another element recognizing it, which carries either a physical label, that is to say particles, or else a chemical label for example with the aid of fluorescent elements or ones which may be rendered fluorescent.
In this regard, according to an advantageous characteristic of the invention, the labeling particles exhibit a sufficient diameter, preferably greater than or equal to around 100 times the diameter of the component(s) to be dosed and possess optical properties allowing their detection by counting.
The expression “possess optical properties” is understood to mean the fact that said particles are able to reflect all or some of a luminous radiation emitted by a detection system, heading for said particles.
Although it is possible to label the component before introducing it into the device, the labeling element capable of labeling the component to be dosed will preferably be placed in the inlet chamber, for example in unfixed dry form, this involving for example labeled antibodies recognizing one of the epitopes of the antigen to be dosed, another antibody being fixed in the fixing and labeling chamber.
In the device according to the present invention, the fixed receptor is chosen as indicated above from among:
antibodies, antigens, complementary nucleic acid sequences,
true receptors for specifically dosing components which are:
antigens, antibodies, nucleic acid sequences, ligands of said receptors.
For the immunological dosings, use will preferably be made of an antigen or a labeled antibody to respectively dose the complementary element and another complementary element will be fixed in the fixing and reading chamber.
It is also possible to provide for multiple dosing making it possible to dose perhaps several antigens or several antibodies. To do this it is sufficient for the fixing and reading chamber to be divided into plurality of angular sectors on which mutually different receptors are fixed, each intended for fixing and reading a different labeled component. For this purpose, it may be particularly advantageous according to the invention for an angular sector of the fixing chamber to be left devoid of receptors so as to constitute a blank sector intended for carrying out an initialization reading of said device to zero it.
Reading may be carried out according to the invention by virtue of a CCD camera which may of course be controlled by a computerized device which will make it possible to reconstruct the dosing of each of the elements as a function of the readings which will be made on the various sectors.
According to a particularly advantageous characteristic of the device according to the invention, the CCD camera is able to count in a discretionary manner by emission/reception of a light signal, the number of labeled fixed components in each fixing and reading chamber, so as to obtain a digital detection signal.
This entails using particles or microspheres to label the component or components to be dosed in the sample, these particles preferably exhibiting a size greater than around 100 times the size of the sought-after molecules, and being capable of returning all or some of a luminous radiation emitted in their direction, reflected radiation constituting so many events which are captured by the CCD camera used and transmitted to a computerized tool adapted for expressing the detected events in terms of absolute number in real time.
The invention also proposes a process for the qualitative and/or quantitative dosing of at least one particular component in a product sample by labeling and fixing.
This process is characterized in that use is made of at least one device according to the invention which contains specific receptors for the component to be dosed, which are fixed in each fixing and reading chamber and in which process,
a) the product sample containing the labeled component is placed in the inlet chamber isolated from the other annular chambers,
b) the cover is turned with respect to the container in such a way as to put the inlet chamber into communication with each fixing and reading chamber, the discharge chamber being isolated from the other annular chambers,
c) the device is rotated about its vertical axis in such a way as to disperse by centrifugation in each fixing and reading chamber the product sample containing the labeled component, the latter then binding by strong interaction to the fixed specific receptors in each fixing and reading chamber,
d) the cover is turned with respect to the container in such a way as to put the fixing and reading chamber into communication with the discharge chamber,
e) the device is rotated about its axis in such a way as to disperse by centrifugation the surplus sample into the discharge chamber,
f) the inside of the device is rinsed with the aid of a rinsing liquid which is circulated by centrifugation through the various annular chambers of said device while reproducing the preceding steps b), c), d) and e) in such a way as to retain in each fixing and reading chamber only the labeled component bound by strong interaction to the fixed receptors,
g) said labeled component is detected and dosed through the wall(s) of said device.
The process according to the invention can be automated and is “generic”, it can be applied to the detection and to the counting of target substances, either of a molecular, particulate, vesicular or cellular nature.
The invention also proposes an apparatus for implementing the aforesaid process, characterized in that it comprises a vertical shaft for rotational driving on which are threaded devices according to the invention, means for maintaining said devices distanced from one another, means for the bidirectional rotational driving of said vertical drive shaft, means for injecting product samples and rinsing liquid into the inlet chambers of said devices threaded on the drive shaft, and means for turning the covers of the devices relative to the containers in such a way as to put the various successive annular chambers of these containers into communication or to isolate them and a means for reading the labeled fixed agents.
Thus, by virtue of the apparatus according to the invention, it is advantageously possible to carry out automatically, according to the process in accordance with the invention, using the device according to the invention, dosings of various components of one and the same sample, or one and the same component in particular in several samples of different products.
DESCRIPTION OF THE DRAWINGS
The description which follows in conjunction with the appended drawings, given by way of nonlimiting examples, will clearly elucidate that of which the invention consists and how it may be embodied.
In the appended drawings:
FIG. 1 is a top view of the cover of an embodiment of the device according to the invention,
FIG. 2 is a sectional view along the plane A—A of FIG. 1,
FIG. 3 is a top view of the container of the embodiment of FIG. 1 of the device according to the invention,
FIG. 4 is a sectional view along the plane A—A of FIG. 3,
FIG. 5 presents two detection curves for a given component in a serum, by fluorescence and by counting of labeling microspheres according to the invention, and
FIG. 6 presents two detection curves for a given component in a serum, by the ELISA method and by counting of microspheres according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Represented in FIGS. 1 to 4 as separate pieces is a device for the qualitative and/or quantitative dosing of at least one particular component in a product sample by labeling and fixing.
Such a device is used advantageously to carry out immunological dosing, detection of microorganisms, dosing of pollutants or else to reveal a particular nucleic acid sequence.
Such a device comprises a container 110 and a cover 120 which are intended to be assembled to form a closed receptacle.
As is represented in the figures, the container 110 and the cover 120 exhibit a circular general shape, with a central axis of symmetry 101 , so that when they are assembled, said closed receptacle thus formed exhibits the shape of a disk with a vertical axis 101 .
The container 110 and the cover 120 each exhibit a bottom 110 a , 120 a which carries coaxial cylindrical walls 111 , 112 , 113 ; 121 , 122 , 123 (here three in number). While said container 110 and said cover 120 are being assembled these coaxial cylindrical walls position themselves pairwise one against the other thereby delimiting here three concentric annular chambers 102 , 103 , 104 inside the closed receptacle.
Starting from the axis and proceeding toward the outside, said cylindrical walls delimit firstly an inlet chamber 102 intended for receiving the product sample and as appropriate allowing the labeling of the component to be dosed, for example an antibody labeled with a particle in dry form, a chamber for fixing and for reading said labeled component 103 , comprising for example an antibody fixed at the bottom of the container, and a discharge chamber 104 .
According to the embodiment represented, the cover exhibits a diameter slightly greater than the diameter of the container, so that the cover positions itself on the container. The cylindrical wall 123 of the cover 120 , which wall is situated outside the other coaxial cylindrical walls 121 , 122 , then forms according to the embodiment represented the exterior peripheral edge of said receptacle. The coaxial cylindrical walls 111 , 112 , 113 of the container 110 are intended to position themselves against the interior faces of the coaxial cylindrical walls 121 , 122 , 123 of the cover 120 .
The coaxial cylindrical interior walls 111 , 112 and 121 , 122 of the container 110 and of the cover 120 which form separations between the successive annular chambers 102 , 103 , 104 each comprise at least one opening 111 a , 112 a and 121 a , 122 a.
Here each of these coaxial cylindrical walls 111 , 112 ; 121 , 122 comprises three openings 111 a , 111 b , 111 c , 112 a , 112 b , 112 c ; 121 a , 121 b , 121 c ; 122 a , 122 b , 122 c regularly distributed over the outline of each wall while being offset pairwise by around 120 degrees.
In the exemplary embodiment represented, the openings of the coaxial cylindrical walls of the container 110 and of the cover 120 are formed by notches.
Said openings of the coaxial cylindrical walls of the container 110 and of the cover 120 are placed at determined angular positions, and the assembled cover 120 and container 110 are able to turn with respect to each other about the vertical axis 101 in such a way that by displacement of one with respect to the other of the cylindrical walls of each pair forming a separation of successive annular chambers, said openings of each pair of the walls are able to be positioned opposite one another or in an angularly offset manner, so as to put into communication or isolate from one another said successive annular chambers.
According to the typical case, the openings 111 a , 111 b , 111 c made in the cylindrical wall 111 of the container 110 are disposed respectively facing the openings 112 a , 112 b , 112 c made in the cylindrical wall 112 of the container 110 . Stated otherwise, each opening 111 a , 111 b , 111 c made in the internal cylindrical wall 111 of the container 110 is positioned facing a corresponding opening 112 a , 112 b , 112 c made in the coaxial cylindrical wall 112 positioned-outside said wall 111 .
On the other hand, the openings 121 a , 121 b , 121 c formed in the cylindrical wall 121 of the cover 120 are positioned offset with respect to the openings 122 a , 122 b , 122 c made in the coaxial cylindrical wall 122 of the cover 120 , which wall is situated outside said cylindrical wall 121 , with an angular offset of around 60 degrees, so that the openings made in one wall are not positioned facing the openings formed in the other successive coaxial wall of the cover.
Thus, with such an arrangement, when the cover 120 is assembled with the container 110 , it is positioned with respect to the latter in such a way that the openings of one pair of cylindrical walls are facing one another so as to put two successive annular chambers into communication, the openings of the other pair of cylindrical walls being positioned in an angularly offset manner so that the other two successive annular chambers are isolated from one another.
Furthermore, as shown by FIGS. 1 to 4 , the cover 120 and the container 110 are provided with means of indexed positioning.
According to the embodiment represented, said means of indexed positioning of the cover 120 and of the container 110 , comprise on the one hand, an opening 123 a extending over an angular sector of the cylindrical wall 123 of the cover 120 which is situated outside the other coaxial cylindrical walls and forms the external peripheral edge of the receptacle, and on the other hand, a nipple 113 a extending radially while projecting from the cylindrical wall 113 of the container 110 intended to be positioned against the external cylindrical wall 123 of the cover 120 , said nipple 113 a being able to engage in said opening 123 a of the external wall 123 of the cover 120 and to navigate in this opening 123 a during relative rotation of the cover 120 and of the container 110 , in such a way as to come into abutment against the two end lateral edges 123 ′ a , 123 ″ a of this opening 123 a.
Here, the opening 123 a created in the external wall 123 of the cover 120 is embodied by a notch which extends over around 70 degrees.
The two abutting positions of the nipple 113 a in the opening 123 a correspond to two determined relative positions of the cover 120 and of the container 110 .
A first abutting position of the nipple 113 a against the end edge 123 ′ a of said opening 123 a , here corresponds to the putting of the inlet chamber for the product sample 102 into communication with the chamber for fixing and reading the labeled component 103 , the discharge chamber 104 being isolated from the other chambers.
The second abutting position of the nipple 113 a against the other end edge 123 ″ a of said opening 123 here corresponds to the putting of the fixing and reading chamber 103 into communication with the discharge chamber 104 and to the isolating of the inlet chamber 102 from the other chambers.
So as to facilitate the relative rotation of the cover 120 and of the container 110 , the cover 120 comprises a nipple 123 b extending radially while projecting from the external face of the cylindrical wall 123 situated outside the other cylindrical walls, said nipple 123 b forming a grip or a sill for turning the cover 120 about the vertical axis 101 with respect to the container 110 .
The container 110 and the cover 120 are each provided with a central through-orifice 105 isolated from the immediately adjacent annular chamber, here the inlet chamber 102 , by a coaxial cylindrical wall 105 a , 105 b . When the cover is assembled with the container the walls 105 a and 105 b of the container 110 and of the cover 120 will position themselves one against the other and the closed receptacle thus formed comprises a central through-orifice, isolated by the two cylindrical walls 105 a , 105 b positioned one against the other, from the immediately adjacent annular chamber 102 .
This central through-orifice 105 is intended for being threaded onto a vertical shaft for rotational driving for setting said receptacle into rotation. The orifice 105 here exhibits a diameter of around 4 mm.
The openings created in the coaxial cylindrical walls of the container 110 and of the cover 105 for putting the annular chambers of the receptacle into communication exhibit a width of around 5 mm.
As shown more particularly by FIG. 1, in its bottom 120 a the cover 120 comprises an orifice 102 a emerging into the inlet chamber 102 . It is placed adjacent to the through-orifice 105 since the inlet chamber is immediately adjacent to said through-orifice 105 .
Of course, provision could be made for this entry orifice to the inlet chamber to be made according to a variant (not represented) in the bottom 110 a of the container 110 .
The container 110 is made from a transparent material in such a way as to allow the reading of the labeled fixed components in each fixing and reading chamber, through the bottom wall of said container for example with the aid of a CCD camera, by transmission and reflection of radiation.
The cover can then be opacified, i.e. treated so as to avoid spurious radiations.
Advantageously, the container and the cover are made by molding a plastic, the coaxial cylindrical walls being formed together with said cover.
Any plastic material conventionally used for “coating” molecules can be used to embody the device according to the invention. Use will be made for example of polystyrene, or preferably, a ZYLAR (registered trademark) plastic, such a plastic exhibiting a very high fixing capacity in terms of “coating”.
According to a variant of said dosing device, there may advantageously be provision for the fixing and reading chamber 103 to be divided into a plurality of angular sectors on which mutually different receptors are fixed, each intended for the fixing and for the reading of a different labeled component. According to this variant, it may be particularly advantageous to provide for an angular sector of the fixing chamber to be devoid of fixed receptors so as to constitute a blank sector on which it will subsequently be possible to carry out reading to determine the initialization zero of the device.
According to another variant there may also be provision for the receptacle to comprise between the inlet chamber and the discharge chamber several other concentric successive fixing and reading chambers for fixing different labeled components.
The dosing device constructed by assembling the container 110 and the cover 120 such as they are represented in FIGS. 1 and 3 allows the implementation of a process for the qualitative and/or quantitative dosing of at least one particular component in a product sample by fixing labeling. This process will be described hereinbelow.
According to this process, use is made of at least one device of the type described above with the two elements, container and cover, such as they are represented in FIGS. 1 and 3, assembled to form the closed receptacle, which contains specific receptors for the component to be dosed, which are fixed in the fixing and reading chamber.
During a first step a), the product sample containing the labeled component to be dosed is then placed in the inlet chamber isolated from the other annular chambers of said receptacle.
Then during a step b), the cover is turned with respect to the container in such a way as to put the inlet chamber into communication with the fixing and reading chamber, the discharge chamber being isolated from the other annular chambers.
Then during a step c), the device is rotated about its vertical axis in such a way as to disperse by centrifugation in the fixing and reading chamber the product sample containing the labeled component to be dosed, the latter then binding by strong interaction with the fixed specific receptors in the fixing and reading chamber.
It is noteworthy to stress that the rotation of the device allows the transfer of the product sample from the inlet chamber to the fixing and reading chamber, but also the agitation of the sample inside this chamber so as to allow the labeled component to bind with the fixed receptors.
During a next step d), the cover is turned with respect to the container in such a way as to put the fixing and reading chamber into communication with the discharge chamber, and then during a step e), the device is rotated about its axis in such a way as to disperse by centrifugation the surplus sample into the discharge chamber.
It should be pointed out that for this purpose, as shown by FIGS. 3 and 4, there is provided in the bottom 110 a of the container 110 of the device, a circular rib 114 in proximity to the interior cylindrical wall 112 forming the separation between the fixing and reading chamber, and the discharge chamber, this circular rib 114 forming a non-return lip in respect of the surplus sample discharged by centrifugation in said discharge chamber, or else in respect of the rinsing liquid recovered in this chamber as will be described hereinbelow.
During a step f), the inside of the device is rinsed several times with the aid of a rinsing liquid which is circulated by centrifugation through the various annular chambers of said device while reproducing the preceding steps b), c), d) and e) so as to eliminate the other components of said product which may be attached by adsorption to the internal walls of the device or else bound by weak interaction (such as adsorption) to the specific receptors fixed in the fixing and reading chamber.
Thus, only the labeled component, bound by strong interaction to the fixed receptors in said chamber is retained in the fixing and reading chamber after rinsing.
It is then possible in step f) to detect and dose through the wall(s) of said device the labeled component bound to the fixed receptors in such a way as to perform qualitative and/or quantitative dosing of this labeled component.
This detection can be carried out advantageously according to the process in accordance with the invention with the aid of a CCD camera. To do this, the labeling of the component to be dosed must be carried out physically or chemically with the aid for example of fluorescent microspheres or ones which are rendered fluorescent.
The reading of the labeled fixed agents may be performed along radii of the fixing and reading chamber.
More particularly, according to the process in accordance with the invention with the aid of a CCD camera, the number of labeled fixed components in each fixing and reading chamber is counted. This is possible using, as labeling elements capable of labeling the component to be dosed, particles or microspheres preferably around 100 times larger than the sought-after molecules, and conjugated with the revealing antibody or antigen. For better resolution by the CCD camera, particles whose diameter is 2 μm are favored.
These microspheres are such that they reflect all or some of the radiation which they receive. They can consist of latex or any other material allowing their detection and their counting.
Thus, the CCD camera captures a determined number of events corresponding to an absolute number of fixed components to be dosed.
The CCD camera is linked to software which outputs a digital detection signal. Such a vision-based system thus provides a real-time count of from a few units to 100,000 microspheres per mm 2 , with subtraction of background noise with the aid of a reference surface and appropriate dialgorithms. It also possesses discriminating power insofar as it can recognize and discard the heterogeneous images liable to falsify the analysis of the data.
FIGS. 5 and 6 show curves of results obtained with the aforesaid method of detection by counting according to the invention and more conventional detection methods of the fluorescence-based or ELISA type, for a given component to be dosed in a given serum.
The curves of FIGS. 5 and 6 demonstrate on the one hand that there is indeed a correlation between the counting of the microspheres and the concentration of the component to be dosed, and on the other hand that the method of counting microspheres according to the invention is more accurate than the so-called conventional detection methods. In particular, dosing by counting of microspheres offers a dynamic range of more than 4Log as against 2Log for the ELISA method. This is particularly advantageous since one thereby considerably increases the limit of detection. The results obtained with strong dilutions of the sample thus show that the method exhibits a sensitivity 2Log greater than that of ELISA. The results obtained on weak dilutions of the sample also show that the method still makes it possible to carry out dosings at analyte concentrations corresponding to a saturation threshold in ELISA. This can therefore advantageously make it possible to avoid or to decrease any effects of dilution on certain components of sample to be tested.
According to the aforesaid process, the labeling of each particular component of the sample can be carried out outside before introducing said sample into said inlet chamber of the device.
As a variant, the labeling of each particular component to be dosed of the product sample can be carried out directly in the inlet and labeling chamber, in a first step by introducing a specific labeled receptor for each component to be dosed, in unfixed dry form, then in a second step by introducing the product sample into said isolated inlet chamber so that the labeled receptor will bind by strong interaction to the corresponding component contained in said product sample.
Of course, this process described with the aid of a device and such as represented in FIGS. 1 to 4 , can be carried out with the aid of a plurality of devices of this type, so as to simultaneously dose one and the same particular component in a plurality of different samples or else to dose various particular components in one and the same product sample.
For this purpose, there is advantageously provided according to the invention an apparatus for implementing this process using a plurality of devices of the type of that represented in FIGS. 1 to 4 , which comprises a vertical shaft for rotational driving on which are threaded said dosing devices, means for maintaining said devices distanced from one another, means for the bidirectional rotational driving of said vertical drive shaft so as to carry out the rotational centrifugation of said devices, means for injecting product samples and the rinsing liquid into the inlet chambers of devices threaded on the drive shaft, and means for turning the covers of the devices relative to the containers in such a way as to put the-various successive annular chambers of said devices into communication or to isolate them, and a means of reading the labeled fixed agents.
The invention is in no way limited to the embodiments described and represented, but the person skilled in the art will know how to vary it in any manner in accordance with the spirit thereof. | A device for dosing at least a particular constituent in a product sample has a receptacle and a cover assembled to form a closed container having a vertical axis. The receptacle and cover bear coaxial cylindrical walls defining concentric annular chambers inside the container, the walls separating chambers each having an opening, the cover and the container being rotatable relative to each other about the vertical axis, said openings being placed in a predetermined manner so that by relative displacement of the walls, the openings are positioned in a straight line or offset to communicate, or isolate said successive chambers. A method for using such a device and an apparatus for implementing said method are disclosed. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. provisional application 61/312,089 entitled “Microprocessor-Controlled Multi-Mode Beverage Dispenser,” filed Mar. 9, 2010, which is incorporated herein by reference.
BACKGROUND
[0002] The device disclosed is related generally to beverage dispensing systems employing a cooling subsystem, more particularly, a self-contained tabletop beverage dispenser incorporating a refrigerant chilled cold plate for cooling a beverage.
[0003] When beer (or other beverage) is charged with a gas, such as a carbon dioxide, to move the beer through the various lines, the gas is entrained to dissolve in the fluid and resides in a stable state for temperatures at or below about 30° F. The gas typically does not bubble out of the fluid, but is carried in the fluid and gives a beverage a distinctive effervescence when consumed. However, as the temperature of the beer rises above 30° F., absent increase in pressure on the system, the gas becomes increasingly unstable and begins to bubble or foam out of the flowing beer. Further warming of the beer increases the foaming effect, as the gas bubbles form and propagate downstream. Foaming is further exacerbated by disturbances in the beer, such as the turbulence generated when the beer is dispensed from the dispensing valve. When beer is warmed to 45° F. or more, such as when exposed to normal ambient room temperature, the gas becomes sufficiently unstable and so much foam is generated when it is dispensed that it often cannot be served to patrons. As a result, as waste increases, and profits decrease.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a perspective view of the tabletop unit showing the housing, the beverage outlets, and the spill tray.
[0005] FIG. 2 is an equipment layout, not to scale, showing the relative positions of the elements of Applicants' novel beer cooling system.
[0006] FIG. 2A is a block diagram illustrating the microprocessor inputs and outputs.
[0007] FIGS. 3 and 4 are perspective views of the equipment layout showing the elements of the cooling system in place with the housing cover removed therefrom.
[0008] FIG. 5 is an elevational view of the beverage or beer lines and refrigeration lines within the cold plate.
[0009] FIG. 6 is a perspective view of a layout for use with Applicants' novel beverage cooling system which shows a tabletop supporting the unit, which tabletop in turn is supported by legs or a cart or the like; the product here, two different beverages, are provided in feed lines to the rear of the housing of the unit.
[0010] FIG. 7 is a perspective view of the cold plate showing refrigeration lines and beer lines laying adjacent one another and embedded within an aluminum casting.
[0011] FIG. 8 is a flow chart illustrating the standby mode.
[0012] FIG. 9 is a flow chart illustrating the compressor mode.
[0013] FIG. 10 is a flow chart illustrating the pump down mode.
SUMMARY OF THE INVENTION
[0014] The present invention is directed to a beverage dispensing system for dispensing chilled beverages, the system comprising a housing with one or more beverage inlet connections extending from said housing and one or more beverage dispenser valves extending from said housing. A beverage cooling system is positioned within said housing, said cooling system comprising a reservoir capable of receiving a supply of refrigerant, a cold plate in fluid communication with said refrigerant reservoir, wherein the refrigerant lines extend through said cold plate, wherein beverage lines also extend through said cold plate adjacent to said refrigerant lines.
[0015] The cooling system further includes an accumulator, a compressor, a refrigerant condenser, and a thermal expansion valve positioned between said refrigerant reservoir and said cold plate to adjust the flow of refrigerant depending upon the temperature of the cold plate.
[0016] If freeze-up of the beverage in the beverage lines occurs, refrigerant may be controlled by means of a hot gas valve to divert the flow of refrigerant from the cold plate, adding hot gas from the high side of the compressor to the cold plate refrigerant inlet line.
[0017] A beer or beverage evaporator valve, typically a solenoid, is provided upstream of the accumulator and downstream of the cold plate. A liquid line valve is provided typically downstream of the condenser and upstream of the reservoir, also solenoid controlled. A thermal expansion valve is provided downstream of the reservoir upstream of and close to the refrigerant inlet of the cold plate, for metering refrigerant into the cold plate in response to a thermal bulb at the outlet of the refrigerant lines on the cold plate.
[0018] Electronic sensors, such as transducers (including thermal or pressure sensors), may be provided in conjunction with a microprocessor to control the operation of the system. In one embodiment, a temperature sensor (such as a thermistor) or pressure transducer is located upstream of the evaporator valve and a pressure transducer is located near the suction or low side of the compressor. When the system is energized, that is, in a “run” or “on” mode, the microprocessor will control the compressor. The microprocessor, responsive to the evaporator (cold plate) condition, will initiate a system shutoff when a predetermined psi, for example approximately 55 psi, is reached. The first step of the system shutoff will be to de-energize the normally closed beer evaporator and liquid line valves (thus closing them), thus “trapping” the refrigerant between the valves and in the evaporator and begin monitoring of the sensor at the low end of the compressor or suction side, continuing the compressor running until a predetermined pressure, for example about 10-35 psi, is sensed (thereby assuring the accumulator is void of liquid). At a compressor low end of 10-35 psi, the compressor de-energizes and the system will wait again for a signal from the transducer just downstream from the evaporator. When this transducer hits 70 psi or the associated temperature, the microprocessor will initiate an “on” command to the compressor will be turned on and the solenoids will be energized and opened.
[0019] Restated, the microprocessor, in response to a high set point (cold plate too warm) from the first transducer (just upstream of the beer evaporator valve and downstream of the cold plate), will energize the compressor and open the liquid line valve and the evaporator valve, and responsive to an intermediate set point (cold plate low temperature) from the first transducer will close the liquid line valve and evaporator valve, but keep the compressor going, and in response to a low set point from the second transducer (accumulator dry), de-energizes the compressor and goes back to begin the cycle, monitoring the first transducer for the high set point.
[0020] There are three modes of operation of the microprocessor/controller (“microprocessor”). The microprocessor has inputs from the first transducer TS 1 and the second transducer PT 1 . The function of the microprocessor is to keep the cold plate temperature between acceptable highs and acceptable lows, or in what may be referred to as a preferred temperature range. This may be found in Table 1, wherein nine such ranges (and a test mode) are providing for setting the microprocessor. For example, certain of these ranges may be more appropriate for beer and others may be more appropriate for soda and still other ranges of the nine set forth in Table 1 may be appropriate for water. Note that the TS 1 range, which correlates to temperature range of the cold plate (evaporator), is a spread of about 2.5 psi between ON and OFF for the compressor setting.
[0021] A second function of the microprocessor program and control is to, upon compressor shutdown, draw down the low side to avoid liquid accumulation in the accumulator and slugging of the compressor when the compressor restarts, as set forth above.
[0022] A third function of the microprocessor controller program is to avoid excessive cycling of the compressor between the on-off mode. This is achieved by an adjusted reading (vaves closed) of the cold plate and maintaining the system in either standby, a compressor mode or pump down mode.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0023] self-contained beverage dispenser 10 of the present invention is shown in FIG. 1 . Although the subject invention will be described in the context of the beverage to be dispensing being beer, it is to be understood the invention is not limited to the dispensing of beer. Beverage dispensing valves 10 a and 10 b stand out the front end of housing 14 . The beverage dispensing outlets may be beer taps or other such dispensers as those known in the art. A beverage spill tray 16 is positioned beneath the outlets 10 a and 10 b. Beverage dispenser 1 may be mounted on a countertop, rolling cart or other support surface. The beverage dispenser 1 may be easily installed at a desired location. One need simply to run the product lines from the beverage supply, for example, a beer keg, to the location for connection to the beverage dispensing unit.
[0024] The refrigerant cooling system 20 of the subject invention is shown in FIG. 2 . The cooling system 20 includes reservoir 22 which acts as the reservoir for the refrigerant, which is in fluid communication with cold plate 24 via refrigerant line 25 . Refrigerant cooling lines acting as an evaporator, extend through cold plate 24 to cool corresponding beverage lines which also extend through cold plate 24 . The cold plate utilized, including, for example, 40 pounds of cast aluminum, is a standard cold plate known to those skilled in the art wherein the beverage and refrigerant lines may be wound or located within the cold plate to increase the length of the lines positioned within said cold plate. The cooling system 20 also includes accumulator 26 , compressor 28 and refrigerant condenser 30 . As shown, refrigerant exits the cold plate 24 and flows to accumulator 26 via refrigerant line 27 . From the accumulator 26 , the refrigerant travels to the compressor 28 via refrigerant line 29 . The refrigerant flows from the compressor 28 to the condenser 30 via refrigerant line 31 .
[0025] The operation of the refrigerant system is described below, in connection with FIGS. 2 and 3 .
[0026] The refrigerant, which in a preferred embodiment is type 404a, enters the compressor 28 at point A as a low pressure gas and is discharged from the compressor as a high pressure gas at point B. It then enters the top of the condenser 30 at point C.
[0027] The refrigerant is cooled in the condenser, exiting it as a high pressure liquid, and passes through a drier 32 (which retains unwanted scale, dirt and moisture) to the liquid line valve 34 , which is open whenever the cold plate 24 is warm enough to require cooling, as determined by a pressure switch Transducer TS 1 (pressure transducer or thermistor, for example).
[0028] The refrigerant, still in a high pressure liquid state, flows through the liquid line valve 34 and enters the reservoir tank 22 , which serves as a storage or surge tank for the refrigerant at point D.
[0029] At point E, the refrigerant exits the reservoir tank, passes through a sight glass 36 (where bubbles will be observed if the system is low on refrigerant) and encounters the thermal expansion valve TXV 38 .
[0030] A pressure differential is provided across the thermal expansion valve. This valve includes a sensor bulb that measures the degree (or lack) of superheat of the suction gas exiting the cold plate and expands or contracts to allow the flow of refrigerant to be varied according to need. The refrigerant leaving the thermal expansion valve will be in a low pressure liquid or liquid/vapor state when it enters the cold plate.
[0031] At the thermal expansion valve 38 there may also be a small equalizer tube 39 connected to the outlet cold plate 24 . The equalizer tube 38 helps to equalize the pressure between the inlet and outlet side of the cold plate 24 .
[0032] After passing through the thermal expansion valve 38 , the refrigerant enters the cold plate 24 at point G. As the liquid or liquid/vapor refrigerant enters the cold plate it is subjected to a much lower pressure due to the suction created by the compressor and the pressure drop across the expansion valve. It will also be adjacent warmer beer lines. Thus, the refrigerant tends to expand and evaporate. In doing so, the liquid refrigerant absorbs energy (heat) from beverage lines within the cold plate 24 .
[0033] The low pressure gas leaving the cold plate 24 encounters the evaporator valve 40 , whose function is to trap refrigerant in the cold plate during system shutdown cycle. From the evaporator valve 40 , the gas passes into accumulator 26 , which help prevent any slugs of liquid refrigerant from passing directly into the compressor, and continues back to the compressor 28 . The thermal expansion valve 38 mentioned above is used instead of a capillary tube in order to provide improved response to the cooling needs of the cold plate 24 .
[0034] The microprocessor controlled electrical control system 50 is illustrated in FIGS. 2 and 2A . Refrigeration on/off switch SW 1 provides power to the entire system by manually depressing the switch. Pressure transducer PT 1 monitors the refrigerant pressure in the compressor low side and cycles off the compressor and condenser fan (not shown) when the pressure drops to a predetermined level, 15 psi in a preferred embodiment, and cycles the compressor and fan back on when the temperature sensor or pressure transducer TS 1 reaches a second predetermined level, 75 psi in a preferred embodiment. TS 1 monitors refrigerant temperature (or pressure) just downstream of the beverage cold plate. When the pressure drops to a predetermined level, approximately 55 psi in a preferred embodiment, TS 1 through control system 50 cycles off the beverage evaporator coil or cold plate by shutting liquid line solenoid coil 34 and evaporator valve 40 . The microprocessor then reads the transducer PT 1 until drawdown to a lower pressure than 55 psi is reached, here for example, 10-35 psi, where the compressor is cycled off by the microprocessor/controller. The monitor then looks to TS 1 . With the compressor off, the cold plate starts to warm. When the refrigerant pressure at TS 1 rises to a second predetermined level, approximately 72-75 psi in a preferred embodiment, the TS 1 through microprocessor/control system 50 turns on the compressor and opens evaporator solenoid coil 40 and liquid line solenoid 34 A push-button defrost switch 42 is provided to cycle on the hot gas solenoid and cycle off the condenser fan to deliver hot gas to the cold plate should the product in the cold plate become frozen.
[0035] Sensor/transducer TS 1 responds to the cold plate 24 temperature by reading the pressure or temperature of the refrigerant as it is discharged from the cold plate. When the cold plate becomes warm enough, the liquid line valve 34 and the evaporator valve 40 open, thereby allowing refrigerant to flow throughout the system. When the cold plate becomes cool enough these valves 34 / 40 will close, trapping most refrigerant in the system but with the electronic control a] lowing refrigerant to pump from the accumulator into the compressor down until PT 1 reads about 15 psi (typically between 10-35 psi).
[0036] As shown in FIG. 2 , defrost valve 42 is installed between the compressor discharge tube and the cold plate inlet. A manually operated momentary switch 44 may be deployed to trigger the defrost cycle. This signals the microprocessor to open the defrost valve 42 for a preset defrost cycle time, normally 30 seconds, and allows high pressure gas from the compressor to be pumped into the cold plate to thaw it, should it freeze up or get too cold. To prevent damaging the system, the switch should not be held longer than necessary.
[0037] The TXV 38 controls and meters the amount of refrigerant that flows into the evaporator based on the temperature with a sensing bulb 41 that is typically located on the suction line where it leaves the evaporator coil. The temperature differential of the evaporator inlet and outlet typically determines the opening and closing of the TXV 38 valve seat to either add refrigerant or constrict refrigerant flow to the evaporator. Other devices known in the art may control pressure of refrigerant into the evaporator.
[0038] An electronic microprocessor/controller 50 operates the compressor, condenser fan, and solenoids 34 / 40 . The microprocessor controller engages a power off switch, a defrost switch 42 , temperature sensor (from evaporator thermal sensor, a temperature sensor or pressure transducer) TS 1 , and an overheat temperature sensor 51 (from high side of condenser), as well as a pressure/transducer PT 1 just upstream of the low end of the compressor.
[0039] Outputs (110 volt AC) include normally closed solenoids (2) 34 / 40 , the compressor (typically about one-third horsepower) and the condenser fan (typically about 14 watt). Defrost solenoid 42 and a power on and defrost cycle LED include controller outputs.
[0040] In the on/run mode (when the power switch is activated), the compressor, condenser fan, and solenoid pair 34 / 40 are activated. Compressor pumps refrigerant and the temperature of the cold plate will drop as the refrigerant goes through the cold plate. The “power on” LED is on. The monitor is looking at TS 1 looking for the solenoid valves shutoff condition, the intermediate set point here, for example, about 55 psi.
[0041] “Stop” mode occurs when the intermediate set point evaporator temperature sensor TS 1 is reached, for example, approximately 29° F. (68.0 psi with Suva® 404A). The solenoids 34 / 40 are closed trapping liquid refrigerant in the cold plate and reservoir. The condenser fan and compressor continue to run until the pressure/vacuum transducer PT 1 set point is reached. This is about 15 psi. This action assures that there is little or no liquid refrigerant left in the accumulator. At this point, the fan and the compressor turn off and wait for a microprocessor signal from the evaporator temperature sensor TS 1 . “Power on” LED remains energized.
[0042] When temperature of the evaporator at TS 1 increases to an upper limit, typically about 33° F. (74.0 psi with 404A or other suitable refrigerant), the “on” mode is automatically activated by the controller and cycles the compressor on and the solenoids open.
[0043] This illustrates the controller in its normal operating mode. However, if the temperature of the high side thermal sensor 51 exceeds a set point (overheat), the system shuts down the compressor, fan, and solenoids and alternately flashes the LED indicators. This is a warning that the system has overheated.
[0044] If the system freezes up or gets too cold, the momentary “defrost” switch is activated. The defrost solenoid is activated and the defrost LED flashes for a defrost cycle. The cycle is timed to last about 15-20 seconds, after which the LED turns off and the dispenser returns to the normal on/run cycle.
[0045] One of the purposes of the electronic controller 50 is to maintain the compressor in an off position until the temperature of the evaporator reaches an upper limit, typically about 33° F., and the on mode is activated again. Thus, if there is any liquid refrigerant in the accumulator and it evaporates, as the system warms up or pressure increases, the pressure switch at the low end of the compressor will not cycle the compressor on. That is to say, the microprocessor controller 50 will provide for compressor run/on when solenoids 34 / 40 are de-energized and closed, but only until PT 1 reads about 15 psi or between about 10-35 psi, (thereby ensuring evaporation of any liquid refrigerant in accumulator 26 ).
[0046] FIGS. 3 and 4 illustrate an equipment layout for the embodiment of Applicants' device as set forth in FIGS. 1 and 2 . It is seen with respect to FIGS. 3 and 4 , that the cold plate 24 is set vertically with respect to a base 25 of the cooling system 20 . Furthermore, it can be seen
[0047] that the condenser 30 is also set vertically and spaced apart from the cold plate 24 . A substantial number of the elements are set between the vertically oriented cold plate and condenser, including the compressor, drier, solenoids, sight glass, liquid line valve, thermal control valve, evaporator valve, reservoir tank, and accumulator. Moreover, the fan for the condenser is mounted inside the unit exhausting air through vents in the rear view of the unit (see FIG. 4 ).
[0048] FIGS. 5 and 7 illustrate an embodiment of an arrangement of refrigeration lines and beer lines that may be used in the cold plate. It is seen with respect to FIG. 5 that refrigeration lines lay in a plane, as do the beverage lines. Adjacent to each beer line plane lays a refrigeration time plane for uniform heat transfer.
[0049] FIG. 6 illustrates a manner in which Applicants' novel cooling system 20 may be set up on a support surface or a table top TT, wherein the product (beverage) being supplied to the system, here from two kegs or other containers of liquid product, may enter the system from the rear. In an alternate preferred embodiment, the lines from the product to the cooling system may enter the system from beneath the table top TT and beneath the base 25 . Another suitable arrangement would be provided on a table top TT with a support member that is in the nature of a cart 31 having wheels (not shown), so that the unit may be wheeled around.
[0050] Part of the advantages of the system described is the microprocessor controlled solenoid valves trapping refrigerant responsive to the microprocessor signals as set forth above. Normally on most systems when the system shuts down, the pressure differential will bleed back down to equilibrium, and in a normal situation when the system starts up, there is a time lag to drive up pressure in the condenser as the system starts back up. In the system set forth herein, however, by the action of the solenoid shutdown, pressure is maintained and bleed down is avoided. That is to say, there is a “stop action” freeze of the refrigeration cycle which allows an almost instantaneous return to the refrigeration cycle without the necessity of loading up the condenser.
[0051] Operation is driven by readings from two pressure transducers TS 1 (cold plate), PT 1 (suction side of compressor). One TS 1 measures pressure of gas in the evaporator which reflects the temperature of the cold plate. The other, PT 2 , measures pressure of the pump down cycle. The firmware controls the compressor 28 , fan 29 , run solenoids 34 / 40 , defrost solenoid 42 , and status LED's 41 / 43 / 45 (se Table 1). There is a ten position switch that determines the setpoints for the cold plate temperature. There is a defrost switch for starting a defrost cycle.
[0052] The unit operates in one of the following modes depending on the pressure transducer readings.
[0053] FIG. 8 , Standby mode (green LED 41 blinking):
[0054] Evaporator pressure indicates cold plate temperature below “on” setpoint.
[0055] Run valves 34 / 40 and defrost solenoid 42 are off (valves closed.) Compressor 20 and fan 28 are off.
[0056] When evaporator pressure TS 1 indicates cold plate temperature above “on” setpoint, example 71.0 psi, unit enters compressor mode.
[0057] FIG. 9 , Compressor mode (green LED 41 blinking, red LED 43 on steady):
[0058] Run solenoids 34 / 40 are on (valves open) and defrost solenoid 42 is off (valve closed). Compressor 28 and fan 29 are on. Evaporator pressure indicates cold plate temperature above “off” setpoint, example 68.5 psi.
[0059] Runs compressor with run valves open, monitors TS 1 for a time period T 1 , every, for example 10 seconds, until evaporator pressure is below 60 or the “off' setpoint, example 68.5 psi, minus 8 (whichever is greater). This pressure reading is done with the run valves open which typically gives a pressure reading of 15 to 20 pounds lower than a reading with the valves closed. Closing the valves, waiting a short period, and then measuring the cold plate gives a more accurate cold plate temperature. The valves closed reading would be one that more accurately reflects the temperature of the cold plate.
[0060] After the evaporator pressure TS 1 (with the valves open) gets below 60 (or off set point minus 8), the unit starts checking the evaporator pressure with the run valves closed for a period of T 2 , for example, every 10 seconds. It does this by closing the run valves (with the compressor still running), waiting 1.5 seconds for the pressure to stabilize, and then taking a TS 1 pressure reading. If the pressure is not below the “off' setpoint, the valves are reopened and the unit stays in compressor mode. Otherwise the unit enters pump down mode with the valve 34 / 40 closed.
[0061] FIG. 10 , Pump down mode (green LED blinking, red and yellow LED's on):
[0062] Pump down pressure above 10 as measured at PT 1 . Run solenoids 34 / 40 are off (valves closed) and defrost solenoid is off (valve closed). Compressor 28 and fan 29 are on.
[0063] Remains in pump down mode until pump down pressure PT 1 is below 10 or evaporator pressure TS 1 is above “on” setpoint. If the pump down pressure reaches 10, the unit enters standby mode. If the evaporator pressure goes above the “on” setpoint, the unit enters compressor mode.
[0064] Defrost mode (green LED blinking, yellow LED on):
[0065] Defrost mode is entered when the defrost switch is manually pressed.
[0066] Run solenoids 34 / 40 are on (valves opened) and defrost solenoid 42 is on (valve open). Compressor 28 is on and fan 29 is off. Defrost mode runs for a period of T 3 , for example, for 40 seconds then standby mode is entered. Defrost mode cannot be reentered until a compressor mode cycle has completed.
[0000]
TABLE 1
Setpoints
On
Off
Temp On
Temp Off
1
65
62.5
27.1
25.5
2
67
64.5
28.4
26.8
3
69
66.5
29.7
28.1
4
71
68.5
31.0
29.4
5
73
70.5
32.3
30.7
6
75
72.5
33.6
32.0
7
77
74.5
34.9
33.3
8
79
76.5
36.2
34.6
9
81
78.5
37.5
35.9
[0000]
TABLE 2
Temperature
Pressure
LOW
28
68
HIGH
36
78
Diff
8
12
Pressure Diff per degree
1.53
[0067] T 1 (see FIG. 8 ) is a period of time in which the system is in a standby mode which was entered after the cold plate was sufficiently cold and the low end PT 1 pressure was below a preset minimum, for example, 10 psi. The system, left in the standby mode, would typically warm up, for example, towards room temperature or when a beer is drawn from adding heat to the cold plate. Thus in standby mode, the cold plate is being monitored for a period of time T 1 . This period should be short enough to be responsive to temperature change at the cold plate, for example, drawing a beer. It should not be too short generating unnecessary monitoring.
[0068] Time period T 2 is a time period between leaving standby mode, when the on set point is exceeded and entering compressor mode. That is, time period T 2 should not be too long, as the system needs heat removed therefrom.
[0069] In compressor mode, the microprocessor (monitor) is looking at the cold plate temperature and comparing it to a pre-selected temperature of either 60 psi or the compressor off temperature −8 psi or an appropriate value below the off set point. It has been determined, through experimentation, that a more accurate reading of the cold plate occurs if run valves 34 / 40 are closed for a period of time, for example, T 3 , here 1.5 seconds, after which period of time the cold plate is monitored. If, in the compressor mode, the closed valve reading is below the off set point, here, for example, 68.5, then the system will enter the pump down mode. If the closed valve reading is greater than the off set point, the valves will open and the time period, for example, T 4 will be applied and then the cold plate pressure will again be checked. For a time period, T 3 experimentation can determine as short a time as possible for pressure in the cold plate to stabilize. For a period of time T 4 is not too long or the off set point here, for example, 68.5, may be overshot. If T 4 is too short, you are hurting your cooling capacity by having the valves closed again for T 3 .
[0070] While the subject of this specification has been described in connection with one or more exemplary embodiments, it is not intended to limit the claims to the particular forms set forth. On the contrary, the appended claims are intended to cover such alternatives, modifications and equivalents as may be included within their spirit and scope. | A temperature-controlled beverage dispenser is disclosed, which provides a cold plate having disposed therein beverage lines and refrigerant lines. The refrigerant lines may be connected to a cooling system, such as a heat exchanger, which is configured to remove heat from the cold plate. The beverage lines may be connected to a beverage supply for dispensing a desired beverage. Valves and a pressure sensor in the refrigerant line are connected to a microprocessor. At regular intervals, the microprocessor closes the valves, waits a short time, and then takes a pressure reading, which corresponds to a temperature. If the temperature falls below a desired value, then the cooling system is shut off. This permits the microprocessor to closely control the temperature of the beverage being dispensed. | 5 |
BACKGROUND
During the lifespan of an oil reservoir, samples from the reservoir can be collected and analyzed. To effectively sample the production fluid from a well, and more particularly a subsea well, sampling systems are often located in close proximity to the wellhead. Wellhead sampling presents a challenge due to the potential for dispersed and mist flow from the wellhead containing both liquid and gas phases (multiphase flow). To take a liquid sample, the liquid phase must be separated from the gas phase. Multiphase flows exhibiting a dispersed or mist flow regime can be difficult to separate into component liquid and gas phase flows, in turn making the collection of liquid-only samples more difficult.
Further, sample systems may use a flow device, such as a venturi or an orifice plate, to generate a pressure differential proportional to the production flow. If the production flow rate is too low, the pressure differential generated by the flow device may be insufficient to retain a sample that contains both liquid and gas.
Further, multiple samples may be taken during the life of the well. Connecting and unconnecting equipment can be time consuming and servicing connections permanently mounted on the wellhead or other subsea structure can be difficult.
SUMMARY
An oil or gas well and related sampling assembly of this disclosure can be used to sample production fluids from the oil or gas well. The assembly includes a receiving structure that houses a saver sub, a retrievable skid, and protection plates. The receiving structure can be fixably attached to a manifold, an Xmas tree, or a length of pipe from which samples will be taken. The saver sub accesses the production flow via its connection with the receiving structure and then releasably connects with the retrievable skid. The receiving structure allows production fluid samples to be taken throughout the lifecycle of the manifold and the saver sub reduces the number of makes and breaks on the couplings in the manifold—instead, the interface between the retrievable skid and the saver sub is cycled with every sample taken. Among other valves and couplings, the retrievable skid houses the sample collection chambers.
Once the samples have been collected, a remotely operated vehicle (ROV) removes the retrievable skid and brings it to the surface. After the sample chambers are emptied and replaced, the sampling bottles are placed back in the retrievable skid, returned subsea, and reinstalled in the sampling system.
BRIEF DESCRIPTION OF THE DRAWINGS
For a detailed description of the preferred embodiments of the invention, reference will now be made to the accompanying drawings in which:
FIG. 1 shows a perspective view of a receiving structure in accordance with various embodiments;
FIG. 2 shows a cross-sectional view of the saver sub interface on the receiving structure;
FIGS. 3 and 4 show perspective views of protection plates in accordance with various embodiments;
FIGS. 5 and 6 show perspective views of a saver sub in accordance with various embodiments;
FIG. 7 shows a bottom view of an embodiment of the multiple quick connect components on the saver sub that interface with the receiving structure;
FIG. 8 shows a top view of an embodiment of the multiple quick connect components on the saver sub that interface with the retrievable skid;
FIG. 9 shows a perspective view of the retrievable skid in accordance with various embodiments;
FIG. 10 shows a top view of an embodiment of the multiple quick connect components on the chassis plate of the retrievable skid that interface with the saver sub;
FIG. 11 shows a perspective view of the retrievable skid;
FIG. 12 shows a perspective view of a pump driven sampling assembly in accordance with various embodiments;
FIG. 13 shows an exploded view of a pump driven sampling assembly;
FIG. 14 shows an alternative embodiment of a pump driven sampling assembly; and
FIG. 15 shows a perspective view of an embodiment of a protection plate mounted on the receiving structure.
DETAILED DESCRIPTION
The following discussion is directed to various embodiments of the invention. The drawing figures are not necessarily to scale. Certain features of the embodiments may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness. Although one or more of these embodiments may be preferred, the embodiments disclosed should not be interpreted, or otherwise used, as limiting the scope of the disclosure, including the claims. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce desired results. In addition, one skilled in the art will understand that the following description has broad application, and the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to intimate that the scope of the disclosure, including the claims, is limited to that embodiment.
Certain terms are used throughout the following description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function.
In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . . ” Also, the terms “couple,” “connect,” “engage,” and “attach” are intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices, components, and connections. The term “fluid” may refer to a liquid or gas and is not solely related to any particular type of fluid such as hydrocarbons. The term “pipe,” or the like refers to any fluid transmission means.
FIG. 1 shows the receiving structure 100 , comprised of a base platform 110 , a saver sub interface 130 , a plurality of posts 140 , and a sloped top structure 170 . The base platform 110 is generally rectangular but may be configured in any suitable shape. The posts 140 extend from and connect the base platform 110 to the sloped top structure 170 . The sloped top structure 170 includes sides that slope inward toward the center of the base platform 110 , creating upper perimeter 171 and lower perimeter 172 ; the upper perimeter being larger than the lower perimeter. In a preferred embodiment, the angle of the sloped top structure 170 is between thirty degrees and sixty degrees.
Two middle saver sub guides 155 extend from the surface of the base platform 110 . The middle saver sub guides 155 bend outward toward the lower rectangular perimeter 172 such that the upper portion of the middle saver sub guides 155 is angular and disposed on the lower rectangular perimeter 172 . Two corner saver sub guides 150 are disposed on the surface of the raised platform 120 . Two corner retrievable skid guides 160 are disposed on the surface of the base platform 110 . Each of the four corner guides (2-saver sub guides 150 , 2-retrievable skid guides 160 ) are made up of two middle saver sub guides 155 positioned orthogonally next to each other such that the lower portions of the guides contact each other, forming an “L” shape. A triangular web 158 bridges the gap between the top angular portions of the guides. The top portions of the corner guides 150 , 160 bend outward toward the lower rectangular perimeter 172 such that the triangular web 158 and upper portion of guides 150 , 160 are angular and disposed on the lower rectangular perimeter 172 .
The raised platform 120 is disposed on the surface of the base platform. The raised platform 120 may be rectangular in shape with two corners cut out on the side toward the center of the base platform 110 ; the two cut outs allowing the middle saver sub guides 155 to attach to the surface of the base platform 110 . The saver sub interface 130 is disposed on the surface of the raised platform 120 and houses various components (not shown) for interfacing with the saver sub.
FIG. 2 shows a cross-sectional view of the saver sub interface 130 , which includes: a top plate 135 , side walls 136 a , and the multiple quick connect (MQC) mating components. The MQC components include: bushing guides 131 , a lockdown housing 134 , and two pass through holes 133 . The MQC allows production fluid to be communicated between the manifold and saver sub (to be described in more detail below). The lockdown housing 134 is typically located in the center of the top plate 135 , is cylindrical, and protrudes below the surface of the top plate 135 . The lockdown housing 134 attaches with a locking mechanism on the saver sub (to be discussed in more detail below). On either side of the lockdown housing 134 are two pass through holes 133 that accommodate couplings (not shown). On either side of the pass through holes 133 are two bushing guides 131 . The bushing guides 131 are secured to the saver sub interface 130 by lock nuts 132 , and receive guide pins located on the saver sub (to be discussed in more detail below).
FIGS. 3 and 4 show protection plates 200 and 201 . The protection plates 200 , 201 , mount side by side on the sloped top structure 170 of the receiving structure 100 . Each protection plate has a locking mechanism 220 that mates with the sloped top structure 170 of receiving structure 100 . In addition, protection plate 200 also has saver sub guides 210 , similar to the corner saver sub guides 150 located on the receiving structure 100 .
As shown in FIGS. 5 and 6 , saver sub 300 includes a base structure 310 , a top plate 320 , a plurality of posts 340 , a three port bottle 370 , pipe work 380 , and retrievable skid guides 350 . The base structure 310 includes a top surface 310 a , a plurality of side surfaces 310 , and additional couplings and guidance pins to be described in more detail below. The top surface 310 a includes notches cut out of two corners, creating indented sides 310 b , 341 . A hole 375 is cut out of the top surface 310 a to allow the three port bottle 370 to sit approximately half above and half below the top surface 310 a.
FIG. 7 shows an underside view of the lower surface 311 c . The lockdown boss 334 is disposed on the underside of lower surface 311 c and connects to the lockdown housing 134 on the receiving structure 100 as shown in FIG. 2 . Couplings 333 are spaced from the lockdown boss 334 . The couplings 333 interface with the pass through holes 133 on the receiving structure 100 , as shown in FIG. 2 , and are positioned accordingly. The receiving structure guide pins 331 are disposed on the underside of the lower surface 311 c and aid in the proper alignment of the saver sub 300 with the receiving structure 100 during installation. The receiving structure guide pins 331 fit inside the bushing guides 131 shown in FIG. 2 .
FIG. 5 shows a plurality of posts 340 and 341 extending between the base structure 310 to the top plate 320 . As shown in FIG. 8 , the top plate 320 includes a lockdown bucket 330 , a lift mandrel 365 , retrievable skid guides 350 , and the mating MQC components: two retrievable skid guide pins 360 , lockdown boss 361 , one half inch coupling 362 , and two one inch couplings 363 .
The lockdown bucket 330 , shown in FIG. 5 , serves as the connection point for the ROV to lock the saver sub 300 onto to receiving structure 100 in a method as is known to those skilled in the art. The lockdown bucket 330 includes a releasable connection moveable between a locked and unlocked position and operable by the ROV. The lift mandrel 365 is disposed on the top plate 320 and protrudes above the top plate 320 . The lift mandrel 365 includes alternating cylindrical and conical sections, and is engageable by a lifting adapter (not shown) as is known by those skilled in the art. The lower portion of the two retrievable skid plate guides 350 are disposed on the top plate 320 and extend from the surface of the top plate 320 at the two posts 341 . The upper portion of the retrievable skid guides 350 is angled to aid the ROV operator to guide the retrievable skid 400 into the receiving structure 100 next to the saver sub 300 .
Two couplings 363 are located along top plate 320 . The couplings 363 interface with the retrievable skid MQC components (to be described below). The lockdown boss 361 is disposed in the smaller rectangular portion of the top plate 320 . The lockdown boss 361 mates with the lockdown boss of the retrievable skid (to be discussed below). The one half inch coupling 362 is disposed on the top plate 320 a distance away from the lockdown boss 361 . The coupling 362 also interfaces with the retrievable skid MQC components. The retrievable skid guide pins 360 are disposed away from coupling 362 and engage the bushing guides located on the retrievable skid (to be discussed in greater detail below).
FIG. 5 shows pipe work 380 disposed between the top plate 320 and the base structure 310 , which moves fluid between the manifold (not shown) and the retrievable skid 400 . The pipe work 380 connects various components; for example, pipe work 380 connects coupling 333 to the three port bottle 370 as well as the three port bottle 370 to the couplings 363 .
FIG. 11 shows the retrievable skid 400 with buoyancy shells 404 a and 404 b . The buoyancy shells 404 a , 404 b are attached to the chassis plate 403 (shown in FIG. 9 ) and, thus, form part of the structural frame of the retrievable skid 400 . The buoyancy shells 404 a , 404 b also serve to reduce the in-water weight of the retrievable skid 400 . However, it should be appreciated by one of skill in the art that the buoyancy shells 404 a , 404 b are not necessary for the retrievable skid 400 .
FIG. 9 shows the retrievable skid 400 without the buoyancy shells. The retrievable skid 401 includes a truss 402 , lockdown bucket 430 , hotstab 470 , pump 440 , sample chambers 420 (four are shown), and MQC components: bushing guides 460 , couplings 462 and 463 , and skid lockdown boss 461 . The truss 402 includes a chassis plate 403 with a plurality of cut outs to accommodate the mounting of various retrievable skid components, including the buoyancy shells 404 a , 404 b shown in FIG. 11 . The chassis plate 403 provides the structural support for the retrievable skid 400 and any impact loads received by a retrievable skid component is transferred to the chassis plate 403 . A plurality of additional posts also form the truss 402 .
The lockdown bucket 430 is disposed on the chassis plate 403 such that the aperture of the lockdown bucket 430 is disposed on the top surface of the truss 402 . The lockdown bucket 430 , shown in FIG. 11 , serves as the connection point for the ROV to lock the retrievable skid 300 onto to the saver sub 300 in a method as is known to those skilled in the art. The lockdown bucket 430 includes a releasable connection moveable between a locked and unlocked position and operable by the ROV.
The aperture of the electro-hydraulic hotstab receptacle 470 (referred to as “hotstab” hereinafter) is similarly disposed on the top surface of the truss 402 . The hotstab 470 mates with a hotstab counterpart on the ROV as known to those skilled in the art. The hotstab 470 is used for hydraulic power of the pump 440 and for power and communication for other components, supplied by the ROV (not shown). A flexible hose 475 connects the hotstab the hotstab pod 477 . The hotstab pod 477 is connected through the electrical harness 480 and the connector 490 to the sensor which is mounted to the chassis plate 403 .
The pump 440 , preferably a positive displacement pump, is preferably disposed in approximately the chassis plate 403 and connects to the hotstab 470 , the three port bottle 370 of the saver sub 300 , and the sample chambers 420 . The pump 440 is powered by the hotstab 470 and receives hydraulic power from an ROV (not shown). The pump 440 draws production fluid samples through the three port bottle 370 , fills the sample chambers 420 , and flushes the system. In a preferred embodiment, the pump 440 has three pumping modes: single phase, multiphase, and flushing.
The sample chambers 420 can be, for example, cylindrical, grouped in a 2×2 matrix formation, and disposed radially on the bottom surface of the chassis plate 403 , such that the sample chambers 420 surround the pump 440 . Although four sample chambers 420 are shown, any number of sample chambers may be used and positioned in any appropriate configuration. The preferred embodiment of a sample chamber 420 has three separate compartments—one for the fluid sample, one for MEG/water/glycol, and one for nitrogen. Filling the sample chamber 420 with fluid is facilitated by drawing water/glycol from the middle compartment, thus, drawing in the fluid sample. Once the sample chamber 420 is returned to the surface, 10% of the fluid sample is purged. Then the valve that communicates between the water and nitrogen compartments is opened, which allows a gas cap to be introduced to the sample.
The MQC components are shown in FIG. 10 . The bushing guides 460 and the two one inch couplings 463 are disposed on the chassis plate 403 . All the couplings 462 , 463 extend above and below the surface of the chassis plate 403 . The skid lockdown boss 461 also extends above and below the surface of the chassis plate 403 . The MQC components on the retrievable skid 400 interface with the upper MQC components of the saver sub 300 in like manner as the lower saver sub MQC components interface with the MQC components of the receiving structure 100 .
FIGS. 12 , 13 , and 15 show an embodiment for a sampling assembly for sampling production fluids from an oil or gas well. The well includes a structure, such as a manifold, an Xmas tree, or a length of pipe (not shown, generally referred to as “manifold”) and a sampling assembly that includes a receiving structure 100 , a saver sub 300 , a retrievable skid 400 , and protection plates 200 , 201 . The receiving structure 100 is secured to the manifold, from which production fluid samples will be taken. The receiving structure 100 is connected to the production flow in a manner known to those skilled in the art. The receiving structure 100 is considered non-releasably connected to the manifold, preferably welded into place. The connection is designed as a long term, permanent type connection rather than a quick connect/disconnect configuration. Via an ROV, as known to those skilled in the art, the saver sub 300 is guided by and installed on the raised platform 120 of the receiving structure 100 . The retrievable skid 400 is installed after the saver sub 300 and is transported and installed via ROV on the receiving structure 100 adjacent to the raised platform 120 . In a preferred embodiment, when the saver sub 300 and the retrievable skid 400 are installed in the receiving structure 100 , the receiving structure 100 transfers the load from the saver sub 300 and retrievable skid 400 to the manifold.
FIG. 13 depicts the components of the pump driven sampling assembly prior to integration. The saver sub 300 attaches to the receiving structure 100 at the saver sub interface 130 disposed on the raised platform 120 . Next, the retrievable skid 400 is placed, by ROV, in the receiving structure 100 ; the retrievable skid 400 partially overlaps and interfaces with the saver sub 300 .
The saver sub 300 accesses the production flow via its MQC connection with the receiving structure 100 . The retrievable skid 400 is then connectable to the saver sub 300 with the MQC “quick” connect/disconnect connection. Thus, the receiving structure 100 allows samples to be taken throughout the lifecycle of the manifold and the saver sub 300 reduces the number of makes and breaks on the couplings between the manifold and the receiving structure 100 —instead, the interface between the retrievable skid 400 and the saver sub 300 , and also possibly the interface between the saver sub 300 and the receiving structure 100 , is cycled with every sample taken. This saves the wear and tear on the manifold itself and allows for servicing the receiving structure 100 by replacing the saver sub 300 when needed as opposed to replacing parts on the manifold itself.
FIG. 15 shows the receiving structure 100 with protection plate 200 installed. Prior to the saver sub 300 installation, protection plate 200 is disposed on the receiving structure in the diametrically opposite side from the raised platform 120 . Saver sub guides 210 located on protection plate 200 serve to guide the saver sub 300 , as shown in FIG. 10 , into the proper location over the raised platform 120 and the saver sub interface 130 . Both protection plates 200 , 201 may be installed when the receiving structure 100 has no components installed or when only the saver sub 300 is installed. Both protection plates 200 , 201 are removed to allow for installation of the retrievable skid 400 .
The retrievable skid 400 shown in FIG. 12 extends above the top of the receiving structure 100 . In a preferred embodiment, the retrievable skid 400 can support its own weight and can withstand impacts from the ROV. FIG. 14 shows an alternative embodiment that includes an alternative receiving structure 102 , an alternative saver sub 302 , and an alternative retrievable skid 402 . In this embodiment, the alternative saver sub 302 and alternative retrievable skid 402 , when integrated in the alternative receiving structure 102 , are fully recessed below the level of the protection plates, 200 , 201 as shown in FIG. 14 , which reduces potential ROV impacts.
Although the present invention has been described with respect to specific details, it is not intended that such details should be regarded as limitations on the scope of the invention, except to the extent that they are included in the accompanying claims. | A sampling assembly for taking single or multiphase production fluid samples from a subsea well. The sampling assembly includes a receiving structure that houses a saver sub and a retrievable skid. The sampling assembly allows for repeated retrieval of collected samples and replenishment of empty sample chambers using the retrievable skid. A releasable connection interface between the retrievable skid and the saver sub allows an ROV to connect the retrievable skid to the saver sub and provide electrical and hydraulic power to the sampling assembly for taking samples. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an exercise machine for performing anaerobic or aerobic exercises, which is designed to be installed rapidly in such a way as to ensure that a minimum amount of space is completely available for performing a training session both in an environment provided for sports training and in a home environment, even when the space available for the machine is limited. The present invention also relates to a multi-station exercise machine, comprising a plurality of training modules, each of which can be arranged with respect to the other modules depending on the requirements for management of the space within the environment in which the machine is installed.
2. Description of the Prior Art
In the field of exercise machines for performing anaerobic exercises, which are generally equipped with a counterweight load group that can be operated by an operating device connected to the load by a cable wound around a plurality of pulleys so as to define a predetermined path, it is known to isolate the load group with a grill or with some other safety screening device. The same also applies to so-called cardiovascular machines which are designed for performing aerobic exercises and where the load group, which is normally electrified, exchanges power cyclically with the user by using an operating device which in the case of running machines is an endless belt, in stepper machines and elliptical machines comprises two footboards, and in exercise bicycles comprises two pedals. In these cases the operating device is separated from the load group by a protective housing in order to prevent traumatic injury or electrocution.
Examples of anaerobic or aerobic machines with this type of protective system are widely found in any gymnasium since these protective devices have been known for a long time and the assigned herein has also manufactured them for some time. Further detailed information in connection with the above may be found at the Internet site www.technogym.com which illustrates the machines manufactured by the assignee and in particular the counterweight machines in the product lines “Selection” and “Biostrength” for anaerobic training and the latest machine “Excite” for aerobic/cardiovascular training.
It should be noted that each of the machines in the three abovementioned product lines has, in addition to a considerable weight, also a respective work or training zone which is contained inside an ideal volume which has a predetermined form and is able to assume varying proportions depending on the physical attributes of the exercising user. This ideal volume has a form and extension which can be easily calculated on the basis of the type of movement which the user must perform in order to carry out the exercises. Obviously, this volume comprises the minimum working volume within which the user is able to access the machine freely and perform predetermined movements, such that he/she is able to experience the exercising activity in a positive manner in that it is reasonably devoid of constraints. Therefore, in the case where two machines—which may also be identical—must be arranged alongside each other, the minimum training volumes of the two machines must be kept suitably separate from each other in order to avoid interference.
The question of identifying the work zone and the corresponding service zone, such that the former can be fully used by a user during training and the latter is suitably isolated, is therefore particularly important at the time of installation and during use of the machine and, therefore, poses serious problems for the person carrying out installation. In fact, it should be commented that the space which is normally available is very limited and, therefore, it is difficult to imagine an exercise machine capable of being installing in a predetermined location within a home, or in the vicinity of another machine, being certain that the space reserved for the two zones, i.e., the work zone and service zone, has the appropriate dimensions. To this end, in order to avoid having to reorganize again at a later date each installation layout—also with some difficulty owing to the considerable amount of weight involved—the best option is to follow the manufacturers instructions who indicated the necessary conditions for correct installation and, therefore, the distance which must be maintained between predetermined points of the machine and the walls of the room or between these points and those of a machine alongside which it is to be located. Obviously it can be easily imagined that the smaller the space available, the more difficult it is to perform installation and, therefore, the greater the amount of time required and the cost of the operation. Therefore, the outcome is unfavourable both for the customer, who wastes more time and money than would be reasonable to devote to installation of an exercise machine, and for the installation engineer who, at the end of a working day, will have installed only a limited number of machines.
Accordingly, the object of the present invention is to provide an exercise machine which is devoid of the above-mentioned drawbacks and which would have a work zone or work volume of predetermined dimensions so as to ensure a minimum space completely available for performing a training session in accordance with the medical/sports program in question.
A further object of the present invention is that the machine be low-cost and allows installation of the machine rapidly by a person with little or no experience in installing gym equipment and without the need for measuring instruments.
A still further object of the present invention is to provide a machine with which it is possible to separate the work zone from the service zone with the load unit, so as to prevent unintentional interference with the latter in a simple and inexpensive manner.
Another object is to provide a machine that would allow association of electrical equipment of varying nature with the machine.
An object of the present invention is also to provide a multi-station exercise machine, equipped with a plurality of exercise machines, each of which is devoid of the abovementioned drawbacks and which for this purpose is equipped with low-cost equipment able to ensure that the machine in question can be easily installed in keeping with the respective work zone/volume, so that the latter, within each station of the multi-station machine, can be freely accessed and used by a user during training and both before and after training.
A yet further object of the present invention is that the equipment should be such that the machine can be easily incorporated in the corresponding multi-station machine, that the multi-station machine may be regarded as a set of minimum training modules which can be combined in a modular manner, that it is low-cost and that the machine itself can be easily and rapidly installed in such a manner as to ensure that the spaces occupied by the machine are sufficient for performing training sessions correctly in accordance with the medical/sports program in question.
SUMMARY OF THE INVENTION
These and other objects of the present invention, which will become apparent hereinafter are achieved by providing an exercise machine including a frame, at least one operating device which can be used by a user to perform a physical exercise, and a load group supported by the frame and connected to the operating device so that it can be operated as required by the user while training. The machine has a work zone for performing the physical exercise in accordance with a given medical/sports program and has a service zone adjacent to the work zone and in which the load group is arranged. The work zone and the service zone are inscribable completely inside a minimum volume of predetermined height, width and depth. The machine further includes volume indicating means which is capable to render a visually discernible, minimum training module which can be freely used so that it can be rapidly installed in a space of limited dimensions both individually and in combination. The volume indicating means includes a panel having dimensions roughly corresponding to the height and width of volume of the machine, so as to separate physically the work zone from the service zone to guarantee the user a minimum training work space and prevent involuntary interaction with the service zone.
The objects of the invention are further achieved by providing a multi-station exercise machine including a plurality of exercising modules, with each module being able to be freely used and equipped with at least one operating device which can be used by a user to perform a physical exercise. The machine further includes a load group supported by a frame and connected to the operating device so that it can be operated as required by the user while training using the operating device. At least one of the plurality of modules has a work zone accessible to at least one user for performing a training session and provided, for this purpose, with the operating device. The module also has a service zone adjacent to the work zone and provided with the load group. The work zone has a front section of a predetermined height and width. Each module further has means for indicating the respective volume which correspond approximately to the height and width so as to separate physically the corresponding work zone from the service zone to prevent the user engaged in training from interacting voluntarily or involuntarily with the respective associated service zone. The volume indicating means has at least one panel having dimensions which correspond approximately to the said height and width.
There is further provided, according to the invention, an equipped wall having plurality of panels which are connected together laterally by joining means able to keep exercise machines at a predetermined distance from each other, whereby a plurality of respective minimum training modules are arranged alongside each other, in order to define a predetermined training circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
The description which follows will facilitate understanding of the invention, the further objects thereof, the general nature of application of invention to the field of exercise machines and the way in which it is able to solve the abovementioned problems in a simple and low-cost manner.
The invention will now be described with reference to the accompanying drawings which illustrate some non-limiting examples of embodiments thereof and wherein:
FIG. 1 is a schematic perspective view of an exercise machine according to a first preferred embodiment of the present invention;
FIG. 2 is a plan view, on a smaller scale and with parts removed for the sake of clarity, of the machine shown in FIG. 1 ;
FIG. 3 shows a front elevation and plan view of some embodiments of a particular detail of FIG. 1 ;
FIG. 4 is a schematic perspective view of a modified embodiment of the machine according to FIG. 1 ;
FIG. 5 is a plan view of a particular installation involving a plurality of machines of the type shown in FIG. 4 ;
FIG. 6 is a schematic perspective view of a second embodiment of an exercise machine according to the present invention and formed of a plurality of machines according to FIG. 5 , with parts removed for the sake of clarity, and arranged alongside each other;
FIG. 7 shows schematically, on a smaller scale and with parts removed for the sake of clarity, a plan view of a plurality of machines of FIG. 4 ; and
FIG. 8 shows a schematic plan view, with parts removed for the sake of clarity, of a portion of the embodiment according to FIG. 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 , 1 denotes in its entirety, an exercise machine which comprises a frame 10 , a work station or zone 20 designed to be used by a user for performing at least one exercising activity of a predetermined type, and a service station or zone 30 situated adjacent to the work station 20 and provided with a load group 31 . This load group 31 , which can be seen partially in FIG. 1 and in plan view in FIG. 2 , is capable to exchange exercising power with the user by using at least one interface 32 , or operating device, connected to the load group 31 in a predetermined manner so as to allow an exercise to be performed. The machine 1 may be equally well of the type comprising counterweights or of any other type for aerobic exercise suitable for exercising the cardiovascular system. In any case, for the sake of convenience of illustration, the present invention is illustrated on the basis of a counterweight machine of the general type. Also in view of the fact, it will be immediately obvious that the above description is also applicable to a so-called “cardio machine”, without this choice necessarily being interpreted as a precise intention to limit the type of group 31 indicated above. For the purposes of illustrative clarification, the machine 1 is of the type described in application Ser. No. 10/674,447 of the assignee herein.
With reference to FIGS. 1 , 2 and 3 , the load group 31 comprises at least two load units 33 and 34 which are arranged alongside each other and are separated from each other so that they may be operated separately by the interface 32 which in the case in question is a handle, which will be indicated using the same reference number. The handle 32 is associated with a cable 35 arranged between the two load units 33 and 34 , to which it is connected with respective end portions which are arranged opposite to each other and act on opposite sides of the handle 32 . The machine 1 also comprises a plurality of transmission devices which are in the form of drive pulleys 36 shown in FIG. 1 , each of the pulleys 36 being supported by the frame 10 between the two load units 33 and 34 along a path P, being visible only partially in FIG. 1 and being engaged by the cable 35 . The path P winds between the pulleys 36 and starts and terminates respectively at the load units 33 and 34 . The two units 33 and 34 are both of the gravitational type and each of these comprises a plurality of blocks/counterweights 38 arranged on top of each other and supported by the frame 10 slidably along a vertical guide 39 for rectilinear movement. The operating device 32 may be formed equally well as a handle or also a belt for clasping a heel or any other constructional form of an interface which can be operated by a user.
The machine 1 is formed so that it is contained inside a prismatic volume V which in FIG. 1 has been shown, for the sake of convenience, in a parallelepiped form and has maximum overall dimensions which depend on the type of machine 1 , on the dimensions of the front section of the frame 10 , on the form and arrangement of the path P, on whether the machine is a single-purpose or multifunctional machine, and therefore on the type of exercise which the user is able to perform freely on the machine 1 , as well as on the build and physical attributes of the user. If one considers a direction 2 which is situated between the work station 20 and the service station 30 and is shown in FIG. 2 by a horizontal dot-dash line, the volume V may be divided into at least two parts and in particular a work volume V L , which is arranged at the front and encloses the station 20 , and a service volume V S , which is arranged at the rear and encloses the service station 30 . The volume V L has a depth W L , which is calculated perpendicularly with respect to the direction 2 , and the volume V S has a depth W S , which is also calculated perpendicularly with respect to the direction 2 . The maximum cross-section of the volume V is inscribable inside a polygonal perimeter with height H and width L which can be easily determined. The machine 1 also comprises a panel 40 supported transversely by the frame 10 in order to isolate the station 30 from the station 20 . The panel 40 also has dimensions which are approximately equivalent to the height H and the width L of the polygonal perimeter so as to prevent a user engaged in training from voluntarily or involuntarily interacting with the service station 30 and so as to allow definition of the volume V L of the machine 1 as a minimum training module M which can be freely used during training. The work volume V L can be easily identified by direct measurement of the height H and the width L of the panel 40 and the depth W, equal to W L +W S , which are indicated in FIG. 2 . The presence of the panel 40 facilitates installation of the machine in any environment since the panel 40 acts as a guide for arranging the machine 1 alongside walls or other apparatus or, even better, allows the composition of a plurality of modules M alongside each other, each of which can be freely used for training.
This panel 40 may be formed by a single board 41 produced by rolling or extrusion of metallic or plastic material of the opaque, transparent or translucent type so that it may be permeated by any shade of light, so that the panel 40 is more homogeneous with the environment in which the machine 1 must be installed, or so as to allow the passage of light produced by light sources of any color, if necessary supported by the panel 40 as in the case of the apparatus which will be described more fully below.
In addition, the board 4 may be curved as in FIG. 3 d or be flat as in FIG. 3 b . Moreover, the board 41 may be modular, thus obtained by combining transversely a plurality of elongate sheets 42 , each of which may have more or less a homogeneous width 1 and extends preferably, but not exclusively, in the vertical direction in FIG. 3 a with a height H equal to that of the panel 40 . The sheets 42 are joined together in pairs by at least one interlocking or hinged connection 43 so as to define, in the first case, a surface with a precise flat or discontinuous form and, in the second case, a discontinuous surface, the sheets 42 of which may be oriented as required with respect to each other, so as to make the panel 40 easily adaptable to the machine 1 and to the environment in which the machine 1 must be installed. In the case of hinged connections 43 , the sheets 42 of the panel 40 may be rotated with respect to each other so as to allow a degree of personalization of the shape of the panel 40 . Still with reference to FIG. 4 , at least one of the sheets 42 has a straight or curved form in plan view and sheets 42 with a straight and/or curved form in plan view may be combined together so as to obtain surface effects which may be modified if necessary over time by varying the orientation, replacement in the event of damage or the like, or the addition of sheets 42 with a different profile for various reasons. The solution of forming the panel 40 by the composition of longitudinal elements which are joined together with connecting members 43 in order to form an interlocking or a hinged system, is particularly interesting since it allows the formation of the panel 40 by combining sheets of limited width and with a longitudinal extension which may be defined as required. In addition, the sheets 42 may also be formed by rolling or extrusion of metallic or plastic material of the opaque, transparent or translucent type for the reasons described above with reference to the board 41 so that the panel 40 is permeable to light, but could also be constructed of other material, for example wood. The possibility of producing panels 40 by the assembly of sheets 42 allows the formation of panels with any longitudinal extension, minimization of the end product stocks, and an increase in the flexibility of production, favoring the optimized management of the warehouse stocks with positive effects on the financial management of the production activity. Obviously, the connecting members 43 may also be installed laterally so as to allow joining with panels 40 of other machines 1 .
The machine 1 also comprises a horizontal element 48 which is visible in the sole FIG. 2 where it is shown in plan view. The element 48 , which can be installed on the floor, can be formed as a footplate which defines the work volume V L at the bottom or also, more simply, as a mat having dimensions which indicate the depth of the station 20 and which therefore correspond approximately to a rectangle with sides W L and L able to provide visual information as to the plan-view extension and contours of the respective minimum training module M which can be freely used.
In connection with that described above, it can be established that the machine 1 comprises a unit 40 ′ which is visible solely in FIG. 2 for the sake of convenience of illustration and which comprises the panel 40 and the horizontal element 48 and provides an indication as to the overall dimensions of the minimum training volume M of the machine 1 .
It should be noted that the horizontal element 48 could perform the respective function of an element indicating the volume also if it were mounted on the frame 10 in a position above the station 20 or the station 30 , if necessary, supported by an upper edge of the respective panel 40 . In this case, the element 48 could perform, in addition to the function of facilitating the operations of installing machines 1 alongside each other in close contact and protecting the module M, a covering function as well. Therefore, in this case the element 48 could be used to protect the machine 1 from atmospheric agents in external installations, but also prevent the deposition of dust on the operating device 32 and/or on everything which is contained within the service zone 30 . Still with the same aim, the element 48 could be formed with an extension such as to cover the work zone 20 and/or the service zone 30 . With reference to FIG. 4 , for example, this figure shows a non-limiting embodiment of a covering 48 ′ which is bounded by an edge which imitates at the front and rear the form of the associated panel and which is bounded laterally by two edges 48 ′ a and 48 ′ b which are parallel to each other and transverse to the panel 40 . In this case the machine 1 has two sides 48 ″, only one of which can be seen in FIG. 4 . The two edges 48 ′ a and 48 ′ b are designed to constrain the manner of installation of an additional machine 1 alongside that of FIG. 4 so as to keep the two machines 1 with the respective panels 40 substantially aligned with each other. By way of example, in FIG. 4 , the additional machine 1 has been shown only partially for reasons of clarity with a dot-dash line. Obviously, this lay-out has a positive effect for the modules M of the two machines 1 arranged alongside each other in that the modules M can be freely used individually without users being able to occupy them in order to perform training sessions simultaneously. This function of the cover 48 ′ is even more obvious in FIG. 5 which shows four machines 1 with the respective covers 48 ′ having their respective edges 48 ′ a and 48 ′ b inclined relative to each other substantially at right angles so that the four machines 1 may be arranged facing each other in pairs as if along the sides of a square. This angle, together with other angles of the edges 48 ′ a and 48 ′ b are able to indicate the correct manner of installing each machine 1 with respect to the walls or other spatial constraints, including other machines 1 with which it must be interfaced. Therefore, the edges 48 ′ a and 48 ′ b , allow the machines 1 to be arranged in predetermined spatial configurations which for brevity's sake need not be further explained.
Moreover, the machine 1 has a device 50 for adjusting the load, the description of which is omitted for the sake of convenience, only a knob 51 is shown. The load adjusting device 50 is described in detail in U.S. application Ser. No. 10/674,447, incorporated herein by reference thereto. This knob 51 is designed to determine the number of counterweights 38 to be raised during the course of execution of the exercise and is arranged at the interface between the work station 20 and the service station 30 . The knob 51 therefore passes through the panel 40 which must have at least one slot 44 which establishes communication between the two stations 20 and 30 . In particular, the slot 44 is vertical in FIG. 1 .
In addition, any apparatus 49 which can be electrically powered may be associated with the panel 40 . The apparatus is shown schematically in the form of a parallelepiped, only the contour of which is shown in the sole FIG. 1 in the form of a dot-dash line. This apparatus 49 could comprise at least one lamp/light source of any color, known and not shown. With particular reference to this Figure, the panel 40 may have at least one housing 40 for storing objects, which could be used to house the apparatus 49 permanently or temporarily. Obviously, the shape of the contour of this housing 45 may be of any nature, although it has been shown as having a rectangular cross-section in FIG. 1 . The apparatus 49 , of the known type, could comprise at least one lamp for illuminating the station 20 and/or the station 30 , or for chromotherapy sessions which can be conducted, if necessary, in combination with an exercising activity, a radio, a computer, a television, a scent diffuser or any other electric household appliance. The housing 45 could also be closed by a door 47 , which is visible only in FIG. 2 , or contain a drawer, not shown. As an alternative or in addition to this housing 45 , the panel 40 may also have an opening 46 which is bounded by a contour of any shape and left open or closed by a sheet of transparent material, known and not shown, which may also be coloured, or a mirror, for obtaining predetermined effects which may help incorporate better the machine 1 within the environmental context.
It must be noted that the housing 45 and/or the opening 46 may also be formed in at least one of the sheets of a modular panel 40 , with the consequence that the panel 40 may be modified over the course of time so as to be adapted to the changing requirements of the user or in order to replace damaged portions thereof.
The use of the exercise machine can be easily understood from the description above and does not require further explanations.
From the description provided above it clearly emerges how the machine 1 can be implemented in a particularly simple and low-cost manner, fully achieving the objects mentioned above.
Finally, it is clear that modifications and variations may be made to the exercise machine 1 described and illustrated here, without departing from the scope of the present invention.
For example, with reference to FIG. 6 , it is possible to imagine converting a plurality of machines 1 so that they may be arranged alongside each other in order to obtain a multi-station machine 100 . In this connection, each machine 1 must be modified with regard to the respective panel 40 which must have fastening members mounted on its respective side edges. For the sake of convenience of description of this embodiment, the machine 1 thus modified will be indicated by the number 101 , the associated panel 40 will be indicated by the number 140 and the respective components which will not be explicitly numbered in a predetermined manner may be clearly identified numerically, by adding 100 to the number with which they were indicated with reference to the machine 1 , if not otherwise indicated. Therefore, the machine 100 comprises a plurality of machines 101 which are arranged alongside each other and each of which is equipped with at least one operating device 132 , at least one panel 140 which differs from the panel 40 by presence, along at least one of the respective side edges 141 , of fastening members 142 of the interlocking or hinged type known and therefore shown only schematically by facing rectangles between the corresponding panels arranged alongside each other. The machines 1 and 101 differ from each other only in that the panels of the machine 101 are provided with members 142 and, therefore, it is particularly inexpensive and easy to perform conversion of a machine 1 into a machine 101 for a multi-station 100 . Moreover, this confirms the fact already discussed, where the presence of the panel 40 means that the machine 1 may be used as a sectional module M.
Still with reference to FIG. 6 , at least one of the panels 140 has at least one housing 145 which is able to house stably an apparatus which can be powered electrically and which may comprise a scent diffuser or a light source, which may be used for chromotherapy sessions, or a computer, radio or television.
It will be noted that, in connection with the above description, the multi-station machine 100 as illustrated above may also be regarded as a wall 160 which is equipped with exercise machines 101 , which are all identical, or by machines 101 of varying types and arranged alongside each other so as to define a training circuit defined by the succession of physical exercise machines, or define physical barriers inside spaces assigned for training, both in order to isolate respective service stations 130 of the various machines 1 and in order to combine together the various modules M so as to form the multi-station machine 100 . Each panel 140 may be individually formed in accordance with varying specifications and using the most varied combinations of housings 145 and openings 146 , which combinations in FIG. 6 have been illustrated randomly on purpose.
In the case shown in FIG. 6 , the panels 140 are connected together along the sides by fastening members 142 in order to keep the machines 101 at a predetermined distance from each other, while ensuring the free use of the minimum training modules M. In this case also the panels 140 may be provided with housings 145 and openings 146 which may be occupied by apparatus 149 , and, in a similar manner to the panels 40 , may be formed as one piece or provided with a plurality of elements which are similar to the sheets 42 . Therefore, the panels 140 may be joined together in pairs so that they can be oriented as required in order to define a discontinuous or, selectively, a continuous surface. Moreover, this allows the formation of panels 140 which can be easily adapted to varying spatial requirements and can be maintained easily and at a low cost in the event of damage. Obviously, within each machine 101 , each operating device 132 is associated with a load group 131 comprising counterweights or of the electrically operated type. If the load group 131 is of the gravitational type, it comprises at least one load unit 131 with counterweights and an adjusting device 150 provided with at least one user interface member 151 associated with the load unit 131 .
Therefore, each module M is associated laterally with at least one other module M by fastening members which allow the machine 101 to be arranged alongside in an arrangement which takes into account the space available, while safeguarding the free use of each module M. In this way, the wall 160 is formed, in plan view, in a predetermined manner, if necessary so as to define a physical barrier inside open or closed spaces, and therefore, adapt the respective training circuits to the most varied requirements.
In a similar manner to the machine 1 , each machine 101 could comprise a horizontal element 148 which is substantially identical to the element 48 in FIG. 2 , to be installed on the floor so as to provide, in plan view, visual information as to the contours of the corresponding minimum training module M. In this case also the element 148 could be mounted on the frame 110 of the machine 100 or if necessary, also on a top edge of the panel 140 and hence in a position raised above the zone 120 so as to act as a cover. In this case, in a manner similar to that described above with reference to the machine 1 , it is possible to combine with each module M a cover 148 ′ which is identical to the cover 48 ′ of the machine 1 and is bounded by edges 148 ′ a and 148 ′ b which allow each machine 100 to be arranged in predetermined spatial configurations which, for the sake of brevity, need not be further explained.
With respect to that described above it is possible to state that each machine 101 comprises a unit 140 ′, shown in FIG. 4 , which comprises a panel 140 , the respective footplate 148 , and indicates the dimensions of the minimum training volume M of the machine 101 .
For the sake completeness, FIG. 7 shows in plan view some examples of lay-outs which may be obtained by combining modules M/machines 101 which are identical to each other or different from each other. It should be noted that individual panels 140 may be used also to close the spaces comprising a plurality of service stations 130 of machines 1 / 101 arranged alongside each other, in order to isolate the service stations 130 so that they are neither visible nor accessible, both when these stations 130 are separate from each other, as in the case of FIGS. 7 c and 7 d , and when the stations 130 are combined with each other, as shown in FIGS. 7 a and 7 b.
With particular reference to FIG. 8 , it is shown forming the panel 140 of at least one of the machines 101 by combining together at least two sheets 140 ″ of different width. In this case, the sheet 140 ″ of larger length could be mounted in a position facing the corresponding service zone 130 , assigning implicitly to this sheet 140 ″ the function of delimiting the corresponding module M at the front; at the same time, the sheet 140 ″ of smaller width could be formed so as to house a computer 71 or any other device which can be powered electrically, for example, the so-called Wellness Expert manufactured by the assignee, or a similar device, inside a housing 145 or an opening 146 which is suitably formed. Obviously, the two sheets 140 ″ corresponding to the machine 101 in question could be oriented relative to each other so as to be substantially mutually coplanar or angled depending on the requirements of the space to be furnished, without this being regarded as a constraint on the spatial arrangement of the said sheets 140 ″.
Though the present invention was shown and described with references to the preferred embodiments, such are merely illustrative of the present invention and are not to be construed as a limitation thereof, and various modifications of the present invention will be apparent to those skilled in the art. It is, therefore, not intended that the present invention be limited to the disclosed embodiments or details thereof, and the present invention includes all variations and/or alternative embodiments within the spirit and scope of the present invention as defined by the appended claims. | An exercise machine ( 1 )( 101 ) has a work zone ( 20 )( 120 ) for performing physical exercise in accordance with a predetermined medical/sport program, a service zone ( 30 )( 130 ) adjacent to work zone ( 20 )( 120 ) and provided with a load group ( 31 )( 131 ), with the work zone ( 20 )( 120 ) and the service zone ( 30 )( 130 ) being located adjacent to each other and inscribable completely inside a minimum volume (V) of a predetermined height (H), width (L) and depth (W), and volume indicating means ( 40 ′)( 140 ′) capable to render a visually discernible minimum training module (M) of predetermined dimensions which can be easily assembled and rapidly installed in a space of limited dimensions. | 0 |
BACKGROUND AND SUMMARY
The invention relates to a hydraulic circuit for operating a tool especially of a construction equipment like e.g. an excavator, crane, wheel loader, drilling machine, grass cutter or others. Furthermore, the invention relates to a control unit and a method for controlling the hydraulic circuit and to a construction equipment comprising such a hydraulic circuit.
If a tool which is mounted at a construction equipment is exchanged by another tool, the operator of the construction equipment has to change and adjust accordingly the hydraulic parameter settings of the construction equipment like the pressure, the flow, the operation mode and other parameter settings which are specifically required for operating the new tool. This is usually very time consuming and implies the risk that inappropriate settings are selected by the operator.
It is desirable to provide a hydraulic circuit and a method for operating a hydraulic circuit by which this time consuming task is substantially reduced and the related risk is substantially reduced as well.
It is desirable to provide a hydraulic circuit which is simple in construction and enables to be controlled with an electronic control unit in a comparatively simple way.
According to an aspect of the invention, a hydraulic circuit is provided and, according to another aspect of the invention, a method for operating a hydraulic circuit is provided. One of the advantages of aspects of the invention is that an operator of the construction equipment is offered a high flexibility to realize settings for a plurality of different tools in an easy and quick manner.
More in detail, these solutions offer a flexible way to set and control the hydraulic circuit in a construction equipment. This is achieved especially by the fact that the settings and operating parameters of a nearly unlimited number of different tools can be programmed and stored, and then a certain tool which has been connected to the construction equipment can easily be selected by the operator, and the hydraulic parameter settings of the construction equipment for this tool can be adjusted in a quick and easy manner.
This is true for very different kinds of tools. For example, a toggle function can be realized on a related tool in an easy way. For example, a tool in the form of a hammer can be operated by the hydraulic circuit as long as a related button is pressed “on”. Furthermore, for operating a related proportional tool, e.g. a proportional and progressive roller switch or a proportional foot pedal can be used in order to generate an accordingly increasing hydraulic flow or hydraulic pilot pressure for actuating the tool.
Another advantage of aspects of the invention is that a proportional foot pedal valve for the tool control can be easily included in order to keep a maximum flow limitation in both directions of the pilot pressure, wherein a de-activation function of the hydraulic circuit is kept, i.e. even if the pedal is pressed in order to operate a tool, the hydraulic circuit can be de-activated, if necessary, by means of the first proportional valve by switching the same such that substantially no hydraulic pressure is applied at its output.
Furthermore, a progressive and proportional control of the output flow of the hydraulic circuit is provided, for which only one PWM (Pulse Width Modulation) output from the control unit or ECU (Electronic Control Unit) is necessary.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details, features and advantages of the invention will become apparent from the following description of exemplary and preferred embodiments of the invention in connection with the drawings, in which shows:
FIG. 1 shows an exemplary and preferred embodiment of a hydraulic circuit for generating a hydraulic flow or pilot pressure according to the invention to control the main pressure of a hydraulic circuit for the actuation of a tool;
FIG. 2 is a schematic illustration of a hydraulic circuit for generating a hydraulic main pressure for the actuation of a tool;
FIG. 3 an first exemplary flowchart for settings in a display for X1 function for parameters of a first tool according to the invention;
FIG. 4 a second exemplary flowchart for settings in a display for X3 function for parameters of a second tool according to the invention;
FIG. 5 schematic displays for setting up a new X1 tool in the IECU;
FIG. 6 schematic displays for setting certain parameters; and
FIG. 7 schematic displays for selecting a certain tool from a saved list of tools.
DETAILED DESCRIPTION
FIG. 1 shows an exemplary and preferred embodiment of a hydraulic circuit according to the invention for operating or actuating a tool. The circuit is provided for setting a hydraulic flow and for generating a hydraulic pilot pressure at one or both of its output lines C 1 and C 2 which lines C 1 and C 2 are continued in FIG. 2 and are connected with a first and a second spool, respectively, of a main control valve 20 which actuates a tool 30 by means of a hydraulic main pressure in a known manner. The tool 30 operated by the hydraulic circuit according to FIG. 1 can be a one-way tool like a hammer or a two-way tool like a shear. Furthermore, the tool 30 can be a proportional tool, and it can be a tool for high pressure, high power and/or high flow (like e.g. a hammer or a shear) or a tool for low pressure, low power and/or low flow (like e.g. a rotary tool or a grass clipper).
The hydraulic circuit according to FIG. 1 comprises a first proportional valve 11 , a first and a second on/off valve 12 , 13 , each in the form of a switch-over valve, a first and a second shuttle valve 14 , 15 and a pedal unit 10 ( FIG. 1(A) shows an enlarged view of it) comprising a pedal 101 for actuating a second and a third proportional valve 102 , 103 , wherein these valves 102 , 103 could alternatively be actuated by a joystick, a two-way switch or other means as well.
The first proportional valve 11 comprises a first, a second and a third port 1 , 2 , 3 , wherein the first port 1 is proportionally switched by means of an electrical solenoid in a known manner between the second and the third port 2 , 3 , so that the flowing-through between the first and the second port 1 , 2 continuously decreases while the flowing-through between the first and the third port 1 , 3 continuously increases and vice versa.
This first proportional valve 11 is actuated by a control unit 40 in dependence on a set of stored parameters for a certain tool 30 (see FIG. 2 ) which has been mounted at the construction equipment and which has been selected by an operator of the construction equipment e.g. on a touch screen or a display 41 of the control unit 40 , in such a way that a certain (admissible) maximum value of a hydraulic flow or hydraulic pilot pressure is applied (and will not be exceeded) at the first port 1 of the proportional valve 11 , by accordingly connecting the port 3 of the valve 11 with the port 1 of the valve 11 .
The first and the second on/off valve 12 , 13 each comprises a first, a second and a third port 1 , 2 , 3 , wherein the first port 1 is connected by means of an electrical solenoid in an known manner either with the second port 2 or with the third port 3 .
The first and the second on/off valve 12 , 13 can be switched by an operator of the construction equipment by means of a related first and second switch 42 , 43 , respectively, at the control unit 40 . In order to operate a one-way tool 30 with one operating direction (like e.g. a hammer), one of the two valves 12 , 13 is switched. In order to operate a two-way tool 30 (like e.g. a shear), one of the valves 12 ; 13 is switched for the operation of the tool 30 in a first direction and the other of the valves 13 ; 12 is switched for the operation of the tool 30 in a second direction.
The first and the second shuttle valve 14 , 15 each comprises a first and a second input 1 , 2 and one output 3 , wherein the one input ( 1 or 2 ), at which the higher hydraulic pressure is applied in comparison to the other input, is connected with the output 3 , and the other input ( 2 or 1 ) at which the lower pressure is applied is blocked. If at both inputs 1 , 2 the same pressure is applied, this pressure is as well applied at the output 3 .
In the second and the third proportional valve 102 , 103 of the pedal unit 10 , each valve has a first port which is proportionally switched between a second and a third port, as described above with reference to the first proportional valve 11 . However, the second and the third proportional valve 102 , 103 are alternatively actuated by means of the pedal 101 in a known manner, i.e. the second valve 102 is actuated by pressing the pedal 101 down in the forward direction (counterclockwise in FIG. 1 ) while the third valve 103 is not actuated during this operation, and the third valve 103 is actuated by pressing the pedal 101 down in the backward direction (clockwise in FIG. 1 ) while the second valve 102 is not actuated during this operation. In case the pedal 101 is in the neutral position as shown in FIG. 1 both valves 102 , 102 are in a non-actuated position as well.
The pedal unit 10 comprising the second and the third proportional valve 102 , 103 comprises a first port 1 , to which the first port of the second proportional valve 102 is connected, a second port 2 , to which the first port of the third proportional valve 103 is connected, a third port 3 , to which the second port of the second and of the third proportional valve 102 , 103 is, connected, and a fourth port 4 , to which the third port of the second and of the third proportional valve 102 , 103 is connected.
The second and the third proportional valve 102 , 103 are alternatively operated by an operator of the related construction equipment by means of the pedal 101 (or another means as mentioned above) in order to proportionally operate a related tool 30 (see FIG. 2 ) mounted at the construction equipment.
The hydraulic circuit is supplied with hydraulic pilot pressure by means of a first pilot pressure source, e.g. a pump P 1 for feeding pressurized hydraulic fluid (typically with a pressure of about 35 to 40 bar) from a first tank T 1 to the second port 2 of the first proportional valve 11 . A first back or return flow line A into the first tank T 1 is connected with the third port 3 of the first proportional valve 11 . This line A is as usual substantially “pressure-less” in that its pressure is about equal to the atmospheric pressure of the surroundings.
The first port 1 of the first proportional valve 11 is connected with the third port 3 of the first on/off valve 12 , with the third port 3 of the second on/off valve 13 and with the third port 3 of the pedal unit 10 .
The fourth port 4 of the pedal unit 10 is connected via a second back or return flow line B with the first tank T 1 . This line B is as usual substantially “pressureless” in that its pressure is about equal to the atmospheric pressure of the surroundings.
The second port 2 of the first on/off valve 12 and the second port 2 of the second on/off valve 13 are connected with a third back or return flow line C which is leading into the first tank T 1 . This line C is as usual substantially “pressureless” in that its pressure is about equal to the atmospheric pressure of the surroundings.
The first port 1 of the first on/off valve 12 is connected with a first input 1 of the first shuttle valve 14 and the first port 1 of the second on/off valve 13 is connected with a first input 1 of the second shuttle valve 15 .
The second input 2 of the first shuttle valve 14 is connected with the second port 2 of the pedal unit 10 , whereas the second input 2 of the second shuttle valve 15 is connected with the first port 1 of the pedal unit 10 .
The output 3 of the first shuttle valve 14 is connected with the first output line C 1 and the output 3 of the second shuttle valve 15 is connected with the second output line C 2 of the hydraulic circuit.
The hydraulic flows or hydraulic (pilot) pressures generated at these two output lines C 1 , C 2 are fed according to FIG. 2 to the spool of a main control valve 20 in order to convert the flow or pressure values in a known manner to a certain flow of hydraulic fluid or main pressure by which the tool 30 is actuated.
More in detail, the first output line C 1 is connected via a first input terminal Sa of the main control valve 20 with the first spool, and the second output line C 2 is connected via a second input terminal Sb of the main control valve 20 with the second, opposite spool.
For generating the main pressure for actuating the tool 30 , a second pressure source, e.g. a pump P 2 is provided for feeding a hydraulic fluid from a second tank T 2 (wherein the first and the second tank Tï, T 2 is usually one common tank) via a third input terminal P to the main control valve 20 . This second pump P 2 is controlled according to the operation of the spools via a fourth terminal LS, and a back or return flow line into the second tank T 2 is provided via a fifth terminal T of the main control valve 20 . This back or return flow line is as usual substantially “pressure-less” in that its pressure is about equal to the atmospheric pressure of the surroundings.
The operation of a main control valve 20 according to FIG. 2 by feeding the right and the left side of the spool with the hydraulic flow or hydraulic pressure via the output lines C 1 and C 2 , respectively, in order to supply the required hydraulic main pressure via a first and a second output terminal TA, TB for actuating the tool 30 is generally known so that it need not to be described here.
In the following, the generation of the hydraulic flow or hydraulic pilot pressure which is supplied to the spool via the first and the second output line C 1 , C 2 shall be described with reference to FIG. 1 and the displays shown in FIGS. 5 to 7 .
After mounting a certain work tool 30 at the construction equipment, the operator starts a first setup sequence for this tool 30 by selecting on the display (or a touch screen) 41 a tool setup menu. By this, a list of stored tools appears on the display 41 . From this list the operator selects the tool 30 which is mounted at the construction equipment. Then, another list with the stored parameter settings for this selected tool, like the flow value, the pressure value, the kind of tool (one-way or two-way tool) and the kind of control of the tool (like on/off, push, toggle or proportional operation) is indicated on the display 41 . Then, the control unit 40 (or a VECU (Vehicle Electronic Control Unit) to which these parameter settings are submitted) adjusts the first proportional valve 11 such that a maximum admissible hydraulic flow or pilot pressure which corresponds to the stored parameter settings for the mounted tool 30 is applied (and will not be exceeded) at the first port 1 of the first proportional valve 11 by accordingly actuating this valve 11 by means of its solenoid.
If the parameter settings of the tool 30 which is mounted at the construction equipment are not stored in the control unit 40 so that the operator cannot find the tool 30 in the list of stored tools, he has the opportunity to store the required parameter settings of the new tool by starting a related second sequence. In such a second sequence, the operator selects on the display (or a touch screen) 41 a related setup menu for a new tool, in which he inputs a name for the new tool and the required settings for this tool like the flow value, the pressure value, the kind of tool (one-way or two-way tool) and the kind of control of the tool (like on/off, push, toggle or proportional operation). Thereafter, he can store these settings under the name of the new tool, so that the new tool is available in the list of stored tools when the first setup sequence is started the next time.
In both cases, the X1 function indicates a high pressure, high power, high flow tool like e.g. a shear or a hammer, and the X3 function indicates a low pressure, low power, low flow tool like e.g. a rotary tool. A flowchart for settings in a display for the X1 function is shown in FIG. 3 , a flowchart for settings in a display for the X3 function is indicated in FIG. 4 .
FIG. 5 exemplarily shows four displays during a setup of a new X1 tool in the control unit 40 . FIG. 6 exemplarily shows four displays for setting the parameters: flow, pressure, operation mode, type of attachment, respectively, furthermore one display for the saving of all of these settings and another display with an overview of the selected parameters for the tool which is now ready for use. Finally, FIG. 7 exemplarily shows how an operator can select a tool from a list of tools and the related parameters as stored, respectively, and another display in the form of an information screen regarding the selected tool if the operator switches on the X1 operation.
After the first proportional valve 11 has been adjusted by the control unit 40 to the tool as mentioned above such that at its first port 1 the maximum admissible flow or pilot pressure for the tool mounted at the construction equipment is applied (and will not be exceeded), the operator can start operating the tool without running the risk to expose the tool to operational modes and hydraulic pressures outside the normal mode of operation and outside to admissible pressure range which would damage the tool.
If a one-way tool 30 is mounted at the construction equipment, this tool is operated by actuating the first or the second on/off valve 12 , 13 by means of the related first or second switch 42 , 43 in dependence, on which output line C 1 or C 2 the hydraulic pilot pressure is needed for operating the one-way tool.
If for example the hydraulic pilot pressure for operating the tool is needed on the first output line C 1 , the first on/off valve 12 is switched from its off position shown in FIG. 1 into its on position, so that the hydraulic pilot pressure at the first output 1 of the first proportional valve 11 is supplied through the first on/off valve 12 and the first shuttle valve 14 to the first output line C 1 . If e.g. the one-way tool 30 connected with the main control valve 20 is a hammer, the hammer is on when pressing down or pushing the first switch 42 , and the hammer is off when the first switch 42 is released (“one-way push tool”).
In case of a two-way push tool, both switches 42 , 43 and accordingly both the first and the second on/off valves 12 , 13 are accordingly used for actuating the tool in a first and a second direction, respectively.
More in detail, if the tool 30 mounted at the construction equipment is a two way tool like a shear the operator (i) actuates the first on/off valve 12 (by switching it from its off position shown in FIG. 1 into its on position) by pressing the first switch 42 for operating the shear in one direction (e.g. opening the shear) while the second on/off valve 13 is in its off position during this time, and (ii) actuates the second on/off valve 13 (by switching it from its off position shown in FIG. 1 into its on position) by pressing the second switch 43 for operating the shear in the opposite direction (e.g. closing the shear) while the first valve 12 is in its off position during this time. In other words, the actuation of the first and the second on/off valve 12 , 13 controls the exertion of pressure onto the left and the right side of the spool, respectively, of the main control valve 20 .
Other tools (“toggle tools”) start running when one switch 42 (or 43 ) is pressed a first time, and stop running when the switch 42 (or 43 ) is pressed a second time.
If the tool 30 mounted at the construction equipment is a tool which is to be proportionally controlled by a proportional flow or pilot pressure, the related maximum (admissible) hydraulic pilot pressure or flow which is applied according to the parameter setup of the tool as explained above at the first port 1 of the first proportional valve 11 is proportionally reduced by means of at least one of the second and third proportional valve 102 , 103 of the pedal unit 10 . In case of operating such a tool, the first and the second on/off valve 12 , 13 remain in their closed position as shown in FIG. 1 , in which each first port 1 is connected with the third back or return flow line C leading into the first tank Tï, so that a substantially zero (i.e. atmospheric) pressure is applied at the first ports 1 of the first and the second on/off valve 12 , 13 .
In the non-actuated position of the pedal 101 as shown in FIG. 1 , the first and the second port 1 , 2 of the pedal unit 10 are connected with the fourth port 4 . The fourth port 4 is connected by means of the second back or return flow line B with the first tank Tï so that a substantially zero (i.e. atmospheric) hydraulic pressure is applied at the first and the second port 1 , 2 of the pedal unit 10 and accordingly at both output lines C 1 , C 2 .
If for example the second proportional valve 102 of the pedal unit 10 is actuated by tilting the pedal 101 forwardly (in FIG. 1 : tilting it counterclockwise, whereby the third proportional valve 103 is not actuated), the first port 1 of the pedal unit 10 is proportionally connected with the third port 3 of the pedal unit 10 . By this, the maximum (admissible) hydraulic pilot pressure which is supplied from the first port 1 of the first proportional valve 11 to the third port 3 of the pedal unit 10 , is proportionally reduced and supplied from the first port 1 of the pedal unit 10 to the second output line C 2 .
If the third proportional valve 103 of the pedal unit 10 is actuated by tilting the pedal 101 backwardly (in FIG. 1 : tilting it clockwise, whereby the second proportional valve 102 is not actuated), the second port 2 of the pedal unit 10 is proportionally connected with the third port 3 of the pedal unit 10 , so that an accordingly reduced maximum (admissible) hydraulic pilot pressure is supplied from the first port 1 of the first proportional valve 11 via the third and the second port 3 , 2 of the pedal unit 10 to of the first output line C 1 .
By these proportionally reduced pilot pressures at the first and the second output line C 1 , C 2 , the tool 30 is proportionally actuated in a first and a second direction, respectively.
If a proportional tool 30 (like e.g. a rotary tool) is operated by the operator by means a roller switch 44 instead of by means of the pedal unit 10 , then the first proportional valve 11 is proportionally actuated by the control unit 40 such that it as well generates a respective proportional hydraulic flow or pilot pressure (up to the maximum admissible flow or pressure value for that tool) according to the actuation, especially the stroke, of the roller switch 44 , instead of the actuation of the (pressure reducing) proportional valves 102 , 103 of the pedal unit 10 . Furthermore, in dependence on the direction in which the roller switch 44 is rolled, either the first or the second on/off valve 12 , 13 is opened by the control unit 40 .
Summarizing the above, the first proportional valve 11 is used for the following three functions:
1. Disengaging the hydraulic flow or pressure to the output lines C 1 , C 2 by reducing the pilot pressure to a value which is zero or at least below the cracking point of the spool of the main control valve 20 ;
2. Limiting the maximum pilot pressure or flow to an admissible value which is set by the control unit 40 or the operator when operating a certain tool 30 ;
3. Controlling the pilot pressure or flow in a dynamic way for proportionally controlling a related proportional tool 30 .
For disabling the hydraulic circuit, the first proportional valve 11 is actuated into the position as shown in FIG. 1 , in which the first port 1 is fully connected with the third port 3 which is connected via the first back or return flow line A with the first tank Tï so that a substantially zero pressure (or, more precise, atmospheric pressure) is applied at the first port 1 of the first proportional valve 11 .
Finally, it shall be mentioned, that for one or more of the tools 30 each more than one set of parameter settings or operation modes (like proportional control, push or toggle modes) can be stored in the control unit 40 , which parameter settings or modes can accordingly be selected by an operator of the construction equipment in dependence on e.g. a certain task or work which has to be done by means of the tool.
In total, the hydraulic circuit according to the invention as indicated in FIG. 1 is provided in an advantageous way for three different functions, namely to deactivate the hydraulic circuit if necessary, to control the maximum hydraulic flow or hydraulic pilot pressure which can be supplied to a certain mounted tool and to control the tool, especially a proportional tool, in a dynamic way.
The control unit 40 may be in the form of a computer and comprise a computer program code adapted to perform a method or for use in a method for controlling the hydraulic circuit, where the method includes a first step of receiving an input, made by a user, indicating a selected tool, and a second step of generating an output signal for actuating the first proportional valve in dependence on stored settings for the selected tool. The computer program may be downloaded to the control unit or one of its components when it is connected to the internet. A computer program product stored on a non-transitory computer readable medium can be provided comprising a program code for use in such a method. | A hydraulic circuit for operating a tool is provided that is particularly useful in construction equipment such as an excavator, crane, wheel loader, drilling machine, or others. Furthermore, a control unit and a method for controlling the hydraulic circuit and construction equipment including such a hydraulic circuit is disclosed. | 5 |
TECHNICAL FIELD
[0001] The present invention relates to electric irons for thermal shaping and styling of hair, and particularly irons with a timer for indicating treatment time to the user.
BACKGROUND OF THE INVENTION
[0002] Hair styling irons having an electrically heated elongate tool are well-known, and commonly used for curling or straightening hair. One of the challenges facing the users of such appliances, particularly for professionals, is how to most efficiently achieve a desired styling effect. A number of factors influence the effectiveness of heat to shape the hair, these include intrinsic properties of an individual's hair, treatments agents applied to the hair (such as water or other softening agents), the time and temperature of the heat application, as well as the manner in which the hair iron is used (the size of a tress which is treated, the tension applied to the hair etc). Consistent results can be obtained most efficiently if these factors can be kept relatively constant for a specific treatment or if, for instance, they can be varied incrementally to provide a different level of treatment, however in the past this has been somewhat problematic. In particular, processing results can be variable if the operation is performed too fast, the processing time is too short and, therefore, the hair is not properly formatted, while processing hair for too long can damage the hair by overheating.
[0003] To address these issues it is known to provide hair curling irons with a timer to indicate an elapsed time from the start of the timer. US2006/0191888 describes a hair iron in which time and temperature are coordinated, and in which the user selects settings for the iron temperature and a desired curl tightness. The elapsed time is controlled such that for a selected curl tightness, the elapsed time is decreased with increasing temperature. However, there are drawbacks with this device associated with its ease of use. In operation, it requires the user to remember to start the timer by pressing a start button each time the iron is used, and for consistent results this button must be pressed at the same stage of the operation each time. Particularly when manipulating the iron behind the head it may be difficult to locate and press the start button. Moreover, programming the controller is a complex operation, in which three different buttons must also be operated to increase and decrease the settings for the timer. There is therefore a need for a hair styling iron having a timer which can be more readily used.
[0004] A further disadvantage of the curling iron of US2006/0191888 is that the coordination between time and temperature in this prior art manner takes no account of the mass of hair being curled, and the fact that the heat required increases with the mass of hear being curled. At any selected temperature a short tress is formatted more quickly than a longer tress, with the result that a short tress may be overheated, while a long tress is under-heated. There is a need for a hair styling iron having a timer which can mitigate this source of variability, to help users produce good results more predictably.
[0005] It is an object of the present invention to overcome or substantially ameliorate the above disadvantages or more generally to provide an improved electric hair styling iron.
DISCLOSURE OF THE INVENTION
[0006] In one aspect the invention provides a hair styling iron comprising:
[0007] a handle to which a barrel is mounted,
[0008] a heating element in the barrel;
[0009] a motorised means for moving the barrel;
[0010] a control circuit including a timer;
[0011] a drive switch which is user actuable and connected to the control circuit for controlling operation of the motorised means;
[0012] and wherein the control circuit monitors at least one change of state of the user-actuable drive switch to determine a starting time, and actuates a response after an elapsed time measured from the starting time.
[0013] By having the drive switch that operates the motorised means also serve to set a starting time, operation of the hair styling iron is simple for the user and component numbers can be reduced, while the ability to provide consistent hair styling results in a timely manner is improved. The response may comprise an alarm, particularly a tactile, audible or visual alarm disposed in the hair styling iron.
[0014] Preferably the motorised means comprises a rotary drive that rotates the barrel. Optionally the motorised means vibrates the barrel.
[0015] Preferably the rotary drive rotates the barrel in a first direction upon actuation of the drive switch, and the response initiated by the control circuit after the elapsed time comprises turning the barrel in a second direction, opposite to the first direction. Preferably the control circuit records a first angle of rotation in the first direction, and the barrel is driven in the second direction through a second angle that is proportional to the first angle. The second angle may be sufficient to loosen the hair from the barrel. The second angle may, for instance, be between 80 and 110 percent of the first angle to provide for the hair to be completely unwound from the barrel.
[0016] Preferably the drive switch provides on-off control of the motorised means and when turned on moves the barrel at a fixed rate. Optionally, the drive switch may provide for modulated control of the motorised means for moving the barrel at a variable, user-controlled rate, such as a rheostat type switch.
[0017] Preferably the drive switch is a momentary switch, the actuation of which must be maintained by the user in order to operate the motorised means. Preferably the drive switch is a push-to-make switch. The drive switch need not be a mechanical type in which the user presses on an operator or mechanism to move a contact, and instead sensor type switches having, for example, capacitive or optical sensing elements, could be used.
[0018] Either the actuation or the release of the drive switch may define the starting time. In one embodiment the change of state comprises the first actuation of the drive switch, and the control circuit actuates the tactile, audible or visual alarm after an elapsed time measured from the first actuation of the drive switch. In another embodiment the change of state comprises the release of the drive switch immediately following the first actuation of the drive switch, and the control circuit actuates the alarm after an elapsed time measured from the release of the drive switch.
[0019] The hair styling iron may operate either in a user-selected time mode or in an automatic time mode, or else it may operate selectively in either the user-selected time mode or in the automatic time mode. In the user-selected time mode the elapsed time is determined based upon user selections made before use, such as a timer setting or temperature setpoint. In the automatic time mode the control circuit calculates an elapsed time depending upon how the hair styling iron is actually used, to account for the amount of hair to be curled.
User-Selected Time Mode
[0020] Preferably the control circuit further comprises timer setting means for allowing users to select one from a plurality of predetermined timer setting values, each associated with an elapsed time. Preferably the timer setting means comprises a timer setting switch connected to the control circuit.
[0021] Preferably the control circuit comprises a thermostat, and means for selecting one from a plurality of setpoint temperatures, and wherein each of the plurality of predetermined timer setting values is associated with both a respective elapsed time and a setpoint temperature.
Automatic Time Mode
[0022] Preferably the change of state comprises both the first actuation of the drive switch, and the release of the drive switch immediately following the first actuation of the drive switch, and the control circuit actuates the alarm after an elapsed time which is calculated by the control circuit in direct proportion to the angle of rotation of the barrel relative to the handle that occurs between the first actuation and the release of the drive switch.
[0023] If the rotary drive rotates the barrel at a constant speed when the drive switch is actuated, the angle of rotation of the barrel is directly proportional to the time between actuation and release of the drive switch, so the control circuit may monitor the switch-operating time between the actuation and release of the drive switch and calculate an elapsed time in direct proportion to the switch-operating time. In this way the elapsed time may be determined in proportion to the length of hair wound onto the barrel during operation of the drive switch.
[0024] Where the drive switch provides for modulated control of the rotary drive then the control circuit may include a rotary encoder for measuring the angle of rotation of the barrel or, for example, the angular speed of the barrel could be integrated by the controller to calculate the angle of rotation of the barrel.
[0025] Preferably the control circuit comprises a thermostat, and means for selecting one from a plurality of setpoint temperatures, and wherein the elapsed time which is calculated by the control circuit is varied in proportion to the setpoint temperature.
[0026] Preferably, if the motorised means vibrates the barrel, then the control circuit may stop the motorised means to provide the alarm. If the motorised means rotates the barrel the control circuit may rapidly reverse the motorised means to vibrate the barrel and thereby provide the alarm. The hair styling iron may include an alarm signal generator, such as a wireless alarm signal generator, for transmitting an alarm signal to a remote tactile, audible or visual alarm. However, preferably the control circuit includes a separate vibrator, audio emitter or a light source to provide the alarm after the elapsed time.
[0027] Preferably a display is connected to the control circuit. The display may indicate a user-selected temperature and/or a user selected timer setting.
[0028] The control circuit may operate the alarm to provide a preliminary tactile, audible or visual alarm immediately before the elapsed time. For instance, the preliminary alarm may comprise two temporally spaced activations of the indicator for relatively short discrete lengths of time, before operating for a relatively long length of time upon expiry of the elapsed time.
[0029] Preferably the alarm is a vibro-tactile device, for instance a rotary motor with an eccentrically mounted weight disposed in the handle for vibrating the handle.
[0030] Preferably the timer-setting switch comprises a single-pole, single-throw instantaneous contact switch mounted to the handle and it is operable to toggle through a set of timer settings.
[0031] In another aspect the invention provides a hair styling iron comprising:
[0032] a handle to which a barrel is mounted,
[0033] a heating element in the barrel;
[0034] a clamp for urging hair into contact with the barrel;
[0035] a motorised means for rotating the barrel;
[0036] a control circuit including a timer;
[0037] a drive switch connected to the control circuit which is actuated by closing the clamp to urge the hair against the barrel;
[0038] and wherein the control circuit monitors at least one change of state of the drive switch to determine a starting time, and actuates a response after an elapsed time measured from the starting time.
[0039] In yet another aspect the invention comprises a method of curling air using a hair styling iron substantially as described above, comprising:
[0040] a) heating the barrel;
[0041] b) wrapping a tress around the barrel;
[0042] c) actuating the drive switch to wind the tress about the barrel,
[0043] d) releasing the drive switch to stop the rotary drive, and
[0044] e) awaiting an automatically generated alarm indicating the end of the elapsed time before removing the tress from the barrel.
[0045] The method may further comprise the step, prior to step c), of selecting one from a plurality of predetermined timer setting values, each associated with an elapsed time.
[0046] The method may further comprise the step of actuating a single button on the hair iron to select either (i) one from a plurality of predetermined timer setting values or (ii) an automatic time mode in which the elapsed time is calculated by the control circuit in direct proportion to the angle of rotation of the barrel relative to the handle that occurs between the first actuation and the release of the drive switch.
[0047] The method may further comprise the step, prior to step c), of selecting one from a plurality of setpoint temperatures, each of which defines a respective elapsed time.
[0048] The method may further comprise the step, prior to step c), of clamping the tress to the barrel.
[0049] Preferably the starting time coincides with the release of the drive switch.
[0050] In another aspect the invention provides a method of curling air using a hair styling iron as described above, comprising:
[0051] a) heating the barrel;
[0052] b) wrapping a tress around the barrel;
[0053] c) actuating the drive switch to wind the tress about the barrel in a first direction,
[0054] d) releasing the drive switch to stop the rotary drive,
[0055] e) receiving an automatically generated signal indicating the end of the elapsed time, and reversing the motorised means, in response to the automatically generated signal, to turn the barrel in a second opposing direction to unwind the tress from the barrel.
[0056] This invention provides a hair styling iron device and method which, by allowing a user to time a particular styling process in a simple manner, allows for more consistent styling results to be produced more efficiently. It will be understood that the invention may comprise any combination of the above-described features and is not limited to the specific features claimed according to the claim dependencies.
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] Preferred forms of the present invention will now be described by way of example with reference to the accompanying drawings, wherein:
[0058] FIG. 1 is a partially cut away side view of a hair styling iron according to the invention;
[0059] FIG. 2 is a fragmentary internal view of the hair styling iron of FIG. 1 , and
[0060] FIG. 3 is a block diagram of a control circuit of the hair styling iron of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0061] FIGS. 1 and 2 illustrate a hair styling iron according to the invention, which generally includes a curling spindle 10 and an elongate, hollow handle 14 . The spindle 10 is turned by a DC gear motor 12 and includes an elongated, generally cylindrical curling barrel 16 that extends generally coaxially from one end the handle 14 . The curling barrel 16 includes an electrical heating element 22 disposed in the curling barrel 16 . A clamping member 18 may be an elongated element pivotably attached to the curling barrel 16 by a transverse pivot 20 , and with a concave inner face generally complementary to the outer face of the curling barrel 16 . The clamping member 18 may be biased by a spring (not shown) toward the barrel 16 . A lever 24 may be fixed to the clamping member 18 for moving the clamping member between an open and closed position to enable retention and release of a strand of hair thereby.
[0062] Both the curling barrel 16 and handle 14 are hollow. The barrel 16 may have a plain surface, or may have other hair-engaging features such as protrusions, ribs, tines or bristles. The handle encloses a printed circuit board 26 to which the principal components of a control circuit 128 are disposed. The handle portion 14 of the styling iron 10 may be provided with a power cable 15 via which the control circuit 128 receives power. The control circuit 128 supplies current to the element 22 , controlling the current according to the setpoint temperature level at which the curling barrel 16 is maintained and that is set by a thermostat switch 28 . Thermostat switch 28 for setting the temperature may be an instantaneous contact type, operated as by individual actuations and releases stepping through a set of predefined temperature settings.
[0063] The control circuit further includes a rotational control switch 30 for initiating and terminating rotation of the spindle 10 in a selected direction 12 ; and a timer setting switch 32 for controlling timer operation. A display 124 may be connected to the control circuit 128 for indicating a user-selected setting (e.g. temperature, time, or the like). The display 124 may be active, including a light source such as a light emitting diode or the like, or it may be a passive display requiring outside illumination. The rotational control switch 30 may be an instantaneous reversing switch (double-pole, double-throw) which must be maintained actuated to operate the motor 12 . The timer setting switch 32 may be an instantaneous contact type, operated as by individual actuations and releases stepping through a set of predefined settings shown on the display 124 . A button (not shown) may make it possible to adjust the rotation speed of the spindle 10
[0064] A vibro-tactile indicator 36 may be employed to provide a response in the form of tactile alarm at the end of the elapsed time measured from a starting time. The vibro-tactile indicator 50 may comprise a motorised eccentric-type vibrator fixed inside the handle, such that the user is able to sense vibration of the handle 14 after the elapsed time. The vibro-tactile indicator 50 may be driven continuously or discontinuously to provide an alarm to indicate the elapsed time.
[0065] A main controller 38 is operatively connected to the display 124 , the rotational control switch 30 , thermostat switch 28 and timer-setting switch 48 . Also connected to the main controller 38 are a motor controller 40 , timer controller 42 and temperature controller 44 for respectively controlling the motor 12 , vibro-tactile indicator 36 and heating element 22 .
[0066] In operation of the styling iron, after connection to a power supply the thermostat switch 28 can be adjusted to select an appropriate temperature, typically a high, medium or low level. In a first embodiment the timer setting switch 32 is present, and allows the user to select one of, for instance, three timer settings for short, medium and long time, each defining a respective elapsed time. In a second embodiment the timer setting switch 32 may be present or absent. If present, timer setting switch 32 may allow a user to select between two modes: a first user-selected mode providing for selection of an elapsed time between predefined timer settings and a second automatic mode in which the elapsed time is determined automatically. If the timer setting switch 32 is absent, the elapsed time is determined automatically by the control circuit 128 .
[0067] In order to curl hair, the clamp actuating lever 24 is depressed so as to open the clamping member 18 . A portion of a tress is inserted beneath the clamping element and the lever is released so as to retain the strand of hair. The rotational control switch 30 is then activated so as to rotate the spindle 12 to wind the hair thereabout and then released when the desired length of hair has been wound up. Any one of these actions may serve to start the timer automatically. For instance, a switch (not shown) actuated by movement of the clamping member 18 toward the barrel 16 may send a starting time signal to the timer controller 42 . However, preferably the timer is started automatically by the main controller 38 monitoring a change of state of the rotational control switch 30 . When the main controller 38 identifies the release of the rotational control switch 30 immediately following the first actuation of the rotational control switch 30 , the controller sends a starting time signal to the timer controller 42 to define the starting time.
[0068] In the user-selected time mode, the timer is started automatically as by monitoring a change of state of the rotational control switch 30 . When the timer controller 42 receives the starting time signal a countdown is initiated and runs for an elapsed time associated with the timer setting selected by the user, before sending an actuation signal to generate a response, such as an alarm provided by the vibro-tactile indicator 36 at the end of the elapsed time. In this user-selected time mode the timer setting alone may not define the elapsed time. The elapsed time may be determined by the control circuit based upon both the timer setting and the setpoint temperature. For instance, for any one timer setting, a low setpoint temperature may be associated with a longer elapsed time than a high setpoint temperature.
[0069] In the automatic time mode, the elapsed time is varied to account for the length of hair wound about the curling barrel 16 . The rotary gear motor 12 may rotate the barrel 16 at a constant speed when the rotational control switch 30 is actuated, so that the angle of rotation of the barrel 16 is thus directly proportional to the time between actuation and release of the rotational control switch 30 . The motor controller 40 monitors the time between the actuation and release of the rotational control switch 30 during which time the motor 12 is operated and sends a feedback signal to the timer controller 42 which is indicative of the angular rotation of the barrel 16 during the time the motor 12 is operated. The timer controller 42 then calculates an elapsed time in direct proportion this switch-operating time. When the main controller 38 identifies the release of the rotational control switch 30 immediately following the first actuation of the rotational control switch 30 , the controller sends a starting time signal to the timer controller 42 to define the starting time. Starting from the calculated elapsed time a countdown is initiated before sending an actuation signal to generate a response, such as an alarm provided by the vibro-tactile indicator 36 at the end of the elapsed time. By controlling the elapsed time for the timer and starting the timer in this manner the appropriate curling time can be indicated to the user, and increased in accordance with the mass of hair that is being curled.
[0070] In the automatic time mode, the elapsed time may also be varied to account for the setpoint temperature. As shown in FIG. 3 , the timer controller 42 receives feedback from the temperature controller 44 for this purpose. The timer controller 42 varies the calculated elapsed time in direct proportion to the setpoint temperature. At a high setpoint temperature the calculated elapsed time is reduced, compared to that determined for a low setpoint temperature.
[0071] After the elapsed time, the user is prompted by the vibro-tactile indicator 36 to press the rotational control switch 30 to reverse the direction in which the spindle 12 rotates so as to unwind the hair therefrom; the rotational control switch 30 is released to terminate rotation, and the clamp actuating lever is depressed so as to release the now curled strand of hair.
[0072] In both embodiments and in both the user-selected time mode and automatic time mode the rotary drive may rotate the barrel in a first direction upon actuation of the drive switch, and the response initiated by the control circuit after the elapsed time may comprise turning the barrel in a second direction, opposite to the first direction. In this manner, once the hair has been heat treated for the elapsed time the response provides that the hair is loosened or completely unwound from the barrel automatically. No user intervention is required to loosen or unwind the hair from the barrel. While the alarm preferably accompanies the automatic unwinding of the hair, the alarm is not needed to indicate the elapsed time to the user, as the reverse rotation of the barrel itself indicates to the user that the elapsed time has passed. Thus the alarm is not essential to all embodiments of the invention. The essential feature is generation of some automatic response at the end of the elapsed time, such as an alarm or the reverse rotation of the barrel, which indicates the end of the elapsed time.
[0073] It will also be understood that the manner in which the hair is unwound is not essential to the invention, and for instance the spindle 12 may simply be disengaged from the gear motor at the end of the curling time via a clutch (not shown) which is operated by the control circuit to provide the response and to allow the spindle to rotate freely, thereby unwinding the curled hair. Such a clutch may also provide torque limiting for optimal tensioning of the hair as it is wound or for safety. An energy storage device such as a spring may be energised by the motor during winding up of the hair and then released by the control circuit at the end of the elapsed time, together with the clutch, to unwind the hair.
[0074] Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof. | A hair styling iron has a handle to which a heated barrel is mounted and a motor for moving the barrel. The iron includes a drive switch which is user actuable and connected to the control circuit for controlling operation of the motor. The control circuit includes a timer and monitors at least one change of state of the user-actuable drive switch to determine a starting time, and actuates an alarm, or another response, such as a reversal of the motor to unwind the hair, after an elapsed time measured from the starting time. The elapsed time may be user-selected or calculated automatically depending upon the length of hair wound onto the barrel, with compensation for barrel temperature. | 0 |
SUMMARY
Slidable jaw wrenches, for example, those commonly termed "Crescent wrenches" possess infinite adjustability but must be repeatedly disengaged and reapplied to the nut, bolt, or other object to which torque is applied as the object rotates. The jaws of such wrenches are also prone to slippage both in the loaded and unloaded condition, requiring constant readjustment. It is also difficult to adjust such wrench to a preselected size other than by application to the nut.
Ratchet handle wrenches, on the other hand, enable the position of the handle to remain relatively constant as the nut rotates due to the relative rotation between the nut engaging socket of the wrench and the handle provided by the ratcheting action. However, the sockets used with ratchet wrenches are not infinitely variable but are available only in discrete sizes and increments. The depth of the socket may limit the amount by which a nut can be threaded on a bolt.
It is, therefore, the object of the present invention to provide an improved wrench which combines the advantageous features of both an adjustable sliding jaw wrench and a ratchet wrench. The jaws of the wrench are infinitely variable yet the handle may remain in the same relative position during operation of the wrench.
Other features of the wrench include an economical and reliable means for retaining the jaws of the wrench in a desired relative position thereby avoiding the need for continual readjustment to obtain proper engagement with the nut. The opening in the wrench may be precisely set prior to application to the nut.
Briefly, the present invention contemplates the provision of an improved wrench comprised of a wrench head and a handle. The wrench head has a fixed jaw and a sliding jaw and includes at least one square hole for receiving a mating projection on the wrench handle. The wrench handle may include a ratcheting mechanism. Means are provided to retain the sliding jaw in a desired position on the wrench head and to indicate the size of the jaw opening.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of one embodiment of the improved wrench of the present invention.
FIG. 2 is a plan view of another embodiment of the improved wrench of the present invention.
FIG. 3 is a side view of the wrench shown in FIG. 2 taken along the line 3--3.
FIG. 4 is a side view of yet another embodiment of the improved wrench of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, the improved wrench 10 of the present invention includes wrench head 12 and wrench handle 14. Wrench head 12 includes a base 16 containing work surface 18, as shown in FIG. 2. A fixed jaw 19 extends from work surface 18 along one side of base 16.
As shown most clearly in FIG. 4, work surface 18 contains slot 20 terminating in the cylindrical cavity 22. Sliding jaw 24 includes flange 26 positioned in slot 20 and rod 28 positioned in cavity 22. The lower, or bottom, portion of rod 28 is formed as a rack.
The rack portion of rod 28 engages worm gear 30 which is rotatably mounted in opening 32 in base 16. The crest 34 of worm gear 30 is knurled to facilitate rotation of the worm gear with the thumb or fingers.
Wrench head 12 includes square hole 36 extending through base 16 from one surface thereof to the other. Wrench head 12 also includes a second hole 38 extending from the end of base 14 into hole 36 at right angles to hole 36 and a third hole 39 extending into hole 36 at right angles to hole 38 as shown in FIG. 2.
A variety of handles 14 may be employed with wrench head 12. For example, the standard ratchet wrench handle 14a shown in FIG. 1, may be used, in which case hole 36 in base 16 may be sized to receive stud 40 of the ratchet wrench handle. The size of stud 40 is proportional to the size of wrench 10. Or, a non ratcheting wrench handle 14b containing stud 40 may be employed, as shown in FIG. 4. Wrench head 12 may include pads 41 shown most clearly in FIG. 3, which prevent interference between wrench handle 14 and worm gear 30. In the embodiment shown in FIGS. 2 and 3, stud 42 may be mounted on the end of bar 14c and inserted in holes 38 and 39.
In use, the wrench head 10 is adjusted to the desired size by moving sliding jaw 24 with knurled worm gear 30. The desired wrench handle 14 is coupled to wrench head 12. In the case of ratchet wrench handle 14a, stud 40 is placed in hole 36 and the ratcheting action of handle 14a adjusted for the tightening or loosening direction of rotation. The jaws of wrench head 12 are slipped over the nut and handle 14 is operated to provide the desired torque to the nut.
In instances in which a non ratcheting wrench handle 14b is employed, stud 40 is inserted in hole 36.
If bar 14c is used, stud 42 is inserted in hole 38 or 39 and the lever operated to provide the desired torque to the nut or other object. The mounting of stud 42 at an angle on wrench handle 14c provides a pair of torque applying positions for the handle in each of holes 38 and 39, as shown in FIG. 2 in connection with hole 38.
To hold sliding jaw 22 in the desired position, a pair of spring leaves 44 may be affixed to sliding jaw 24, as by rivets 46 to resiliently grip base 16 of wrench head 12. As shown most clearly in FIG. 2, spring leaves 44 may be arcuate, having an edge 48 terminating parallel with the edge of sliding jaw 24. The edge 48 of spring leaves 44 may be employed in conjunction with graduations 50 along work surface 18 to indicate the size of the opening between the jaws of wrench 10. This assists in adjusting the wrench prior to application of the wrench to the nut. It also permits use of the wrench as a nut and bolt size guage. In instances in which the sliding jaw wrench does not hold well enough to loosen the nut or for other reasons is inappropriate for the job, the indication of the spacing of wrench jaws 19 and 24 will help in selecting the correct socket or open end wrench to replace the sliding jaw wrench. One side of base 12 may contain graduations in inches while the other side may contain graduations in some other unit of measurement, such as metric.
Various modes of carrying out the invention are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter which is regarded as the invention. | An improved wrench includes a wrench head having a fixed jaw and a sliding jaw. The head includes a square hole for receiving a mating projection on a wrench handle. The wrench handle may include a ratcheting mechanism. Means are provided to retain the sliding jaw in a desired position on the wrench head and to indicate the size of the jaw opening. | 8 |
BACKGROUND OF THE INVENTION
This invention relates generally to support structure in a tumbler-style washing machine. More specifically, the invention pertains to the type of washing machine having an elongated rotatable tubular drum adapted to rotate about a horizontal axis, and a bearing support system for the drum which includes a number of buffers distributed along its length.
When a washing drum is secured to fixed support structure or to a bearing system originally secured to such structure, the bearing forces of the individual buffers may vary, both during idle periods and due to motion during operation, owing to the distribution of the mass of the drum, inaccuracies in manufacture, varying loads and changing tolerances between components which result through prolonged use. Such varying forces will vary even when the mass distribution of the drum is substantially uniform, or at least periodically uniform and even when the bearing points are distributed substantially uniformly along the drum, allowing for the existing mass distribution. Such variations in bearing forces whether occurring regularly or irregularly during operation, are extremely undesirable.
For example, if a tubular, rotatable drum is suspended to rotate about its longitudinal axis by means of a number of bearings, and, if required, driving elements such as chains or the like, each chain being guided around the surface of the drum and over a pulley disposed about the drum, variations in the load on the chains may frequently result in breakdown. Such breakdown may be due to the fact that the drum, which is usually welded from relatively thin sheet metal, will flex and distort relatively easily. This may be particularly true where the drum is substantially long (12 meters or more) and/or has a relatively small diameter. In addition, in the manufacture and assembly of such a drum, the intended round or tubular configuration may not be achieved since individual drum segments may become radially displaced during assembly such that parts of the drum are disposed eccentrically to the drum axis.
As a result of such factors, the chains or other bearing elements, even though uniformly spaced along the drum, may be subjected to greatly varying loads and the loading conditions will vary continuously during operation.
Under unfavorable circumstances, it may also happen that only a few in a plurality of bearing chains will actually bear a load, at least for a time, with the other chains in the plurality being subjected to little or no load. This overstressing of a few of the bearing elements will quite often result in breakdown. In order to avoid such damage, the chains or other bearing elements must be made considerably oversized. This, however, will result in very heavy and expensive chains or other bearing elements and will also result in the undesirable need for operatively associated elements, such as drive pulleys, of unreasonably cumbersome size.
In order to avoid or largely reduce the aforementioned disadvantages and to absorb or attenuate the impacts or similar stresses resulting therefrom or caused by external factors (such as the motion of the articles being treated during the washing and conveying process) it has heretofore been proposed that the pulleys for guiding the chains or the like should each be held on a substantially horizontally extending rocker beam element which projects generally transverse to the longitudinal axis of the drum, and that one end of the rocker be made pivotal about a horizontal axis while the other end is resiliently borne by a buffer in the form of a rigidly mounted spring. Such a bearing system can reduce the effect of non-uniform stressing of the chains or the like caused by inaccuracies during manufacture, but it does not achieve uniform distribution of stress on the chains during operation. Another disadvantage of this system is that the springs have to be individually adjusted by hand and readjusted by hand after the inevitable stretching of the chains during operation. Even when such laborious adjustment has been performed, the uniform stress placed on the chains is immediately lost when the drum has rotated through a fraction of a complete revolution due to the inaccuracies heretofore described with regard to manufacture and assembly of the drum. More specifically, departures from roundness and the radial offset of the individual segments will destroy any uniformity of stress distribution as soon as the drum is partly rotated away from the position in which the adjustment was made. Moreover, the known system heretofore described cannot be utilized for adjusting the level of the drum, though the ability to make such adjustment is very desirable.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide a bearing system in which a washing drum is borne by a number of buffers distributed along the drum so that the bearing forces are equal at all the bearing points, that is, at the location of all the bearing elements, so that, for example, if a horizontally elongated tubular rotatable drum is suspended from chains or the like, all of the chains will be substantially uniformly loaded during operation in spite of variance of the configuration of the drum. It is also an object of this invention to achieve automatic, subsequent adjustment of load and stress on bearing elements in a washing machine after the bearing elements, such as chains and the like, have stretched in operation, and to provide a preferably automatic means for adjusting the level of the rotatable drum.
To achieve the foregoing objectives, the apparatus of the invention includes buffering means comprising a plurality of piston-cylinder units, the cylinders of which are supplied with a fluid pressure medium and wherein each cylinder is connected to at least one other cylinder in the plurality. As explained hereinafter, it is presently preferred that the pressure medium is a gas which, for economic reasons, is preferably air.
If a washing drum is provided with a bearing system of the aforementioned kind, and if, for example, all the cylinders in the piston-cylinder units forming the buffering means are interconnected, in accordance with one form of this invention, uniform pressure is obtained in the cylinders as a result of their interconnection after the cylinders have been supplied with pressure medium from a pressure medium source and after the drum has been thereby elevated and the piston-cylinder units have subsequently been disconnected from the pressure source. As a result, the bearing forces at each piston-rod are the same, as will be shown in detail with reference to another example.
If, after operation, the complete drum has to be raised to the operating level, an additional adjustment in level has to be made, then, in accordance with a form of this invention, it is preferable not to connect all the cylinders together but only to connect the cylinders into a number of groups, preferably with a group of neighboring or adjacent cylinders disposed at one end of the drum whereby the distance between each pair of adjacent piston-cylinder units remains approximately the same.
According to this invention, the pressure medium conduits or lines to the groups of cylinders can each be connected via a controllable shut-off means to a common pressure source or a pressure medium supply line leading to a pressure source. The controllable shut off means are preferably solenoid valves, each means being actuated by a level pick-up measuring the height, at the appropriate place, of the drum to be suspended, so that the shut-off means opens the pressure medium supply when and as long as the drum is below a given minimum height at the point of measurement. Preferably, level pick-ups are disposed at each end portion of the drum.
BRIEF DESCRIPTION OF THE DRAWING
Other features and advantages of the present invention will become apparent from the ensuing detailed description and by reference to the accompanying drawings wherein:
FIG. 1 is a diagrammatic perspective view of a tumbler-type washing machine drum supported for operation by the bearing system of the present invention, and
FIG. 2 is a more detailed diagrammatic representation of a bearing system in accordance with this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 diagrammatically illustrates a continuous tumbler-type washing machine comprising a horizontally elongated tubular drum 3 disposed in a box-like housing 1. The drum 3 is supported from a frame structure 37 which, although not shown in detail in the drawing, may be considered as the top surface of housing 1.
The frame structure 37 has disposed thereon, in a spaced-apart orientation, eight rockers or rocker beam members 62. One end 63 of each rocker 62 is pivotally secured to a bearing 74, and each bearing 74 is rigidly secured to the frame structure 37. The rockers 62 are thereby adapted to be pivotally moved around a horizontal axis in a substantially vertical plane from their substantially horizontal normal position. Each rocker 62 has an end 64 which is mounted to the frame structure 37 by a buffer 76'. A guide pulley 61 is journaled to each rocker 62 and an endless chain 13' is supported on each guide pulley 61.
Each pulley 61 and its associated chain 13' is driven by a separate motor (not shown) so that chains 13' drive drum 3 as well as suspendedly support it. As shown in FIG. 1, each chain 13' is guided around the bottom outer surface of the drum 3 so that the drum is suspendedly held and driven by the eight chains 13'. A distance k between each pair of adjacent chains 13' is the same in each case and equal to the length of a section of drum 13, which is made up of seven such sections. It is necessary to distribute the bearing means along a component such as the washing drum 3 in the aforementioned manner in order to avoid the considerable sagging which would otherwise occur owing to the weight of the drum, particularly from the load carried therein during operation.
Drum 3 is mainly constructed of relatively thin sheet metal and, therefore, sags considerably and departs from its intended tubular roundness owing to the changes in shape resulting from welding and the like and some unavoidable relative radial displacement of the individual segments. Consequently, if it were not for the special arrangement and operation of buffers 76' (if, for example, each buffer 76' were replaced by rigid bearings or springs) the suspension chains 13' would be non-uniformly loaded such that perhaps only a few of the eight chains 13' would be loaded (the load thereon being correspondingly heavy) whereas the other chains 13' would bear little or no load. Such non-uniform loading of the chains may result in fractures unless the chains are made unacceptably oversized to guard against the most unfavorable case wherein the total load would have to be borne by only two or three chains, and even then the loading would not be uniform.
If, however, the means bearing the rocker 62 (the buffers 76' in FIG. 1) are adjusted so that the load on the chains is substantially uniform, it is found that the load is no longer uniform if the drum 3 rotates only through a fraction of its total circumference where, due to the aforementioned departures from roundness and the radial displacement and the like, the geometrical errors may be completely different in the new position. In addition, any adjustment made by hand will alter during operation, owing to the unavoidable stretching of chains 13'. Accordingly, when a washing drum, such as drum 3, is suspended in the aforementioned manner (and such suspension is extremely advantageous for a number of reasons) the chains 13' are non-uniformly loaded and may break, resulting in disturbance in operation or total breakdown of the equipment. However, these characteristics inherent in known bearing systems are avoided by the bearing system of this invention since the rockers 62 are borne by buffers 76' comprising piston-cylinder units.
The bearing system of the present invention may be understood by reference particularly to FIG. 2, which for simplicity shows only six buffers 76' corresponding to a drum made up of six sections. This difference in number of sections and associated components, as compared to FIG. 1, makes no difference in the principle of the invention, but somewhat simplifies the explanation thereof. It should be understood that the principles hereafter explained would be applicable to a drum made up of any reasonable number of sections, whether more or less than the drum 3 specifically illustrated.
As heretofore mentioned, buffers 76' are piston-cylinder units comprising cylinders 90 adapted to be supplied with compressed air. The air comes from a pressure medium source (not specifically shown in FIG. 2) connected to a pressure medium supply line or conduit 91 containing a shut-off means 92 and a pressure gauge 93. The air pressure is about 8-10 bars and can be adjusted by a pressure regulating valve on the shut-off means 92. Compressed air coming from conduit 91 travels through a solenoid valve 94 into a pressure medium pipe 95 and through a solenoid valve 94' into a pressure medium pipe 95'. After leaving pipes 95 or 95', the compressed air travels through branch pipes 96 and 96' to a first group of cylinders 90 or a second group of cylinders 90', the adjacent cylinders in the first group being interconnected in the same manner as the cylinders 90' in the second group. Cylinders 90, i.e. the first group of piston-cylinder units or buffers 76', are disposed along the left-half of drum 3, whereas cylinders 90' are disposed along the right-half of the drum. The piston-cylinder units are all identical so that not only the cylinders but also the associated pistons are of similar construction.
A lever 97, 97', respectively, is disposed at either end on drum 3, one end of each lever being secured to housing 1. Levers 97, 97' are secured to housing 1 so as to be vertically pivotable and have magnets 98,98' respectively at their free ends. Near the free end of each lever 97, 97' there is a pair of solenoid switches, first solenoid switch 99, 99' being disposed above the corresponding lever 97, 97' and a second solenoid switch 100, 100' being disposed below the corresponding lever when the lever is in the normal position.
The bearing system of the present invention is adapted to be placed in an inoperative or shut-down position, for example, at night, by lowering drum 3 below its normal operating position and resting it upon sliding elements (not shown) which are provided at edges of each section whereby each individual section is supported separately both during operation and shut down. When the washing machine is placed into operation again, the shut-off means 92 is opened and adjusted so that the air pressure in the supply line 91 builds up to 8-10 bars, which may be monitored at the pressure gauge 90.
Since the drum 3 is below the operating position, as indicated at the left of FIG. 2, the solenoid switch 100 is closed and thus electrically connected to the corresponding solenoid valve 94 which opens and omits compressed air from line 91 to the pressure medium pipe 95 and thence via branch pipes 96 to the first group of cylinders 90. Of course, when the machine is brought back into operation, the same applies to the second group of cylinders. In FIG. 2, the second group is shown in a different position, that is, the position when the right end of drum 3 is already at the planned operating level. In this position, (which, of course, is reached by the left group after a certain time) the solenoid switch 100' opens, thus disconnecting the associated solenoid valve 94' from the current supply and closing it, so that no more compressed air can flow from line 91 into pipe 95'. After this switching off or cut-off operation, the group of cylinders formed by the piston cylinder units 76' in the right-hand group form a closed system, with the connecting pipes 96' and 95, which can be influenced only from the exterior via pistons 101'.
After both ends of drum 3 have been raised to the operation level, pistons 101, 101' bear the total weight G of drum 3, its contents, parts of the rockers 62 and the pulleys 61 secured thereto, and the associated drives (not shown). The total weight G borne by buffers 76' is made up of the individual weights G 1 -G 6 acting on the individual buffers 76', which may vary relatively considerably if buffers 76' are not the bearing system according to the invention but are instead, for example, rigid bearings or the like. The variations in bearing forces resulting in varying loads on chains 13 are due not only to the differences in mass distribution due to the loads or the like, but are closely dependent upon non-circularity of the drum 3 and on other inaccuracies during manufacture, due to radial displacement of the components, etc.
With continued reference to FIG. 2, if there are differences in the individual loads G 1 , G 2 , G 3 on the left group of buffers 76' (with respect to which the operation of the system according to the invention will be explained in detail) and if it is assumed that the weight force of G 1 is greater than the weight forces G 2 and G 3 the result is that the cylinder 90 loaded by the strongest force G 1 is at a higher pressure than the other two cylinders 90 in the left group of buffers. Since, however, cylinders 90 are interconnected by lines 96 and 95, the pressure is equalized between cylinders 90. If the two cylinders 90 were subjected only to the weight forces G 2 and G 3 , their pistons 101 would move upwards until they struck the end wall of the cylinder, since the force on pistons 101 is equal to the piston surface multiplied by the pressure in cylinder 90 which varies with the force G 1 so that the resulting force is always greater than the counteracting forces G 1 , G 2 and G 3 .
In the present case, the force is not single, but the component to be borne, i.e. drum 3, extends through the entire bearing system. Consequently, owing to the pressure equilibrium resulting from the connection to the cylinders 90 acted upon by force G 1 , the pistons 101 acted upon by forces G 2 and G 3 absorb greater forces G 2 ' and G 3 ' when they extend. Since, however, the total force G acting on all the pistons 101, 101' is constant, the initially more heavily loaded pistons are inevitably and automatically relieved from load and an equilibrium of forces is obtained such that the load is equal on all the pistons in a group, that is, on all the chains 13' as shown in FIG. 1. A corresponding process as heretofore described occurs in the other group of pistons.
If the bearing forces at all the bearing points, not only inside the single group of pistons, are to be equal, the two pressure medium lines 95 and 95' can be connected by line 102, advantageously containing a shut-off means 103 for bringing drum 3 up to a preset level as previously described when operation begins. Owing to this level of compensation, which is another desired objective of this invention, line 102 can usually be omitted inasmuch as no automatic level compensation could be obtained during operation.
If, as a result of inevitable losses of compressed air during operation, drum 3 sinks sufficiently to close solenoid switches 100 or 100' as shown on the left side of FIG. 2 the associated solenoid valve 94 and/or 94' opens so that additional compressed air can flow from the compressed air source.
It can be seen that by means of the bearing system of the present invention, the chains 13' (at least in one group of cylinders) are always uniformly loaded without any subsequent adjustments being necessary. This increases the reliability in operation and, more particularly, considerably increases the working life of the chains in the entire machine.
Owing to the automatic operation, no subsequent adjustment is required, thus correspondingly reducing the maintenance. As can be readily seen, the bearing system according to the invention is particularly suitable for bearing the drums of tumbler type washing machines. However, such drums do not need to be suspended only in the manner as shown with respect to the presently preferred embodiment.
A further advantage of the illustrated embodiment using the bearing system according to the invention is that after the machine has been switched off, the chains are even more gently treated owing to the resulting unloading, since the drum 3, after operation thereof has ceased, rests on bands or rings, each disposed between two adjacent segments of drum 3. Since the bands are pressed firmly against the outer drum when it is lowered, the individual segments are very efficiently supported even in the inoperative state.
It should also be noted with respect to the illustrated embodiment that an inherent characteristic of the arrangement shown is that the drum 3 cannot begin operation until it has reached the set operating level.
The structure described herein and shown in the accompanying drawing is presented only for the purpose of explaining the invention and it is not intended to limit the invention's scope. It is contemplated that the apparatus of the invention may be variously adapted, changed or modified without departing from the spirit and scope of the invention as defined in the appended claims. | A tumbler-style washing machine having a tubular elongated drum adapted to be rotatable about its horizontal axis is provided with bearing-support structure for suspending and driving the drum, including a plurality of pulley-driven endless chain loops which suspend the drum from overhead rocker beam members. The rocker beam members are adapted to rock a limited distance in a vertical plane, to compensate for variations encountered during operation of the machine, such as load change, chain stretch and drum level fluctuation, etc., and a plurality of piston-cylinder units serve as buffering means for the rocker beam members. The piston-cylinder units are preferably supplied with internal fluid pressure and may be variously interconnected with each other and with specific control means to achieve an automatic support-adjusting action during operation of the washing machine. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to a vehicle suspension system and in particular to a vehicle suspension impact energy absorption arrangement and integrated rear impact collision safety arrangement.
BRIEF SUMMARY OF THE INVENTION
A vehicle impact energy absorption arrangement comprises a vehicle frame, a slider suspension arrangement coupled with the vehicle frame, and an impact force absorbing arrangement. The slider suspension arrangement comprises at least one trailing arm member having a first end and a second end, a support bracket coupled to the vehicle frame and pivotably supporting the first end of the first trailing arm, and a spring member positioned between the second end of the trailing arm and the vehicle frame. The impact force absorbing arrangement comprises a mounting member coupled to the vehicle frame, a first pivot member pivotably coupled to the mounting member, a second pivot member pivotably mounted to the mounting member, at least one elastically deformable biasing member positioned between the first pivot member and the mounting member and between the second pivot member and the mounting member, wherein the first pivot member is configured to pivot and elastically deform the at least one biasing member when impacted by the slider suspension arrangement, and wherein the second pivot member is configured to pivot and elastically deform the at least one biasing member when the second pivot member receives a forwardly directed force.
Another aspect of the present invention is to provide a vehicle impact energy absorbing arrangement that includes a vehicle frame, a slider suspension arrangement coupled to the vehicle frame, and an impact force absorbing arrangement. The slider suspension arrangement comprises at least one trailing arm member having a first end and a second end, a support bracket coupled to the vehicle frame and pivotably supporting the first end of the at least one trailing arm, and a spring member positioned between the second end of the trailing arm and the vehicle frame. The impact force absorbing arrangement comprises a mounting member coupled to the vehicle frame, a first pivot member pivotably coupled to the mounting member and at least one elastically deformable biasing member positioned between the first pivot member and the mounting member, wherein the first pivot member is configured to pivot and elastically deform the at least one biasing member when impacted by the slider suspension arrangement.
Yet another aspect of the present invention is to provide a vehicle impact energy absorbing arrangement that includes a vehicle frame, a slider suspension arrangement coupled to the vehicle frame, and an impact force absorbing arrangement. The slider suspension arrangement includes at least one trailing arm having a first end and a second end, a support bracket coupled to the vehicle frame and pivotably supporting the first end of the at least one trailing arm, and a spring member positioned between the second end of the trailing arm and the vehicle frame. The impact force absorbing arrangement includes a mounting member coupled to the vehicle frame, a first pivot member pivotably coupled to the mounting member, and at least one elastically deformable biasing member positioned between the first pivot member and the mounting member, wherein the first pivot member is configured to pivot and elastically deform the at least one biasing member when impacted by the slider suspension arrangement.
Still yet another aspect of the present invention is to provide a vehicle impact force absorbing arrangement for use on a vehicle that includes a slider suspension arrangement, the vehicle impact force absorbing arrangement including a mounting member coupled to the vehicle frame, a first pivot member pivotably coupled to the mounting member, a second pivot member pivotably coupled to the mounting member, at least one elastically deformable biasing member positioned between the first pivot member and the mounting member and between the second pivot member and the mounting member, wherein the first pivot member is configured to pivot and elastically deform the at least one biasing member when impacted by the slider suspension arrangement, and wherein the second pivot member is configured to pivot and elastically deform the at least one biasing member when the second pivot member receives a forwardly directed force.
The principle objects of the present invention are to provide a durable, impact force absorbing arrangement that can be easily and quickly assembled, may be retrofit onto existing trailer assemblies, is economical to manufacture, capable of a long operating life, reduces damage typically associated with excessive force being applied by an operator to a slider suspension assembly, increases the safety of passengers in a vehicle that collides with the rear of a trailer assembly while simultaneously reducing the damage to the trailer typically associated with rear collisions, and is particularly well adapted for the proposed use.
These and other advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial side elevational view of a vehicle impact energy absorption arrangement mounted to an associated vehicle;
FIG. 2 is a perspective view of a vehicle slider suspension arrangement;
FIG. 3 is a partial side elevational view of the vehicle impact energy absorption arrangement, wherein a slider suspension arrangement has impacted the impact force absorbing arrangement;
FIG. 4 is a partial side elevational view of the vehicle impact energy absorption arrangement, wherein the impact force absorbing arrangement has been impacted by a secondary vehicle; and
FIG. 5 is a partial side elevational view of an alternative embodiment of the vehicle impact energy absorption arrangement.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in FIG. 1 . However, it is to be understood that the invention may assume various alternative 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 exemplary embodiments of the inventive concepts defined in the 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.
The reference numeral 10 ( FIG. 1 ) generally designates a vehicle impact energy absorption arrangement embodying the present invention. In the illustrated example, the vehicle impact energy absorption arrangement includes a vehicle frame assembly 12 , a slider suspension arrangement 14 coupled to the vehicle frame assembly 12 , and an impact force absorbing arrangement 16 .
The vehicle frame assembly 12 includes a pair of longitudinally-extending frame members, of which frame member 18 is illustrated in FIG. 1 . The frame assembly 12 also includes a plurality of cross-wise extending frame members (not shown).
The vehicle slider suspension arrangement 14 ( FIG. 2 ) comprises a plurality of support brackets 20 pivotably supporting corresponding trailing arms 22 , and spring members in the form of pneumatic springs 24 . Each trailing arm 22 includes a first end 26 pivotably coupled to a support bracket 30 , and a second end 28 configured such that the pneumatic spring 24 is operably positioned between the second end 28 of the trailing arm 22 and a slider rail 30 of the slider suspension arrangement 14 as well as the frame member 18 of the vehicle frame assembly 12 . An axle member 32 extends between pairings of the trailing arms 22 located on opposite sides of the associated vehicle. The slider suspension arrangement 14 is longitudinally adjustable in the directions 34 with respect to the vehicle frame assembly 12 .
In the illustrated example, the impact force absorbing arrangement 16 includes a mounting member 40 coupled to the vehicle frame assembly 12 , a first pivot arrangement 42 pivotably coupled to the mounting member for pivoting about a pivot axis 44 , and a second pivot arrangement 46 pivotably coupled to the mounting member 40 for pivoting about a pivot axis 48 , and a biasing member 50 operably positioned between the first and second pivot arrangements 42 , 46 and the mounting member 40 . In the illustrated example, the first pivot arrangement 42 includes a pivot arm 52 having a downwardly-extending portion 54 and a rearwardly-extending portion 56 . The biasing member 50 is positioned between the rearwardly-extending portion 56 of the biasing member 50 and the mounting member 40 . The second pivot arrangement 46 includes a downwardly-extending portion 58 and a forwardly-extending portion 60 . The biasing member 50 is operably positioned between the forwardly-extending portion 60 of the second pivot arrangement 46 and the mounting member 40 . The biasing member 50 may comprise a pneumatic spring, a hydraulic damper, a rubber bushing, and the like.
In operation, and as best illustrated in FIG. 3 , the impact force absorption arrangement 16 is adapted to absorb the impact between the slider suspension arrangement 14 and the impact force absorbing arrangement 16 , thereby reducing the forces exerted by the slider suspension arrangement 14 on the vehicle frame assembly 12 . Specifically, excessive forces generated on the overall system during position adjustment of the slider suspension arrangement 14 with respect to the vehicle frame assembly 12 may result in damage to the slider suspension arrangement 14 , the vehicle frame assembly 12 , or both. In the illustrated example, the slider suspension arrangement 14 is moved rearwardly in a direction 64 until the slider suspension arrangement 14 impacts a bumper member 66 positioned on a forward side of the downwardly-extending portion 54 of the first pivot arrangement 42 . Impact of the slider suspension arrangement 14 with the bumper member 66 causes the first pivot arrangement 42 to pivot about the pivot axis 48 in a direction 68 , thereby causing the rearwardly-extending portion 56 of the first pivot arrangement 42 to compress the biasing member 50 in a direction 70 . The biasing member 50 absorbs the impact energy exerted by the slider suspension arrangement 14 and reduces or eliminates any damage to the slider suspension arrangement 14 and/or the vehicle frame assembly 12 .
As best illustrated in FIG. 4 , a rear impact collision of a secondary vehicle 72 with the downwardly-extending portion 58 of the second pivot arrangement 46 causes the second pivot arrangement 46 to rotate about the pivot axis 48 in a direction 80 , thereby causing the forwardly-extending portion 60 of the second pivot arrangement 46 to compress the biasing member 50 in a direction 82 . The biasing member 50 is adapted to absorb the energy exerted by the secondary vehicle 72 onto the second pivot arrangement 46 , thereby ensuring the safety of the passengers in the secondary vehicle 72 , and simultaneously reducing the damage to the vehicle frame assembly 12 or the remainder of the vehicle.
FIG. 5 illustrates an alternative embodiment of the vehicle impact energy absorption arrangement 10 a. Since the vehicle impact energy absorption arrangement 10 a is similar to the previously described vehicle energy absorption arrangement 10 , similar parts appearing in FIGS. 1-4 and FIG. 5 , respectively are represented by the same, corresponding reference numeral, except for the suffix “a” in the numerals of the latter. In the illustrated example, the vehicle impact energy absorption arrangement 10 a is configured to lower the reaction point of the arrangement to a position equal to or below a center of mass of the slider suspension arrangement 14 . Specifically, the suspension arrangement 14 includes a brace 90 that is configured to abut the bumper member 66 a during rearward movement of the slider suspension arrangement 14 a in the direction 64 a. A structural reinforcement member 92 structurally reinforces and attaches the bumper member 66 a to the downwardly-extending portion 54 a of the first pivot arrangement 42 a. The location and configuration of the brace 90 lowers the reaction point of the forces exerted on the slider suspension arrangement 14 during position adjustment of the suspension slider assembly arrangement with respect to the vehicle frame assembly, to a position below the slider suspension arrangement 14 , thus generating a moment that forces the slider suspension arrangement 14 in an upward direction as opposed to forcing the slider suspension arrangement away from the vehicle frame assembly 12 . The vehicle impact energy absorption arrangement 10 a is also configured to provide improved aerodynamic efficiencies. Specifically, the brace 90 may be configured to act as an aerodynamic shield or windbreak. Further, the configuration and positioning of the above-described components of the vehicle impact energy absorption arrangement 10 a may serve to reduce the wind drag associated with the overall assembly by forcing airflow completely or significantly below the vehicle impact energy absorption arrangement 10 a.
The present inventive vehicle impact energy absorption arrangement can be easily and quickly assembled, may be retrofit onto existing trailer assemblies, is economical to manufacture, capable of a long operating life, reduces damage typically associated with excessive force being applied by an operator to a slider suspension assembly, increases the safety of passengers in a vehicle that collides with the rear of a trailer assembly while simultaneously reducing the damage to the trailer typically associated with rear collisions, and is particularly well adapted for the proposed use.
In In the foregoing description, it will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts as disclosed herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise. | A vehicle impact energy absorption arrangement includes a vehicle frame, a slider suspension arrangement coupled to the vehicle frame and including an axle member, and a spring member biasing the axle member, and an impact force absorbing arrangement that includes a mounting member coupled to the vehicle frame, first and second pivot members each pivotably coupled to the mounting member, and an elastically deformable biasing member positioned between each of the pivot members and the mounting member, wherein each of the pivot members is configured to pivot and elastically deform the at least one biasing member when impacted. | 1 |
[0001] This application is a continuation of International Patent Application No. PCT/CN2006/002887, filed Oct. 27, 2006, which claims priority to Chinese Patent Application No. 200510116802.X, filed Oct. 27, 2005, and Chinese Patent Application No. 200610109591.1, filed Aug. 14, 2006, all of which are hereby incorporated by reference
FIELD OF THE INVENTION
[0002] The present invention relates to the field of the data sync specifications of Synchronization Makeup Language (SyncML) defined by the Open Mobile Alliance (OMA), and in particular, to a method, system, client and server for implementing data sync based on the SyncML protocol.
BACKGROUND OF THE INVENTION
[0003] To formulate the standard specifications for the data sync of personal information and enterprise data among a plurality of platforms and networks, the OMA proposes SyncML data sync specifications. The objective of SyncML development is to implement the collaborative work among terminal users, device developers, basic component developers, data providers, so as to make it possible to access data of any network anywhere at any moment by using any terminal device. The typical scenario is the data sync between a mobile device/an application server and a network server. In addition, the SyncML can also be used in the peer-to-peer data sync, such as the data sync between two personal computers (PC).
[0004] FIG. 1 is a schematic diagram illustrating the data sync based on the SyncML specifications. After having negotiated parameters in a data sync initialization phase, a client and server send the data that has changed to each other to guarantee the data is synchronized between the two parties.
[0005] A Data Synchronization Client (DS Client) generally refers to an intelligent terminal, such as PC software, mobile phone or Personal Digital Assistant (PDA) etc. A Client Database is configured in the device to store the user data, including: an address book, calendar, note, short message, e-mail, etc. The formats of all these data are defined in standard specifications, and the DS Client is able to convert the data into a standard format and send the converted data to a DS Server which processes the data and stores them in its database.
[0006] The DS Server may receive a sync message containing sync commands from the DS Client and send a sync message back to the DS Client. The DS Server may be a network server or a PC. A Server Database is configured in the DS Server to store the data of the DS Server.
[0007] Data identifiers are stored in both the DS Client and the DS Server. The DS Client uses a Local Unique Identifier (LUID) as the data identifier while the DS Server uses a Global Unique Identifier (GUID) as the data identifier.
[0008] FIG. 2 is a schematic diagram illustrating the data storage of a DS Client and a DS Server. As shown in FIG. 2 , only the correspondence relationship between various LUIDs and data needs to be maintained in the DS Client, but in the DS Server, not only the correspondence relationship between various GUIDs and data but also the correspondence relationship between various GUIDs and LUIDs needs to be maintained. There are multiple data sync types, as shown in Table 1.
[0000]
TABLE 1
Sync type
Description information
Two-way sync
A normal sync type in which the client and the server exchange information about
modified data in these devices. The client sends the modifications first.
Slow sync
A form of two-way sync in which all items are compared with each other on a
field-by-field basis. In practice, this means that the client sends all its data from a
database to the server and the server does the sync analysis (field-by-field) for this data
and the data in the server.
One-way sync from client
A sync type in which the client sends its modifications to the server but the server does
only
not send its modifications back to the client.
Refresh sync from client
A sync type in which the client sends all its data from a database to the server (i.e.,
only
exports). The server is expected to replace all data in the target database with the data
sent by the client.
One-way sync from
A sync type in which the client gets all modifications from the server but the client does
server only
not send its modifications to the server.
Refresh sync from server
A sync type in which the server sends all its data from a database to the client. The
only
client is expected to replace all data in the target database with the data sent by the
server.
Server Alerted Sync
A sync alert type, which provides the means for a server to alert the client to perform
synchronization. When the server alerts the client, it also tells the client which type of
synchronization to initiate.
[0009] In addition, the data sync procedure defined in the SyncML specifications usually includes three phases:
[0010] 1. A sync initialization phase, in which, it is mainly to implement authentication, negotiation of the sync database to be synchronized, negotiation of sync capabilities (including: which data formats and sync types are supported by client and/or server, etc.), and such negotiation procedures may have to be conducted for several times.
[0011] 2. A sync phase, mainly including: one side of the DS Client and DS Server sending the data that have changed to the other side of the two via an operation command according to the data status modification; and the other side performing the operation command (e.g., an operation command of update, delete, or add), with the data that have changed to update its own data so as to achieve the purpose of the data sync.
[0012] 3. A sync accomplishment phase, which mainly includes: the DS Client and the DS Server confirming the accomplishment of the sync to each other.
[0013] In the prior art, the storage mode of Folder and File has been defined for the data, which simulates the tree structure based on the folders and files in the PC. For the data with hierarchy relationship logically or physically, the data can be presented as a tree structure consisting of at least one node, each node of which may be a folder node (also referred to as a folder item) or an item node (also referred to as a data item). But, it is not possible to sync a specific node with its content or a sub-tree as required in the prior art. Besides, the method for synchronizing the address book by groups is implemented by using the filter technique based on the Group field within the vCard, the defect of which is that the sync protocol is tightly coupled with specific data formats, which is not general for all data formats, so a specific node with its content or a sub-tree in the tree structure may not be synchronized as required.
[0014] However, at present, there are a lot of data needed to be synchronized which are stored as a fact of the tree structure with hierarchy relationship logically or physically. For example, some data are organized by folders in a tree structure view which logically or physically exists in a user's mobile phone, such as an address book, categorized short messages and e-mails organized by mailboxes, etc. In addition, a calendar or email with attachments could be considered as organized in a hierarchy manner as well. In accordance with the prior art, the user can only sync the whole database rather than a part of the database. Taking short messages as an example, the user can only sync the whole database of the short message but can not sync only one category of the short message named “bless” and leave another category named “joke” not synchronized this time. With regard to the attachment stored outside of the calendar/email, the attachment can not be synchronized and the hierarchy relationship of the attachment and the calendar or email can not be described in the prior art. Meanwhile, it can not be implemented that one data item exists in two categories. For example, Zhang San belongs to the groups of “colleague group” and “friend group” in the address book at the same time.
[0015] To sum up, the existing data sync techniques can not satisfy the actual demands, and especially, can not support the notion of one data item in a hierarchy manner or the data sync of any node level in the hierarchy structure.
SUMMARY
[0016] Embodiments of the invention disclose a method of synchronizing a plurality of devices, including:
[0017] obtaining, by a first device, an extended address of an informational node of a plurality of informational nodes of a second device, the plurality of informational nodes arranged in a hierarchical tree structure; and
[0018] utilizing the extended address to locate the informational node amongst the tree structure to enable synchronization of the informational node;
[0019] wherein the extended address includes a hierarchical location of the informational node.
[0020] The embodiments of the invention also disclose a system of synchronizing a plurality of devices, including:
[0021] a first device, capable of communicating with a second device, wherein the second device stores in a hierarchical tree structure a plurality of informational nodes;
[0022] the first device obtains an extended address of a node of the plurality of nodes of the second device;
[0023] the extended address is extended with a hierarchical location of the informational node; and
[0024] the extended address is capable of being used to locate a specific informational node amongst the tree structure to enable synchronization of the informational node.
[0025] The embodiments of the invention disclose another method of synchronizing a plurality of devices, including:
[0026] receiving, by a second device, a synchronization command from a first device;
[0027] synchronizing, by the second device, an informational node stored in a hierarchical tree structure in the second device, wherein
[0028] the synchronizing the informational node is performed in response to the synchronization command, the request comprising an extended address representative of a location of the informational node within the hierarchical tree structure.
[0029] Therefore, the embodiments of the invention is adopted to flexibly implement the data sync with regard to a certain level, without transmitting the data of the whole database between the client and the server during the data sync, so as to raise data sync efficiency and save system resources as well as fulfill the actual user demands.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a schematic diagram of data sync implementation.
[0031] FIG. 2 is a schematic diagram illustrating the data storage of a client and a server.
[0032] FIG. 3 a is a schematic diagram illustrating the data structure defined by a user in accordance with a first embodiment of this invention.
[0033] FIG. 3 b is a schematic diagram illustrating the data storage of a client in accordance with a first embodiment of this invention.
[0034] FIG. 4 a is a schematic diagram illustrating the data structure defined by a user in accordance with a second embodiment of this invention.
[0035] FIG. 4 b is a schematic diagram illustrating the data storage of a client in accordance with a second embodiment of this invention.
[0036] FIG. 5 a is a schematic diagram illustrating the data structure defined by a user in accordance with a third embodiment of this invention.
[0037] FIG. 5 b is a schematic diagram illustrating the data storage of a client in accordance with a third embodiment of this invention.
[0038] FIG. 6 a is a schematic diagram illustrating the data structure defined by a user in accordance with a fourth embodiment of this invention.
[0039] FIG. 6 b is a schematic diagram illustrating the data storage of a client in accordance with a fourth embodiment of this invention.
[0040] FIG. 7 a is a schematic diagram illustrating the data structure defined by a user in accordance with a fifth embodiment of this invention.
[0041] FIG. 7 b is a schematic diagram illustrating the data storage of a client in accordance with a fifth embodiment of this invention.
[0042] FIG. 8 a is a schematic diagram illustrating the data structure defined by a user in accordance with a sixth embodiment of this invention.
[0043] FIG. 8 b is a schematic diagram illustrating the data storage of a client in accordance with a sixth embodiment of this invention.
[0044] FIG. 9 is a schematic diagram illustrating the system architecture for data sync in accordance with the embodiments of this invention.
DETAILED DESCRIPTION OF EMBODIMENTS
[0045] This invention will hereinafter be described in detail with reference to accompanying drawings and specific embodiments.
[0046] The embodiments of this invention disclose a method for implementing data sync, where one side of a client and a server sends a first sync command to the other side. Before the first sync command is sent, the client and the server determine the address of the node to be synchronized. After receiving the first sync command, the recipient side of the first sync command performs data sync of the determined node to be synchronized according to the received first sync command. The node to be synchronized may be any node of a hierarchy tree structure, e.g., a whole database, a logical or physical folder, or a data item.
[0047] The data sync can be divided into three phases according to the SyncML protocol, including: a sync initialization phase, a sync phase and a sync accomplishment phase. The process of the sync accomplishment phase in the embodiments of this invention is the same as that in the prior art, so only the sync initialization phase and the sync phase are described hereinafter.
[0048] In the sync initialization phase, the address of the node to be synchronized should be designated by the negotiation of the client and the server through sending a second sync command, which may be a database address, a logical or physical folder identity, or a data item identity. One side of the client and the server sends a second sync command that carries the address of the node to be synchronized to the other side which then determines the node currently to be synchronized according to the address of the node to be synchronized carried in the second sync command. The node to be synchronized may include one or more nodes. If the node to be synchronized includes more than one node, one side of the client and the server sends a second sync command for all the nodes to the other side, carrying the addresses of all the nodes, and the other side determines all the nodes included in the current to-be-synchronized node according to the addresses of all the nodes carried in the second sync command. ON one side of the client and the server sends one second sync command for each node to the other side which carries the address of the node, and the other side determines all the nodes included in the nodes currently to be synchronized one by one according to each node address carried in each second sync command. Alternatively, the address of the node to be synchronized may be configured in the client and the server in advance such that there is no need to negotiate the node to be synchronized via the second sync command in the sync initialization phase. The node to be synchronized mentioned in the embodiments of this invention may include the database, folder, data item, or the combination of at least one folder and at least one item. The implementation of the embodiments of this invention is hereinafter described with regard to the node to be synchronized including at least one folder to clarify the principle of the embodiments of this invention while other possible combination of the node to be synchronized will not be specified, however which is still covered by the protection scope of this invention.
[0049] Specifically, there are two kinds of modes to realize carrying the address of the node to be synchronized in the second sync command as follows (in case of the node to be synchronized including at least one folder, the address of the node to be synchronized is the address of the folder to be synchronized).
[0050] Mode 1: An element for indicating a target database (also referred to as an element for carrying the address of the data to be synchronized) in the existing protocol is extended to be able to indicate the folder (actually it can indicate any node within the tree structure) to be synchronized, which originally as an element for indicating a database-level address is extended as an element capable to indicate a node address of any level. The detailed implementation process may include: pre-defining the format of the Uniform Resource Identifier (URI), i.e., pre-designating the URI of which level identifies a database-level address and the URI of which level identifies a node-level address, and indicating the node to be synchronized by the pre-defined URI. For example, designating the URI of “/files” is the database-level address and the URI of “/files/folder1” is the address of the folder, named folder1, in the database, wherein, “files” is a database name and “folder1” is a folder identity. The Unique Identifier (UID) of a database or a folder or a data item can be used in the URI to more accurately designate the address of the node to be synchronized. For example, “/4980” is designated to be the address of the database to be synchronized, “/4980/4560” is designated to be the address of the subfolder or data item (determined by its data type) with identified by UID 4560 in the No. 4980 database identified by UID 4980. If there are more levels in the database, the URI with a multilevel structure will be adopted, such as, “/4560/4980/556” etc. The URI indication method by using mixture of the number UDI together with the folder name may also be adopted, such as, “/files/4890”. Certainly, if there are multiple folders to be synchronized, multiple URIs may be given to indicate these folders. The interior node or leaf node is the data item or logical folder. Moreover, data with external attachments can be represented by one interior node with its sub-node as the leaf node and both of them are data items. Moreover, in a hierarchy structure, one folder node may have at least one sub-node and/or at least one data item node, so an address of the node to be synchronized may consist of a folder identity and a data item identity, e.g., the node address “/Macy/03/05”, wherein, “03” is the identity of the data item belonging to the database “Macy”, and “05” is the identity of the sub-item (e.g., the attachment) of the parent-node of the data item “03”.
[0051] Mode 2: An element for indicating a filter condition in the existing protocol is extended to indicate the folder (actually it can indicate any node within the tree structure) to be synchronized. The specific implementation includes, extending the existing filter condition (e.g., Filter command) to indicate the folder to be synchronized. Certainly, if there is more than one folder to be synchronized, these folders can be indicated in the filter condition at the same time.
[0052] These two modes for indicating the folder to be synchronized are hereinafter described in detail.
[0053] I. Mode 1 is a scheme for negotiating the folder to be synchronized by extending the element for indicating the target database of the existing protocol, wherein the address of the folder to be synchronized carried in the element for indicating the target database is usually referred as a URI.
[0054] In the embodiments of this invention, while negotiating the folder to be synchronized by sending a second sync command, a client and a server may further negotiate the sync type negotiation parameter. When the client and the server negotiate the folder to be synchronized by sending the second sync command, the sync type negotiation parameter can be further carried in the second sync command, according to which the current sync type can be determined. The second sync command can be implemented by using an Alert element of the Sync Marker-up Language (SyncML) protocol, where, the element for carrying the address of the folder to be synchronized may be a sub-element of the Alert element (e.g., an Item element), and the element for carrying the sync type negotiation parameter may be a sub-element of the Alert element (e.g., a Data element). The second sync command implemented by using an Alert element can also be called a Sync Alert command. Other sub-elements in the Alert element functioning as the second sync command, such as a Code element etc, can also be used to carry the sync type negotiation parameter and the address of the folder to be synchronized, and an attribute of the Alert element also can be used to carry the sync type negotiation parameter and the address of the folder to be synchronized. The command structures in these cases will not be herein shown one by one, but they should be covered in the protection scope of this invention. And in the future specifications, the name and structure of these elements, sub-elements or attributes may change, but these changes can not be regarded as the limitation for the present invention.
[0055] The Alert command may further be extended to implement the multi-folder sync such that it can be used to designate one or more folders to be synchronized. The scheme for implementing the function is given hereinafter.
[0056] In the sync initialization phase, supposing that the negotiation of the folder to be synchronized is initiated by a client to a server, the negotiation process is as follows.
[0057] The client sends an Alert command that carries the address of the folder(s) to be synchronized to the server, and the address may be the UID or URI of the folder to be synchronized. Then, the server may return a response to the client. An example of the Alert command is given hereinafter. For example, the folder to be synchronized that the client designates is named as folder1. The client sends an Alert command to the server, carrying the sync type and the address of the folder to be synchronized (e.g., UID or URI). If the folder structure of the client is the same as that of the server (if the node to be synchronized only includes at least one folder, the folder structure refers to the data hierarchy structure.), the client directly determines the local address of the folder to be synchronized as the address of the folder to be synchronized in the server according to its local folder structure. If the folder structure of the client is different from that of the server, the client may need to determine the address of the folder to be synchronized in the server, wherein there are several determination methods as follows: 1. The client first acquires the folder structure of the server from the server, and determines the address of the folder to be synchronized in the server according to the acquired folder structure; 2. The server sends the address (e.g., UID or URI) of the folder to be synchronized to the client; 3. The client directly designates the address of the folder to be synchronized, and if the address designated does not exist in the server, the server creates the folder to be synchronized at the address designated by the client; 4. The client determines the address of the folder to be synchronized according to the information input by the user, i.e., the user designates the address of the folder to be synchronized; 5. The client and the server setting the address of the folder to be synchronized in advance. Even if the folder structure of the client is the same with that of the server, the client can also use the above methods to determine the folder to be synchronized. For example, both the client and the server make an agreement that, if a backup sync is to be performed, the folder named “backup” in the server database should be used. The above folder structure may be stored in the server after being created, or it is not stored in the server but created in real time for the designated database by the server if the client requires. If the server sends the Alert command to initiate the sync procedure, the address of the folder to be synchronized may include: the address of the folder to be synchronized in the client (i.e., the source address) and that in the server (i.e., the destination address. The two addresses may be the same or different. With regard to the client as a sync originator, the local address of the folder to be synchronized (i.e., the source address) can be obtained by multiple means, e.g., pre-configuring the source address, or designating the source address by the user, or sending the source address to the client by the server, etc. However, the address of the folder to be synchronized in the server (i.e., the destination address) has to be indicated to the server by the client when initiating the sync procedure. It is the method for indicating the destination address to the server by the client functioning as the sync originator which is herein described while the method for determining the source address by the client will not be discussed here.
[0058] It can be implemented via an independent sync session that a client acquires a folder structure of a server, wherein a new sub-element or an attribute should be extended or defined in the Alert command to carry the sync type negotiation parameter, and a new sync type should also be defined only for acquiring the folder structure of the database but not for synchronizing the database. Other sync type may also be defined for acquiring the folder structure of the database and sync data. An implementation scheme for acquiring the folder structure is provided hereinafter.
[0059] 1. A client sends a command for creating a sync session to a server. Before sending an Alert command for determining the address of the folder to be synchronized, the client sends to the server a sync command for acquiring the folder structure of the target database. In order to distinguish this sync command for acquiring the folder structure of the target database from the above two sync commands, the sync command can be called a third sync command. The third sync command can be implemented by using a Get element, e.g., the Get command instance shown in the following example. The existing Get command is only used for acquiring device performance information, so that, in order to request acquiring the database folder structure, the definition of the existing Get command should be extended, in which, an identifier for indicating a request for acquiring the database folder structure is added in the definition.
[0000]
<Get>
......
<Target><LocURI>/contacts?List = struct</LocURI></Target>......
</Get>
[0060] In the Target element shown in the above Get command instance, “/contacts” refers to the URI of the target database, “?List=struct” refers to the identifier for indicating the request for acquiring the database folder structure. And after receiving the Get command, the server finds out the database corresponding to the URI of the target database.
[0061] 2. The server returns to the client the folder structure of the target database by a response of the Get command, e.g., a Results command. Suppose that the folder structure of the server database is that: under a root folder (i.e., the first-level folder node) of “/contacts”, there are four sub-nodes including A, B, C and D, which are called the second-level folder node; and sub-nodes of A1 and A2 are under the second-level folder node A, and the two sub-nodes are called the third-level folder node. Herein, the returned Results command can be organized as the following several modes.
[0062] (1) One Item element is used for indicating the URI of one node in the folder structure. After receiving the Results command, the client constructs the folder structure of the server according to the URI indicated by each Item element. The form of the Results command is as follows:
[0000]
<Results> ......
<Item> ......
<Source><LocURI>/A</LocURI></Source>......
</Item>
<Item>......
<Source><LocURI>/A/A1</LocURI></Source>......
</Item>
</Results>
[0063] (2) All the folder structure data are encapsulated into one element. For example, the folder structure data can be encapsulated in a Data element which is in an Item element, the Item element being a sub-element of a Results element, the folder structure data encapsulated in the Data element may exist as a file or a segment of data represented by XML. In this case, the form of the Results command is as follows:
[0000]
<Results> ......
<Item> ......
<Data>folder structure data</Data>
</Item>
</Results>
[0064] Other sub-elements or attributes may also be used to indicate the request of acquiring the folder structure in the Get element functioning as the third sync command. The command structures of the Get element and Results element under these cases will not be shown one by one, and no matter which kind of Get element and Results element are used together, they should also be covered in the protection scope of this invention. Similarly, an Add command or a Replace command may also be extended to carry the hierarchy structure data, the extension mode of which is the same as that of the Results command, and should also be covered in the protection scope of this invention.
[0065] Alternatively, the client may determine the address of the folder to be synchronized by means of the server imitatively sending to the client the address of the folder to be synchronized. The server sending the address of the folder to be synchronized may be implemented by sending a notification to the client. The format of the notification can be the notification format in the data sync protocol, or the notification can be sent by the server via other engines, e.g., a Short Message Service (SMS), Wireless Application Protocol Push (WAP Push) Service, Session Initiating Protocol Message (SIP Message), Multimedia Message Service (MMS), and etc. The client may pick up the URI of any kind of hierarchy structure to be synchronized.
[0066] Upon determining the address of the folder to be synchronized, the client may further send an Alert command carrying the determined source and target address to be synchronized and the negotiation parameter of the sync type, the address of the folder to be synchronized and the negotiation parameter of the sync type can be carried in an Item element, and the form of the Alert command is as follows:
[0000]
<Alert>
<Sync type>Two-way sync</Sync type>
<Item>
<Target><LocURI>/files/folder1(the URI of the folder to be
synchronized in the server, named folder1)</LocURI></Target>
<Source><LocURI>/files/folder1(the URI of the folder to be
synchronized in the client, named folder1)</LocURI></Source> ......
</Item>......
</Alert>
[0067] If there are multiple folders to be synchronized, one sync type and multiple Item elements can be carried in one Alert command, and each Item element is used for carrying the address of one folder, wherein, the sync types of the multiple folders to be synchronized are the same.
[0068] After receiving the Alert command sent by the client, the server returns to the client a response that carries the negotiation result of the folder to be synchronized so that the client may determine whether to continue by sending the synchronization data to server or re-negotiate. The response may be a sync command for returning a status code in the existing protocol, for example, a Status command.
[0069] If there are multiple folders to be synchronized, the mode for returning the response to the client by the server includes: with regard to all the folders to be synchronized, the server returning one response that carries the negotiation results of all the folders; or, the server returning one response for each folder carrying the negotiation result of the one folder, where multiple Status commands can be used respectively for the multiple folders to return the negotiation results of these folders (the negotiation result may be called the status code).
[0070] To adopt a different sync type for a different folder, the following schemes can be used.
[0071] 1. With regard to multiple folders to be synchronized, the client sends to the server an Alert command that carries the addresses of all the folders and the negotiation parameters of the sync types respectively corresponding to each folder. The server determines all the folders to be synchronized according to the addresses of all the folders carried in the Alert command and determines the sync types corresponding to the folders respectively. Herein, the Alert command carries multiple elements (for example, Item elements) originally used for carrying the address of the destination database to be synchronized which are extended to be able to indicate a node-level address and a sync type and is used for bearing the address of one folder (Actually it can indicate any node within the tree structure) to be synchronized and the sync type of the one folder.
[0072] 2. For each one of the folders to be synchronized, the client sends to the server an Alert command that carries the address of the one folder and the negotiation parameter of the sync type of the one folder. The server determines each folder to be synchronized and the sync type thereof according to the folder address and the negotiation parameter of the sync type of the folder in each Alert command. Herein, the Alert command carries one element originally used for carrying the address of the destination database to be synchronized and one element originally used for carrying the sync type which is extended to be able to indicate a node-level address and is used for bearing the address of the folder (actually it can indicate any node within the tree structure) to be synchronized. The one element originally used for carrying the sync type is used for bearing the negotiation parameter of the sync type.
[0073] However, if there are multiple folders to be synchronized and the sync types of the multiple folders are the same, then for all the folders to be synchronized, the client sends to the server one Alert command that carries the addresses of all the folders and the negotiation parameter of the sync type of these folders. The server determines the sync types and all the folders to be synchronized according to the addresses of all the folders and the negotiation parameter in the Alert command. Herein, the Alert command carries multiple elements originally used for carrying the address of the destination database to be synchronized (for example, the Item element) and one element originally used for carrying the sync type (for example, the Data element), where each element originally used for carrying the address of the destination database to be synchronized is extended to one element capable of indicating a node-level address and is used for bearing the address of the folder to be synchronized. The element originally used for carrying the sync type bears one negotiation parameter of the sync type. The Alert element acting as the second sync command may also use other sub-elements or attributes to carry the negotiation parameter of the sync type, the address of the folder to be synchronized, and etc. The command structures in these cases will not be shown one by one, but they should be covered in the protection scope of this invention.
[0074] II. Mode 2 is a mode for determining the address of the folder to be synchronized by using a filtering mechanism.
[0075] The existing filtering mechanism can only implement the file-level and item-level filtering, which mainly depends on the format of the data to be synchronized. And in one embodiment of the present invention, the existing filtering mechanism is extended to the node level (Here, the node level refers to the folder level), and it is not limited by the format of the data to be synchronized and can be used for all kinds of data formats. by inserting a sub-element for carrying a folder-level filtering condition into the existing Filter element of the SyncML protocol, for example, the element can be named FolderLevel, where the Common Gateway Interface (CGI) syntax can be used to indicate the folder to be synchronized. An attribute or a newly added sub-element of the Filter element may also be used to carry the folder-level filtering condition, and the command structure of this case is not shown hereinafter which should be covered in the protection scope of this invention.
[0076] The form of the Filter command is given as follows, carrying two folders to be synchronized respectively numbered 112 and 113.
[0000]
<Filter> ......
<NodeLevel>
<Item>
<Meta><Type>syncml:filtertype-cgi</Type></Meta>
<Data>&LUID &EQ ; 112&AND; &LUID &EQ; 113 (using the CGI
syntax of the Filter element to indicate the numbers of the folders to be
synchronized include 112 and 113) </Data>
</Item>
</NodeLevel> ......
</Filter>
[0077] In the sync phase, the operation type of the sync based on any node is indicated by sending a first sync command which may further indicate the address of the folder to be synchronized, or further carry the data content.
[0078] If the address of the folder to be synchronized is carried in the first sync command, the element used for carrying the address of the data to be synchronized in the existing Sync command can be extended, e.g., a Target element, so as to extend the sync granularity from the database level to any node level. For example, the Target element capable of indicating a node-level address (e.g., UID or URI of the folder to be synchronized) can be carried in the Sync command. The existing Sync command can only carry the Target element that just indicates the address of the database to be synchronized. However, the Sync command according to an embodiment of this invention can indicate the address of any node level and carry the data belonging to the range of the indicated addresses but not all the data of the whole database.
[0079] In the above solution, one Sync command can carry the address of one folder to be synchronized, if there are multiple folders to be synchronized, the addresses of the multiple folders can be carried in multiple Sync commands respectively or even in one Sync command. For example, the addresses of two folders to be synchronized, correspondingly named folder1 and folder2, are carried in two Sync commands respectively. In the above Sync element acting as the first sync command, other sub-elements or attributes may be used for carrying the address of the folder to be synchronized, and the command structures in these cases will not be shown one by one, but should be covered in the protection scope of this invention.
[0080] When the first sync command (for example, a Sync command) carries an operation type, the specific mode for carrying an operation type is the same as that of the prior art, which is to use an element of Add, Replace, Delete, or Move etc., for carrying the operation type. For example, a sub-element can be carried in the Sync Command, the sub-element may be an Add element for indicating an adding operation, or a Replace element for indicating a replacing operation, or a Delete element for indicating a deleting operation, or a Move element for indicating a moving operation, etc. In this way, the recipient side receiving the first sync command can perform the sync operation designated by the operation type for the folder to be synchronized according to the operation type carried in the first sync command. So, it is possible to select an Add element, a Replace element, a Delete element or a Move element and to carry the selected element in the Sync command to indicate various operation types according to the practical situation.
[0081] The various information carried in all the above-mentioned first, second and third sync commands of the embodiments of this invention, for example, the data of the node to be synchronized, the node-level address filtering condition, the sync type, the hierarchy structure data, etc, can not only be carried in the sub-element or attribute in the various commands shown above, but also be carried in other sub-elements or attributes. Considering that there are so many implementation cases of these commands, the forms of these commands are not shown one by one here but should be covered in the protection scope of this invention.
[0082] The sync phase is hereinafter described with reference to some specific embodiments. For the sync procedure initiated by a client is similar to that initiated by a server, the sync phase is described hereinafter by taking an example that a client initiates the sync procedure and a server performs the data sync operation. In the following embodiments, the first sync command is implemented by using the Sync element of the SyncML protocol, and the Sync element may carry the operation type of Adding, Replacing, Deleting, or Moving etc.
[0083] In order to enable the user to create a physical or logical folder and designate any of the folders to be recursively synchronized and non-recursively synchronized, three tables may be configured respectively in the client and the server:
[0084] 1. A Data Item Table, used for storing information of all the data items, including the correspondence relationship of the UID of the data item and the contents (Data), wherein the UID of the data item is denoted as Item LUID and Item GUID respectively in the client and the server.
[0085] 2. A Folder Table, used for storing information of all the folders, the information of each folder including the number of the folder, the name of the folder (Name), the parent folder to which the folder belongs (Parent Source), the status of the folder (Folder Status) and the correspondence relationship thereof, wherein, the status of the folder mainly includes: Existing (identified by E), Adding (identified by N), Updating (identified by U), Deleting (identified by D), Moving (identified by M) and Copying (identified by C). The status of Deleting may further include two statuses, Permanent Deletion (identified by P-D, also called Hard Deletion) and Non-permanent Deletion (identified by P-ND, also called Soft Deletion), and the UID of the folder is denoted as Folder LUID and Folder GUID respectively in the client and the server. In the prior art, LUID is different from GUID. However, they could be the same. The evolution of LUID-GUID mechanism would not affect the scope this invention.
[0086] 3. An Index Table of “data items-folders”, used for storing the affiliation of the data items, including, the UID of the data item, the parent item (Parent Source), the status of the data item (Data Status), and the correspondence relationship thereof, wherein, the UID of the data item is denoted as Item LUID and Item GUID respectively in the client and the server.
[0087] Moreover, the table of the correspondence relationship between the UID of the data in the client and that in the server should be stored in the server, i.e., the correspondence relationship between GUID and LUID.
[0088] In the first of the present invention, a user adds a new folder “bless” under the root folder (e.g., /sms) for short messages, adds two sub-folders of “Spring Festival” and “Mid-autumn Festival” under the folder “bless”, and respectively adds data under the folders, e.g., a datum N1 is added under the folder “bless”, a datum N2 is added under the folder “Spring Festival”, and a datum N3 is added under the folder “Mid-autumn Festival”.
[0089] As shown in FIGS. 3 a and 3 b , FIG. 3 a is a schematic diagram illustrating the data structure defined by the user in the first embodiment of this invention, wherein a square frame indicates a Folder, a circle indicates a data Item, a solid line indicates the status of Existing, and a dashed line indicates the status of New. FIG. 3 b is a schematic diagram illustrating the data storage of a client in the first embodiment of this invention. In the client, a Data Item Table, a Folder Table and an Index Table of “data items-folders” are stored. The status of data added in each table is shown correspondingly in FIG. 3 b.
[0090] When the user requests to sync the folder “bless”, the client creates the following sync commands orderly.
[0091] First, after determining the data to be synchronized is a folder according to the command for synchronizing the folder “bless” from the user, the client determines according to the Folder Table that the status of the folder “bless” is N. Afterwards, the client constructs a sync command indicating of adding a folder, e.g., an Add sub-element is added in the Sync command to construct an Add sync command which may also be called a sub-command of the Sync command. In the constructed Add command, a Meta field is used for indicating that the data type is folder. The data type is determined according to the Folder Table where a LUID field is used for indicating that the UID of the data to be synchronized is 1006, a Data field is used for indicating that the data content is “bless”, and a SourceParent field is used for indicating that the parent folder is the root folder.
[0092] Second, the client determines the status of the data item under the folder “bless”, and as the status corresponding to the data item 2001 in the Index Table is N, an Add sync command is constructed. After determining based on the Data Item Table that the data content corresponding to the data item 2001 is N1, in the constructed Add sync command, a Meta field is used for indicating that the data type is vCard (known as the kind of Data Item), a LUID field is used for indicating that the UID of the data to be synchronized is 2001, a Data field is used for indicating that the data content is N1, and a SourceParent field is used for indicating that the parent folder is 1006.
[0093] If the client has determined that there is no data item newly added under the folder “bless”, it then checks the status of the sub-folder(s) under the folder “bless”, the implementation of which is the same as that for determining the folder “bless”. Two Add sync commands are constructed, in one Add command, there is a Meta field indicating that the data type is Folder, a LUID field indicating that the UID of the data to be synchronized is 1007, a Data field indicating that the data content is “Spring Festival”, and a SourceParent field indicating that the parent folder is 1006; and in the other Add command, there is a Meta field indicating that the data type is Folder, a LUID field indicating that the UID of the data to be synchronized is 1008, a Data field indicating that the data content is “Mid-autumn Festival”, and a SourceParent field indicating that the parent folder is 1006.
[0094] After determining that there is no data item newly added under the folder “bless”, the client checks the status of the data items under the folder “Spring Festival” and the folder “Mid-autumn Festival”, the implementation of which is the same as that for determining N1, i.e., the client respectively constructs two Add sync commands.
[0095] In this way, the recursive sync is implemented by sending the Add sync command for each data item newly added. The non-recursive sync refers to the following cases: 1. only synchronizing one folder but not the data item under the folder, e.g., modification of the folder name; 2. only synchronizing one folder and the data item under it but not synchronizing the subfolder(s).
[0096] At last, all the constructed Add sync commands are sent to the server. If the data amount within one Add command is relatively small, multiple Add commands can be included in one message and sent to the server by one-time exchange; and if the data amount of one Add command is relatively large, more than one message is needed to carry multiple Add commands, and all the Add commands can be sent to the server by multiple exchanges. In practice, it is possible to send only one Add sync command including multiple folders and data items, while the one Add sync command should be regarded as multiple logical Add commands.
[0097] The process for performing the sync operation after the server receives the above Add command is hereinafter described. The table related to the process is similar to the table shown in FIG. 3 b.
[0098] After receiving the sync command for adding the folder “bless”, the server determines that, the type of the data to be synchronized is Folder according to the Meta field included in the received sync command, the UID of the data to be synchronized in the client is 1006 according to the LUID field, the name of the folder to be synchronized is “bless” according to the Data field, and the parent folder is the root folder according to the SourceParent field. Afterwards, a local UID of the server (Folder GUID) is assigned to the data to be synchronized, such as, 100006. Then, the corresponding item is added in the folder table configured in local, i.e., the item, including 100006, bless, the root folder, the status of the data item and their correspondence relationship, is added. Besides, the UID of the data to be synchronized in the client (i.e., LUID), the UID of the data to be synchronized in the server (i.e., GUID) and the correspondence relationship thereof are stored in the configured table of the correspondence relationship between LUID and GUID, i.e., 1006, 100006 and their correspondence relationship are stored.
[0099] If the server has received the sync command for adding the data item N1, it determines that, the type of the data to be synchronized is the data item according to the Meta field in the received sync command, the UID of the data in the client is 2001 according to the LUID field, the data content is N1 according to the Data field, and the parent folder is 1006 according to the SourceParent field. Afterwards, the data item N1 is stored in the local database, and then a local UID of the server (Folder GUID), such as, 200001, is assigned to the data to be synchronized, the corresponding item, such as 200001, N1 and the correspondence relationship thereof, is added in the Data Item Table configured in local; the corresponding item, such as, 200001, 100006, the status of the data item N1 and the correspondence relationship thereof, is added in the Index Table; and the UID of the data to be synchronized in the client, the UID of the data to be synchronized in the server and the correspondence relationship thereof, i.e., 2001, 200001 and the correspondence relationship thereof, are stored in the configured table of the correspondence relationship between LUID and GUID.
[0100] The mode for adding the folders “Spring Festival” and “Mid-autumn Festival” in the server is the same as that for adding the folder “bless”, and the mode for adding the data items N2 and N3 is the same as that for adding the data item N1.
[0101] In addition, it should be noted that, if the server sends sync commands to the client to perform the sync operation, the UID of the data to be synchronized in the server is included in the sync commands, after performing the sync operation, the client returns to the server, the correspondence relationship between the UID of the data in the client and that in the server, i.e., the correspondence relationship between LUID and GUID, and the server stores the received correspondence relationship in the table of the correspondence relationship between LUID and GUID configured in local.
[0102] Thus, the sync operation for adding data can be implemented, where, the data may be a specific data item or a folder created by the user as desired which is not limited by the physical data structure of the system. It can be seen that the advantages of an embodiment of the invention is that, for a datum that may belong to multiple nodes in a data structure, only one copy of the datum is transmitted in the data sync of the multiple nodes, and only one copy of the datum is stored by the side performing the sync operation, thereby greatly saving the resources of the network and the device. For example, suppose that N1 belongs to the folders “bless”, “Spring Festival” and “Mid-autumn Festival”, during the sync operation in the server, two corresponding entries should be added in the Index Table, i.e., item 1 “200001, 100007, the status of the datum N1 and their correspondence relationship” and item 2 “200001, 100008, the status of the datum N1 and their correspondence relationship”.
[0103] In the second embodiment, the user updates, the attribute of the folder “bless” under the root folder for short messages (/sms), the data item U1 in the folder “bless”, and the data item U2 in the folder “Spring Festival”. In this embodiment, U2 belongs to the folders “Spring Festival” and “Mid-autumn Festival”.
[0104] As shown in FIGS. 4 a and 4 b , FIG. 4 a is a schematic diagram illustrating the data structure defined by the user in the second embodiment of this invention, wherein, a square frame indicates a Folder, a circle indicates a data Item, a solid line indicates that the status is Existing, and a dash-dotted line indicates that the status is Update. FIG. 4 b is a schematic diagram illustrating the data storage of a client in the second embodiment of this invention. A Data Item Table, a Folder Table and an Index Table are stored in the client. The status of data in each table is shown correspondingly in FIG. 4 b.
[0105] If the user requests synchronizing the folder “bless”, the client creates the following sync commands orderly.
[0106] At first, on determining the data to be synchronized is a folder according to the command received from the user for synchronizing the folder “bless”, the client determines the status of the folder “bless” in the Folder Table is U, and constructs a sync command for indicating updating, e.g., a Replace sync command which can be called a sub-command of the Sync command. And in the constructed Replace command, a Meta field is used to indicate that the data type is Folder, which is determined according to the Folder Table, a LUID field is used to indicate that the UID of the data to be synchronized is 1006, a Data field is used to indicate that the specific data is “bless”, and a SourceParent field is used to indicate that the parent folder is the root folder.
[0107] Afterwards, a client determines the data item status in the folder “bless”, as in Index Table, the data item corresponding to the number 1006 is 2001 the status of which is U, a Replace sync command is constructed. After the specific data content corresponding to the data item 2001, determined from the Data Item Table, is N1, in the constructed Replace sync command, a Meta field is used to indicate that the data type is vCard (known as the kind of Data Item), a LUID field is used to indicate that the UID of the data to be synchronized is 2001, a Data field is used to indicate that the specific data is U1, and a SourceParent field is used to indicate that the parent folder to which the data item belongs is 1006.
[0108] Then, after determining there is no data items to be replaced, in the folder “bless”, the client checks the status of one or more subfolders in the folder “bless”, the implementation of which is the same as that for determining the folder “bless”, and in this embodiment, the status of the subfolders of the folder “bless” has not been changed, so the subfolders need not to be processed.
[0109] At last, when determining there is no subfolders to be synchronized under the folder “bless”, the client checks the status of the data item in the subfolder “Spring Festival”, the implementation of which is the same as that for determining the data item U1. That is, the client constructs a Replace sync command, and after the specific data content corresponding to the number 2002, determined from the Data Item Table, is U2, in the constructed Replace sync command, a Meta field is used to indicate that the data type is vCard (known as the kind of Data Item), a LUID field is used to indicate that the UID of the data to be synchronized is 2002, a Data field is used to indicate that the specific data is U2, and a SourceParent field is used to indicate that the parent folder to which the data item belongs is 1007.
[0110] In this way, the recursive sync can be implemented by sending a Replace sync command for each data to be replaced. Certainly, the non-recursive sync can be implemented as well, the implementation principle of which is similar to that of the recursive sync, and no further description about it is given here. Whether to perform a recursive sync can be determined during negotiating the folder to be synchronized in the sync initialization phase, wherein, a recursive sync identifier is further carried in the second sync command of the embodiments of this invention. A recursive sync identifier with value ‘true’ indicates that a recursive sync should be performed to the folder to be synchronized, so that, the data sync should be performed to the root node and all the sub-nodes of the folder to be synchronized. If a recursive sync identifier with value ‘false’ is carried in the second sync command, it indicates a non-recursive sync should be performed to the folder to be synchronized, so that, only to the root node of the folder to be synchronized, the data sync should be performed. If no recursive sync identifier with value ‘true’ presents, it could be considered as recursive sync always. If it is determined that a recursive sync should be performed to the folder to be synchronized in the sync initialization phase, the data content carried in the first sync command sent by the client or the server in the sync phase includes: the data contents of the root folder and each subfolder of the folder to be synchronized, and the receiving side of the first sync command synchronizes the data contents of the root folder and each subfolder of the folder to be synchronized in turn according to the data contents carried in the first sync command. And if it is determined that a non-recursive sync should be performed to the folder to be synchronized in the sync initialization phase, the data content carried in the first sync command sent by the client or the server in the sync phase includes: the data content of the root folder of the folder to be synchronized, and the recipient side of the first sync command only syncs the data content of the root folder of the folder to be synchronized. Herein, the data content described in the embodiments of this invention indicates the content of the folder and the data item of the folder to be synchronized, for example, the folder name (Name) and the data of the data item (Data).
[0111] Afterwards, all the constructed Replace sync commands are sent to the server, the detailed transmitting method is the same as that for transmitting an Add sync command, which will not be described further here.
[0112] The process for performing the sync operation after the server receives the above Replace command is hereinafter described. The table related to the process is similar to the table shown in FIG. 4 b , which will not be shown here.
[0113] After receiving the sync command for replacing the folder “bless”, the server determines the type of the data to be synchronized is Folder according to the Meta field of the received sync command, the UID of the data to be synchronized in the client is 1006 according to the LUID field, the name of the data to be synchronized is “bless” according to the Data field, and the parent folder of the data to be synchronized is the root folder according to the SourceParent field. Afterwards, the number of data to be synchronized, which is to be replaced, in the local server, e.g., 100006, is acquired from the configured table of the correspondence relationship between LUID and GUID. Then, the corresponding item is replaced in the local configured folder table, i.e., the attribute information of “bless” in the item is replaced, wherein, the item includes: 100006, bless, the root folder, the status of the data item “bless” and the correspondence relationship thereof.
[0114] After receiving the sync command for replacing the data item U1, the server determines the type of the data to be synchronized is Data item according to the Meta field of the received sync command, the UID of the data to be synchronized in the client is 2001 according to the LUID field, the specific data content is U1 according to the Data field, and the parent folder is 1006 according to the SourceParent field. Afterwards, the UID of the data to be synchronized, which is herein to be replaced, in the local server (e.g., 200001) is acquired from the configured table of the correspondence relationship between LUID and GUID, and the item corresponding to the local UID of the data to be synchronized is replaced in the data item table configured in local, i.e., the information of U1 in the item of 200001, U1 and their correspondence relationship is replaced.
[0115] The method for replacing U2 in the server is the same as that for replacing U1, which will not be described further here.
[0116] It should be noted that, in this embodiment, U2 belongs to both the folder “Spring Festival” and the folder “Mid-autumn Festival”, but only once does the Replace command need to be sent to replace U2, and U2 only needs to be replaced once in the server, so that the U2 in both of the two folders can be replaced. It is because that, only one copy of the data is stored in the server actually, and the description of the data is indicated in Index Table. It can be seen that, the redundancy data can be decreased farthest by using the method of the embodiments of this invention, so that resources can be saved.
[0117] In the third embodiment, the user moves the data item “M1” from the folder “music” to the folder “favorite”, and moves the whole folder “mp3” to “favorite”.
[0118] As shown in FIGS. 5 a and 5 b , FIG. 5 a is a schematic diagram illustrating the data structure defined by the user using the third embodiment of this invention, wherein the square frame indicates a Folder, and the circle indicates a data Item; the solid line indicates that the status is Existing, and the dual-dash-dotted line indicates that the status is Move. FIG. 5 b is a schematic diagram illustrating the data storage of a client using the third embodiment of this invention. Data Item Table, Folder Table and Index Table are stored in a client. The data status in each table has the corresponding reflection in FIG. 5 b.
[0119] When the user request to sync root folder, the client creates the following sync command orderly:
[0120] At first, a client checks all subfolder statuses of the root folder according to the command for syncing the root folder received from the user. In this embodiment, all subfolder statuses of the root folder are unchanged, which does not need to be processed. Then, the client checks whether the data item status under the root folder is changed. In this embodiment, the data item status under the root folder is unchanged, which does not need to be processed.
[0121] Afterwards, the client checks whether each subfolder status is changed in turn. In this embodiment, the client determines the status of “mp3” subfolder under music folder is M, then, constructs a Move sync command. The Move sync command may also be called a sub-command of the Sync command, which is used to carry the pending move data. In the constructed Move command, a Meta field is used to indicate the data type is a Folder, the data type is determined according to a Folder Table, a LUID field is used to indicate the number of data to be synchronized is 1006, and a SourceParent field is used to indicate the parent folder after the folder is moved is 1004.
[0122] Then, the client determines the status of data item under music folder, as the data item corresponding to 1006 is 2001 in Index Table and its status is M, a Move sync command is constructed, and in the constructed command, a Meta field is used to indicate the data type is an Item, a LUID field is used to indicate the number of data to be synchronized is 2001, and a SourceParent field is used to indicate the parent folder after the folder is moved is 1004.
[0123] In this way, there is no other moved data in this embodiment, and no further process here.
[0124] Afterwards, all the constructed Move sync commands are sent to the server. The detailed transmitting mode is the same as that of transmitting an Add sync command, which will not be described further here.
[0125] The process of performing the sync operation after the server receives the above Move command is hereinafter described. The table related in the process is similar to the table shown in FIG. 5 b , and the table is not shown here.
[0126] After receiving the Move sync command that indicates moving mp3 folder, the server determines the data type to be synchronized is a Folder according to the received Meta field of the Move sync command, and determines the number of data to be synchronized in the client is 1006 according to the LUID field, and determines the parent folder after the mp3 folder is moved is 1004 according to the SourceParent field. Afterwards, the pending move data number in the server (for example: 100006) is acquired from the configured table of correspondence relationship between LUID and GUID, and the parent folder is changed into the parent folder carried in the received Move sync command, i.e. the parent folder corresponding to 100006 in the table is changed from 1005 to 1004, in the item corresponding to the number of local data to be synchronized in local configured Folder Table.
[0127] After receiving the Move sync command that indicates moving M1 data item, the server determines the data type to be synchronized is an Item according to the received Meta field of the Move sync command, and determines the number of data to be synchronized in the client is 2001 according to the LUID field, and determines the parent folder after the M1 data item is moved is 1004 according to the SourceParent field, afterwards, the replaced number of data to be synchronized in local server, for example: 200001, is acquired from the configured table of correspondence relationship between LUID and GUID, the parent folder is changed into the parent folder carried in the received sync command, i.e. the parent folder corresponding to 200001 in the table is changed from 1005 to 1004, in the item corresponding to the number of local data to be synchronized in local configured Index Table.
[0128] It can be seen that, the method of the embodiments of this invention only needs to modify the correspondence relationship of the corresponding data table and does not need to move the actual data when the move sync operation is performed, so that the limited resources is saved to the maximum extent.
[0129] It should be noted that, when a folder as well as its subfolder and the data item are moved, for example, when an mp3 folder is moved, only one Move command needs to be sent in connection with the mp3 folder, and other Move commands in connection with the subfolder and data item under mp3 folder does not need to be sent, because its subfolder and the parent folder to which the data item belongs are unchanged.
[0130] When the operation type carried in the first sync command is delete, and the step of syncing the data item under the folder to be synchronized further includes: deciding whether the data content of data item of the folder to be synchronized is only stored under the folder to be synchronized, if so, further carrying a permanent deletion identifier with value ‘true’ in the first sync command; otherwise further carrying a permanent deletion identifier with value ‘false’ in the first sync command; the data sync operation performed to the folder to be synchronized by the first sync command includes: deciding whether a permanent deletion identifier with value ‘true’ is carried in the first sync command, if so, deleting the data content of the data item under the folder to be synchronized; otherwise cancelling the correspondence relationship between the data item and the folder to be synchronized. If no permanent sync identifier with value ‘true’ presents, it could be considered as permanent deletion always.
[0131] In the fourth embodiment, the user deletes the “D1” data item under “bless” folder, and selects a permanent deletion with respect to the data “U2” under “Spring Festival” folder, and selects a non-permanent deletion with respect to the data “D3” under “Spring Festival” folder. In this embodiment, the deletion of the data item is only described.
[0132] As shown in FIGS. 6 a and 6 b , FIG. 6 a is a schematic diagram illustrating the data structure defined by the user using the fourth embodiment of this invention, wherein the square frame indicates a Folder, and the circle indicates a data Item; the solid line indicates that the status is Existing, and the dotted line indicates that the status is Delete. FIG. 6 b is a schematic diagram illustrating the data storage of a client using the fourth embodiment of this invention. Data Item Table, Folder Table and Index Table are stored in a client. The data status in each table has the corresponding reflection in FIG. 6 b.
[0133] When the user requests to sync “bless” folder, the client creates the following sync command orderly:
[0134] A client determines the status of the data item under bless folder. As the status of a data item 2001 is P-D, a Delete sync command is constructed. The Delete sync command may also be called a sub-command of the Sync command which is used to carry deleting some data; and in the constructed Delete sync command, a Meta field is used to indicate the data type is an Item, a LUID field is used to indicate the number of data to be synchronized is 2001, and an identifier indicating the permanent deletion also need to be included in the Delete sync command.
[0135] After determining there is no deleted data item under bless folder, a client checks the subfolder status under the bless folder. In this embodiment, the subfolder status under the bless folder is unchanged, which does not need to be processed.
[0136] After determining there is no deleted subfolder under the bless folder, the client determines the status of data item under the Spring Festival subfolder. The detailed method is the same as that of determining D1. That is, the final result is to construct two Delete sync commands, in one Delete sync command, a Meta field is used to indicate the data type is an vCard (known as the kind of Data Item), a LUID field is used to indicate the number of data to be synchronized is 2002, and an identifier indicating the permanent deletion also needs to be included in the command, for example: P-D. And in the other Delete command, a Meta field is used to indicate the data type is a vCard (known as the kind of Data Item), a LUID field is used to indicate the number of data to be synchronized is 2003, and an identifier indicating the non-permanent deletion also needs to be included in the command, for example: NP-D.
[0137] The constructed Delete sync command does not need to include the pending deletion data, and only needs to indicate the type and UID of the pending deletion data in either the permanent deletion or the non-permanent deletion scenarios. The foregoing is an implementing mode of the Delete command, i.e. the command includes three kinds of information of type, UID and identifier used to carry the permanent deletion or the non-permanent deletion; certainly, there are other implementing modes, for example, the Delete command is divided into two commands, one is a P-Delete command, the other is a NP-Delete command, thus, each deletion command only needs to include the type and number of the pending deletion data.
[0138] At last, all the constructed sync commands used to carry the deletion are sent to the server.
[0139] The process of performing the sync operation after the server receives the above Delete command is hereinafter described.
[0140] After receiving the sync command that indicates deleting D1 data item, the server determines the data to be synchronized type is an Item according to the received Meta field of the sync command, and determines the number of data to be synchronized in the client is 2001 according to the LUID field, and determines the deletion is the permanent deletion, afterwards, the pending deletion data number in local server, for example: 200001, is acquired from the configured table of correspondence relationship between LUID and GUID, the item corresponding to the local number of data to be synchronized is respectively deleted, i.e. the whole item numbered 200001 is deleted, in local Data Item Table and Index Table. At the same time, the data D1 is deleted in local database.
[0141] After receiving the Delete sync command used to carry deleting D2 data item, the server deletes the whole item of the corresponding data table, the method of deleting D2 is the same as that of deleting D1, which will not be further described here.
[0142] After receiving the Delete sync command used to carry deleting D3 data item, the server determines the data to be synchronized type is an Item according to the received Meta field of the Delete sync command, and determines the number of data to be synchronized in the client is 2003 according to the LUID field, and determines the deletion is the non-permanent deletion, afterwards, the pending deletion data number in local server, for example: 200003, is acquired from the configured table of correspondence relationship between LUID and GUID, the item corresponding to the number of local data to be synchronized is only deleted, i.e. the whole item numbered 200003 is deleted and the D3 data is not deleted in local database, in Index Table.
[0143] It can be seen that, the method of the embodiments of this invention only needs to send a identifier between a client and a server and does not need to send the detailed data content when the deletion sync operation is performed, so that the limited resources is saved to the maximum extent.
[0144] In the fifth embodiment, the user deletes the whole “bless” folder. It equals to delete all subfolders and data items of the “bless” folder. In this embodiment, D1 and D2 only exist under bless folder, D3 exists under bless and joke folder, and this embodiment is only the description of deleting the folder.
[0145] As shown in FIGS. 7 a and 7 b , FIG. 7 a is a schematic diagram illustrating the data structure defined by the user using the fifth embodiment of this invention, wherein the square frame indicates a Folder, the circle indicates a data Item; the solid line indicates that the status is Existing, the dotted line indicates that the status is Delete. FIG. 7 b is a schematic diagram illustrating the data storage of a client using the fifth embodiment of this invention. Data Item Table, Folder Table and Index Table are stored in a client. The data status in each table has the corresponding reflection in FIG. 7 b.
[0146] When the user request to sync root folder, the client creates the following sync command orderly:
[0147] At first, the client checks all subfolder statuses under the root folder according to the command for syncing the root folder received from the user. In this embodiment, the bless status is determined as D from the Folder Table, the client will further perform the steps of: determining whether the data item of the pending deletion folder and the data item of the subfolder of the folder only exist under the pending deletion folder, if so, constructing a Delete sync command, and including the information that indicates permanent deletion in the Delete sync command; otherwise, respectively constructing a Delete sync command in connection with each data item and folder, and including the information that indicates permanent deletion in the Delete sync command corresponding to the data item or folder that only exists under the pending deletion folder, and including the information that indicates non-permanent deletion in the Delete sync command corresponding to the data item or folder that does not only exists under the pending deletion folder. That is to say, if a data item or folder still exists under other folders (here other folders does not include bless subfolder), and the non-permanent deletion information is included in the Delete sync command corresponding to such data, if it is not such data, and the permanent deletion information is included in the Delete sync command corresponding to it. Afterwards, all constructed Delete sync commands are sent to the server. Herein, a deletion command is respectively constructed in connection with each data item and folder, which actually is the recursive sync.
[0148] The process of performing the sync operation after the server receives the above Delete sync command is hereinafter described.
[0149] If the command received by the server is the Delete sync command in connection with the data item, the processing mode is the same as that of the fourth embodiment, which will not be described further here.
[0150] If the command received by the server is the Delete sync command in connection with the folder, the pending deletion data number in local server is acquired from the configured table of correspondence relationship between LUID and GUID, then no matter the permanent deletion or the non-permanent deletion will delete the item corresponding to the number of local data to be synchronized from the local configured Folder Table.
[0151] It also should be noted in connection with the folder deleting operation that, as a sync initiator, when a client deletes a folder, for example deletes the bless folder, it can only construct one Delete sync command in connection with the folder, and other operations performed by it, for example “determining whether the data item of the pending deletion folder and the data item of the subfolder of the folder only exist under the pending deletion folder” and so on, all performed by the server so as to simplify the operation of the client. Certainly, vice versa.
[0152] In actual applications, the fourth embodiment is usually used incorporated with the fifth embodiment.
[0153] In addition, for the deleting operation, after the server finishes the sync operation, the client will delete the item of its own corresponding data table.
[0154] In the sixth embodiment, the user copies the data item “M1” from “music” folder to “favorite” folder; and copies the “mp3” folder to “favorite” folder.
[0155] As shown in FIGS. 8 a and 8 b , FIG. 8 a is a schematic diagram illustrating the data structure defined by the user using the sixth embodiment of this invention, wherein the square frame indicates a Folder, the circle indicates a data Item; the solid line indicates that the status is Existing, the heavy line indicates that the status is Copy. FIG. 8 b is a schematic diagram illustrating the data storage of a client using the sixth embodiment of this invention. Data Item Table, Folder Table and Index Table are stored in a client. The status of data added in each table has the corresponding reflection in FIG. 3 b.
[0156] It should be noted that, in the above embodiments, a table of correspondence relationship between the number in the client and the number in the server, for example: a table of correspondence relationship between LUID and GUID, the purpose to have LUID-GUID mechanism is to consider that the fact that there are devices with limited capability which may not support a long UID. In the case that all devices can support the long UID, LUID-GUID mechanism evolves like the client and the server using the same UID either generated by the client or the server, then the process can be directly performed by using the same UID, and the LUID-GUID mapping is not necessary any more. Thus in this case, the implementation of the embodiments of this invention is not limited.
[0157] When the user needs to sync the root folder, the operation of the client and the server is the same as that of the first embodiment. The difference of them is: in the first embodiment, the client sending one Add sync command in connection with each data item and folder, and in this embodiment, if the client sending a Copy sync command in connection with a folder (the Copy sync command is also a sub-command of the Sync command, which is used to carry pending copy data), it does not need to send Copy sync commands in connection with subfolders and data items under the folder, so that the data transmission amount is further decreased and network resources are saved. The process of the server in this embodiment is the same as that of the first embodiment, and also performs one by one in connection with each folder and data item.
[0158] Any more, when the Copy sync is performed, the user determines according to the demand whether a copy of actual data needs to be copied, if so, the data sync operation of the side that performs the sync operation further includes: copying the data in local database, and adding the corresponding item in local configured data folder table.
[0159] If the modifying operation of the client is conflicted with that of the server, for example: adding, replacing or deleting some entries in the moved folder, the embodiments of this invention can guarantee the absolute data sync between the client and the server by extending the existing conflict resolution mechanism. The detailed implementation is: extending the existing conflict resolution mechanism to add new resolution named ‘Win-Win’ for merging the data content from client and server based on some configuration, and assuring the absolute same data between the client and the server by the win-win mode in addition to current ‘Client-Win’ or ‘Server-Win’ resolution. When the data operation of the client is conflicted with that of the server, the server detect the conflict and perform ‘Win-Win’ resolution. Then server send back the sync operation according to the conflict resolution result and the client performs the sync operation according to the data operation of the server, the data operation includes: adding operation, replacing operation, moving operation, deleting operation, copying operation or any combination of them. For example, the user moves A folder and enables it to be a subfolder of B folder in the client, and adds an item in A folder in the server, here, the server will move A folder and enable it to be a subfolder of B folder, and the client also adds an item in A folder so as to guarantee the absolute identical data between the client and the server.
[0160] The embodiments of this invention further discloses a system for data sync based on the above method, the system includes: a client and a server, which communicate with each other by exchanging sync commands. The client and the server are further used to determine a folder to be synchronized, and perform the data sync of the folder to be synchronized.
[0161] FIG. 9 is a schematic diagram illustrating the system architecture for data sync in accordance with the embodiments of this invention. As shown in FIG. 9 , the client includes a first module for processing a node address and a first module for data sync, and the server includes a second module for processing the node address and a second module for data sync.
[0162] In the client, the first module for processing the node address is used for determining and transmitting the address of a node to be synchronized to the first module for data sync, receiving the address of the node to be synchronized from the first module for data sync, determining the node to be synchronized according to the address received, and providing synchronization between the client and the server for the data under the node to be synchronized; the first module for data sync is used for receiving the address of the node to be synchronized from the first module for processing the node address, constructing a sync command that carries the address of the node to be synchronized, transmitting the sync command to the server, receiving a sync command from the server, acquiring the address of the node to be synchronized from the sync command, and transmitting the acquired address to the first module for processing the node address. The first module for processing the node address may be further used for receiving the address of the node to be synchronized inputted by a configuration command from the user so that the user can set the address of the node to be synchronized for the client.
[0163] In the server, the second module for processing the node address is used for determining and transmitting the address of the node to be synchronized to the second module for data sync, receiving the address of the node to be synchronized from the second module for data sync, determining the node currently to be synchronized according to the received address, and providing synchronization between the client and the server for the data under the node to be synchronized; the second module for data sync is used for receiving the address of the node to be synchronized from the second module for processing the node address, constructing a sync command that carries the address of the node to be synchronized, transmitting the sync command to the server, receiving a sync command from the server and acquiring the address of the node to be synchronized from the sync command by analysis, and transmitting the acquired address to the second module for processing the node address.
[0164] It can be seen from the above system for data sync that the embodiments of this invention further disclose a client for data sync and a server for data sync. The principle for implementing the client and the server is the same as that of the client and the server in the above system, thus the operating principle and the internal structure thereof are not further described here, but should be covered in the protection scope of this invention.
[0165] The foregoing is only preferred embodiments of this invention and is not for use in limiting this invention. Any modification, equivalent replacement or improvement made under the spirit and principles of this invention should be included in the protection scope of this invention. | This invention discloses a method for synchronizing a plurality of devices, including: obtaining, by a first device, an extended address of an informational node of a plurality of informational nodes of a second device, the plurality of informational nodes arranged in a hierarchical tree structure; and utilizing the extended address to locate the informational node amongst the tree structure to enable synchronization of the informational node; wherein the extended address includes a hierarchical location of the informational node. This invention further discloses a system, client and server for data sync, and the folder-level data sync can be implemented by using the method of this invention. | 7 |
BACKGROUND OF THE INVENTION
The present invention concerns a blade for installation in detachable fashion on a snowshoe. It also relates to a snowshoe for fitting with said blade.
Snowshoes are instruments which have been known for a great many years. They have been employed by the Scandinavian population for several centuries in order to travel on snow. Up to the present time, snowshoes have been used for utilitarian or military purposes, so as to allow the population or mountain troops to move on snow or for traveling as required by their everyday lives
Currently, snowshoes are mostly used by athletes for cross-country travel or hiking, or even for competitive events. Athletes, however, although they engage in athletic activity for their pleasure, are more and more demanding with respect to the equipment which they use, and, as a matter of fact, products which are currently sold are not proving totally satisfactory.
Thus, snowshoes must combine stopping and lifting criteria while still retaining maximum comfort for the user, in addition, the combination of these criteria take on particular importance under difficult practice conditions, such as, for example on hard snow or icy snow or with steep slopes. Current snowshoes, unfortunately, do not allow for obtaining an adequate foothold under such conditions and they do little for easing the user's movement. In addition, it may also be necessary to lessen the foothold of the shoe under certain types of utilization of the shoe or certain snow conditions, for example during downhill use.
The present invention proposes to resolve the aforementioned drawbacks by simple, reliable, safe and reasonably priced means. It presents an improvement with respect to snowshoes which permits adaption of the shoe to snow and slope conditions, thanks to surface holding means, such as a blade. Said means are fitted, preferably in detachable form, under the snowshoe as needed and if so desired by the user.
SUMMARY OF THE INVENTION
According to the invention the blade for the snowshoe is characterized in that it comprises installation means for permitting its installation, in detachable form, on the shoe.
According to a complementary characteristic of the blade, which is in part characterized in that its installation means include at least one upper support surface for acting as support against a lower support surface of the screen shoe.
According to the preferred embodiment, the installation means comprises locking means during rotation, including a central projection, for engaging itself inside a hole of a screen of the shoe, the shape of the central projection being complementary and adapted to the shape of said hole.
According to an additional characteristic, the blade comprises locking means for locking the blade on the snowshoe.
According to another characteristic, the locking means comprises a bar which rests on the upper surface of the screen of the snowshoe.
According to one embodiment of the blade, the bar includes a portion of a wall pivoting on a central projection.
According to an additional characteristic of the blade, it comprises two lateral walls fitted with a set of teeth. The lateral walls are arranged on both sides of a longitudinal plane of symmetry of the blade.
According to a variation of the embodiment of the blade, the lateral walls are parallel to the longitudinal plane of symmetry of the snowshoe at the time of installation.
Furthermore, the invention likewise concerns a snowshoe for receiving a removable blade, such as the one described below. The shoe has additional installation means for cooperating with the installation means of the blade.
Moreover, according to a variation of the embodiment, the snowshoe comprises locking means for locking the blade in position on the shoe.
One advantage of the present invention is that adjusts snowshoe traction for snow or ice conditions.
Another advantage resides in its removability.
FIG. 1 is a top view of the snowshoe with its blade, but without the boot;
FIG. 2 is lateral view of the snowshoe of FIG. 1 with the boot being indicated by a dotted line;
FIGS. 3 and 4 are similar view as FIGS. 1 and 2, illustrating the snowshoe alone without a binding and without the blade and in a different scale;
FIG. 5 is a bottom view of the snowshoe of FIG. 3;
FIG. 6 is a view in longitudinal section along line VI--VI of FIG. 5;
FIG. 7 is a view in traverse section along line VII--VII of FIG. 5;
FIG. 8 is a lateral view of a blade alone;
FIG. 9 represents a rear view of the blade of FIG. 8;
FIG. 10 is a perspective view depicting the shoe and the blade before installation;
FIG. 11 is a perspective view depicting the shoe and the blade during installation;
FIG. 12 is a perspective view depicting the shoe with the blade installed;
FIG. 13 is a sectional view depicting the blade installed on the snowshoe in transverse section;
FIGS. 14 and 15 are identical views to FIGS. 3 and 6, respectively, depicting the shoe fitted with the blade;
FIG. 16 to 18 illustrate alternative embodiment of the blade;
FIG. 16 represents the shoe and a alternate embodiment of the blade in transverse section;
FIG. 17 represents in lateral view a second alternate embodiment of the blade; and
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The snowshoe identified has the shape of a perforated plate, in a vertical plane of general symmetry (P) extends below a boot (6). The snowshoe has a main frame (2), including a peripheral wall (3) delimiting a lower zone or screen (4). A set of internal walls support a binding (5) for retaining the boot (6) of the user.
Said screen (4) with its ensemble of internal walls forms a general lower surface on the snow. Its relatively large support makes it possible that the user will not sink too deeply into the snow. It should be noted that the binding (5) for retaining the boot (6), by way of example, is articulated relative to the screen (4) of the snowshoe along a transverse axis (XX'). This enables the boot to be vertically pivoted as shown by (F1, F2). Beneficially, said binding (5) includes an articulated plate (9) carrying retention means for the boot, i.e. a front retention means (10) and rear retention means (11). Thus, a front extremity (12) of the boot is retained, for example, by a front or back strap (13), while the rear extremity (14) is retained thanks to a pivoting rear strap or clip (15), including a retention lever (16). It goes without saying that the retention means, front and rear, could also be reversed, i.e. that the front strap (13) could be placed in the rear and the rear strap (15) and its lever (16) could be placed in the front. The plate (9) is preferably rigid and extends longitudinally. It comprises an upper support surface (17) in order to support the sole of the boot. Of course, the snowshoe invention can be equipped with any other type of bindings for the boot, for example the one described in French Patent Application No. 94 05919 by applicant.
According to one embodiment of the snowshoe on which the blade is to be mounted, the perforated plate has a generally elongated shape. Its front is preferably raised and of slightly pointed form to form a front spatula (8). Its central zone (60) is located below the boot (6) of the user and thus below the plate (9). In case a binding as illustrated in FIGS. 1 and 2, a longitudinal ridge (18), extends, for example, from a traverse axis of articulation of the plate (XX') up to the heel (19) of the snowshoe. Said longitudinal ridge (18) serves beneficially as support for the boot (6) or for the plate (9) in case of binding of the articulated plate type. It should be added that the longitudinal ridge (18) comprises a central horizontal support surface (21b). It should be noted that the two inclined surfaces (21a, 21b) converge in upward direction as depicted in FIG. 7.
As illustrated in FIGS. 5 and 6, the central surface (20) of the longitudinal ridge (18) defines at least one elongated hole (180a, 180b, 180c). In the represented mode, the longitudinal ridge comprises two lateral longitudinal projections (25a, 25b) extending in downward direction (BA) on both sides of the front hole (180a) and central hole (180b). It should be noted that the longitudinal ridge, its holes and its lateral extension constitute complementary installation means for cooperation with the installation means if the blade, described below. It goes without saying that the snowshoe could also have a different shape without going outside the claimed field of projection of the invention.
As illustrated in FIGS. 8 and 9, particular attention is drawn to a surface-holding means of the snowshoe in the snow, such as a blade (30), and, more specifically the installation means and the locking means for said blade (30) on the snowshoe (1). The blade (30) designed to be mounted on the snowshoe (1) in detachable fashion. It is beneficially constituted by a metal profile, such as of aluminum, for example. Needless to say, the blade could also be constructed of any other material sufficiently rigid and solid in order to ensure its surface-holding function on the snow without going outside the claimed field of protection of the invention.
According to the preferred embodiment , the blade (30) comprises installation means for engaging the snowshoe (1). It likewise comprises locking means for locking it in position on the snowshoe. The installation and locking are preferably effected in detachable manner.
The installation means for the blade (30) include in part an upper support surface (31) for supporting itself in mating engagement with the lower support surface (320 of the screen (4). The lower support surface (31) of blade (30) and constitutes, in part, the complementary installation means of the snowshoe. It should be noted that the lower support surface (320 of the screen (4) is constituted by the lower end walls of the inclined surfaces (21a, 21b) and those of the longitudinal projections (25a, 25b). The upper support surface (31) of the blade (30) is formed by two lateral support surfaces (31a, 31b 310a, 310b) which respectively cooperate with the lower edges of the longitudinal projections (25a, 25b) and the inclined surfaces (21a, 21b) of the screen, as shown in FIG. 13. Of course, the upper support walls of the blade and the lower support walls of the screen which constitute the respective installation means of the snowshoe and the blade could be different and remain complementary without going outside the claimed field if projection of the invention.
As illustrated in FIGS. 10, 11 and 12, the installation means of the blade and the snowshoe also include a blocking means for preventing rotation, which are constituted by a central projection (33) which is received in the front hole (180a). The blocking during rotation is effected by cooperation and thrust of the lateral fronts (33a, 33b) of the central projection (33) with the internal walls (250a, 250b) of the lateral projections (25a, 25b) which edge the front hole (180a). It should be noted that the shape of the central projection is complimentary and adjusted to the shape and the dimensions of the hole (180, 180b, 180c), which receives same in order to precisely block any pivoting of the blade in relationship to the snowshoe.
According to the preferred realization mode, the blade (3) comprises locking means, which permits its mounting on the snowshoe in removable fashion. The locking means are constituted in part by a bar (35) which rests on the upper face of the screen, i.e. on the central wall (20) of the longitudinal ridge (18) of the snowshoe and, more precisely, on the edges of its front hole (180a) . It should also be noted that the central projection (33) of the blade (30) is such that its upper wall (330) comprises a rear extension (330a) extending toward the rear, for receipt through the from hole (180a) in order to rest on the support surface (20) of the longitudinal ridge (18) as indicated in FIGS. 11 and 12. The rear extension (330a) thus permits the locking means of having two upper support zones on the screen of the snowshoe in order to maintain the upper support surface (31) of the blade (30) against the lower support surface (32) of the screen, as shown in FIG. 13.
It is important to note that the preferred embodiment of the blade, the snowshoe and their respective installation means, said means beneficially permit the blade to be engaged with the underside of the snowshoe.
According to the preferred embodiment, the bar (35) is pivotally mounted to a portion of the wall on the central projection (33) for rotation around an axis or axle (34). Of course, according to this embodiment, the bar (35) can likewise comprise tightening means. The post (34) can be threaded to cooperate with a small wing nut, for example in order to firmly lock the blade on the snowshoe and to eliminate all play between the two, which might impede the user during hid forward movement. It goes without saying, that the locking means could also be obtained by equivalent devices without going outside the limitations of the claimed field of the invention. Likewise, the locking means destined to lock the blade in its position can be arranged directly on the snowshoe and be constituted, for example, by a sliding type of bar.
As indicated in FIGS. 8 and 10, the blade (30) includes two lateral walls (35, 37) fitted with a series of teeth (36a, 36b, 36c, 37a, 37b, 37c). The lateral walls (36, 37) extend from the support walls (310a, 310b) and form with them a slightly right angle in a manner to extend vertically in downward direction as depicted in FIG. 9. They arranged parallel on both sides of a longitudinal plane of symmetry (Q) of the blade (30), beneficially in symmetrical fashion, said plane (Q) of blade (30) being destined to align with the general longitudinal plane (P) of symmetry of the snowshoe at time of installation of the blade on the shoe.
According to the preferred embodiment, the teeth (36a, 36b, 36c, 37a, 37b, 37c) of the lateral walls have the same size. Their extremities are located in a common horizontal plane (H1) as indicated in FIG. 8. It is, of course, obvious that the width of the teeth could be different from one wall to the other or even within the same wall. Thus, according to the embodiment illustrated in FIG. 17, the width of the teeth increases beneficially from the front (AV) to the rear (AR). It should be noted that the points of the teeth (36a, 36b, 36c, 36d, 37a, 37b, 37c, 37d) can thus be arranged either in the same plane or in several different planes, said planes being situated beneath a horizontal plane (H2) defined by the lower edge (7) of the frame (2).
According to the preferred embodiment, the positioning and installation on the snowshoe is effected as indicated in FIGS. 10 and 12. The central projection (33) in from hole (180a) in such manner so as to position the rear extension (330a) on the ridge wall portion (18) which separates the front hole (180a) from the central hole (180b). When all of the respective support surfaces (31, 32) are in position, it suffices to lock the blade with the aid of its pivoting bar (35).
It should be noted that the installation means and the blade locking means and the snowshoe can have a different configuration without going outside the protected field of the invention. Thus, the blade could, for example, be received from the top of the screen to ride on the longitudinal ridge, for example, the pivoting bar now locking the blade from the underside of the snowshoe.
In addition, to one specific embodiment, not represented, the blade could no longer be installed on the screen of the snowshoe but directly under the articulated plate of the binding. The installation means and means of locking the blade to the plate could be similar to those described earlier.
According to another variation of a specific embodiment, the lateral walls (36, 37) are inclined relative to the plane of symmetry (Q) of the blade in such a manner so as to converge toward the top (HA), as indicated in FIG. 16. According to this mode, the external front of the upper portions of said walls (36, 37) constitute a support wall for cooperating with the lower front of the inclined surfaces (21a, 21b) of the screen (4) which thus constitutes a lateral reinforcement for said walls.
According to another embodiment of the blade illustrated in FIG. 18, the lateral walls (36, 37) are no longer arranged in parallel viv-a-vis the plane (Q) but are arranged in such manner so as to converge toward the front (AV). They thus form an angle (a) ranging from 0 to 60°, open to the rear (AR) in a longitudinal plane with plane (Q).
Needless to say, the inclination of the lateral walls, the number of teeth on said walls as well as their configuration could be different without going outside the claimed field of protection of the invention.
According to a non-represented mode, the blade comprises a transverse surface-holding wall connecting its lateral walls. The said transverse wall can likewise comprise a set if transverse or longitudinal teeth.
The invention has been described with reference to the preferred embodiment. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. | A snow shoe (1) has a longitudinal support structure or ridge (18) surrounded by a screen (4). The longitudinal ridge defines a plurality of apertures (180a, 180b, 180c), an upper surface (20), and lower projecting surfaces (21a, 21b, 25a, 25b). A detachable blade or knife (30) includes a central projection (33) which extends through the aperture in the central ridge and mates with portions of the lower ridge which define the aperture. The blade includes a rearward extending tab (330a) which extends through the aperture and engages the upper wall of the central ridge. A rivet or other pivot pin (34) pivotally holds a bar (35) to the upper projection of the blade. When the upper projection is received in the aperture, the bar pivots to engage the upper surface of the central ridge. A plurality of knives or teeth (36a, 36b, 36c, 36d, 37a, 37b, 37c, 37d) extend downward to engage ice or packed snow. | 0 |
TECHNICAL FIELD
[0001] The present invention relates to a knitted lingerie article corresponding to what is currently marketed under the name “boxer short” and which generally designates a short knitted underpants, for men as well as for women of all ages. It is understood here that the term boxer short is not limited to the short underpants but also extends to long underpants, for example of the type known under the name “long boxer short”, “legging”, etc.
BACKGROUND
[0002] The boxer short is a relatively complex article as it is intended to cover the low part of the trunk as well as the top part of the thighs over a sufficient length. It comprises a panty portion ended at its upper portion by a belt positioned at the waist, and at its lower portion by two lapels separately positioned on the thighs. It is commonly made from a knitted tube corresponding to a diameter allowing to seamlessly dress the low part of the trunk, and is equipped during a confection operation of a sewn crotch bottom allowing to link the two tubes dressing the thighs. We know how to knit on the circular machines such as the machines SANTONI of SM8-8 type, for example for diameters comprised between 10 and 16 inches (between 25 and 40 cm), tubes intended for of the confection of boxer shorts with a double belt in the top portion and a double lapel in the low portion, this tube may be knitted in both directions (belt-lapel or lapel-belt). We also know the confection of the tube bottom to make the low part of the boxer short, with an attached bottom which can be made on the same type of knitting machine. According to the known prior art of documents US2000073 and FR2805285, the crotch bottom or gusset is a substantially rectangular piece which is put between the edges of two slots or incisions performed at the front and at the back of the knitted tube. The enclosed FIGS. 1 to 3 show in more detail this confection operation. The boxer short 101 is made in the shape of a knitted tube, with an upper belt 102 and a lower border 103 , where lapels or reinforcements corresponding to future thigh passages are formed or may be formed. The knitted tube 101 comprises a front face 105 and rear face 106 (in one piece since it is about a circular knitting). The portion 104 intended to form the front pocket of the boxer short intended to maintain the genitals is represented by hatching on the front face 105 . We proceed ( FIGS. 1 and 2 ) to a cutting operation creating an incision 107 at the front part 105 and an identical or different incision 108 at the back 106 of the knitted tube, in the middle, at its lower portion. The incision 107 has edges 110 , 111 and the incision 108 has edges 112 , 113 . Each incision 107 , 108 is then laterally spaced apart and stretched, as suggested by the arrows of FIGS. 1 and 2 , so as to put substantially, in the extension of one another, the edges 110 , 111 on the one hand and 112 , 113 on the other hand, and form thus substantially rectilinear bottom lines which are sewn together by means of a substantially rectangular crotch bottom 115 (called here “bottom lines” the lower edges of the front and the back of the tubular knitted fabric, intended to be sewn to one another, between the thigh passages, directly or by means of additional pieces of crotch bottom such as the gusset). The document FR2805285 had represented an improvement compared to the classical confection by providing bottom lines with a different length at the front and at the back and by making the crotch bottom 115 with different elastic zones at the front and at the back. This suggestion has allowed to partially solve an often encountered problem with this type of garment, namely the absence of wearing comfort, related in particular to the presence of troublesome seams at the crotch and/or to a bad conformation of this bottom to the anatomy of the wearer, and more particularly to the presence of troublesome seams on the front at the genitals, in particular for man. However, the wearing comfort remains to improve further and this is the purpose of the present invention. More precisely, it is about finding a new method for the confection of the crotch, remaining simple, but leading to an improved comfort.
[0003] We know, from the documents WO 2012087210 and WO 2011008138, two methods for the confection of boxer shorts from two knitted rectilinear strips which are applied one on the other. These documents teach that it is possible to tie the two strips together according to some patterns of parallel or T lines which are then incised, so as to give rise to particular crotch shapes. These two methods do not relate to the confection of the boxer shorts from tubular knitted fabric and do not give transposable teaching to this manufacturing method.
BRIEF SUMMARY
[0004] The purpose of the invention is achieved thanks to a method for manufacturing a boxer short comprising the circular knitting of a main tube, the preparation of a crotch bottom, the cutting in the low portion at the front and at the back of the incisions tube, the opening by lateral extension of the incisions to form first and second globally transverse bottom lines and the sewing of the crotch bottom to the globally transverse bottom lines for forming the crotch and the thighs passage and for confectioning the boxer short, characterized in that we cut, respectively at the front or at the back, two incisions forming, by opening of the incisions, a first globally transverse bottom line composed, on the one hand, of a low transverse edge and, on the other hand, of a top transverse edge of bottom line rising higher than the low transverse edge, in that at least one incision is cut, respectively, at the back or at the front, forming, by opening of the incision, a second bottom line having at least one low transverse edge, in that the crotch bottom is prepared in the shape of at least one crotch piece, and in that said low transverse edge of the first bottom line is sewn to a portion facing the low transverse edge of the second bottom line and in that the at least one crotch piece is sewn between the top edge of the first bottom line and a portion facing the second bottom line.
[0005] Preferably, particularly for a male garment, it is at least at the front that the two incisions are cut, the back may have just a single incision. It is indeed at the front that it is mainly appropriate to improve the comfort of the garment. However, it is possible to provide a boxer short where the two incisions are provided at the back and only one at the front. It is also possible, and sometimes even advantageous, to provide a boxer short where the front as well as the back include two incisions.
[0006] The incisions may be formed at the front and/or at the back of the knitted tube by simple symmetrical incisions with respect to the median vertical axis of a front or rear face, which are vertical or slightly oblique with respect to the vertical. The incisions are preferably rectilinear, but may also be curved, formed of segments, etc.
[0007] The two incisions formed on the front (or rear) side, are in a preferred embodiment, two substantially vertical and symmetrical incisions with respect to the median axis of the boxer short. When the knitted fabric is laterally stretched to open these incisions and form the first globally transverse bottom line, a kind of central tab is formed between the incisions, the edge of which will constitute the low transverse edge of the bottom line, surrounded on either side by two lateral ends of bottom line rising higher than the tab edge. In this case the crotch bottom is prepared in the shape of two separate crotch pieces; the low edge of the front tab is sewn, situated in the middle of the first bottom line, in the middle of the second facing bottom line and the two separate crotch pieces are sewn between the ends of the first bottom line and the ends facing the second bottom line.
[0008] If the second bottom line is formed by a single incision, normally on the rear face, this second bottom line after lateral extension of the incision is substantially a rectilinear transverse or slightly arched line. Advantageously, the length of the cuts at the front and at the back is not the same: the length of the cut at the back is normally superior to that of the cuts at the front so as to form two transverse bottom lines which have a substantially equivalent transverse extension.
[0009] Thus, according to this embodiment, there is a method for manufacturing a boxer short comprising the circular knitting of a main tube, the preparation of a crotch bottom, the cutting in the low portion at the front and at the back of the incisions tube, the opening of the incisions for forming first and second bottom lines and the sewing of the crotch bottom to the bottom lines to form the crotch and the thighs passage and for confectioning the boxer short, characterized in that we cut at the front two incisions forming, by opening of the incisions, a first bottom line composed, on the one hand, of a low edge of front tab between the two incisions and, on the other hand, of two lateral ends of bottom line rising higher than the tab edge, in that an incision is cut at the back forming, by opening of the incision, a second bottom line, in that the crotch bottom is prepared in the shape of two separate crotch pieces, and in that said front tab edge is sewn, situated in the middle of the first bottom line, in the middle of the second bottom line and in that the two separate crotch pieces are sewn between the ends of the first bottom line and the ends of the second bottom line.
[0010] The second bottom line is situated, after confection, at the rear side of the boxer short, so that the tab portion fastened thereto and which comes from the front portion, seamlessly surrounds, and therefore without discomfort, the genitals of the wearer. The two crotch pieces are rejected on the edges of the tab and participate in the formation of the thigh passages.
[0011] In a variant of this same embodiment, it may be provided that the second bottom line is equally formed by two substantially vertical and symmetrical incisions, in which case there is formed by extension of the incisions, a central tab provided with a low edge: the low edge of the first tab is sewn on the low edge of the second tab and the separate crotch pieces are sewn between the ends facing the first and the second bottom line. In this variant, the length of the two cuts at the front and at the back is advantageously the same, so as to form two transverse bottom lines which have a substantially equivalent transverse extension.
[0012] According to a second embodiment, the two incisions formed at the front and/or at the back of the knitted tube are in the shape of a double T incision, that is to say an incision including the T base starting from the edge of the knitted fabric and the T-bar transversely disposed at the base. When the knitted fabric is laterally stretched to open this double T incision and form the first globally transverse bottom line, a low edge is laterally formed on either side of a central portion of the bottom line which rises higher than the edge situated at the two ends of the bottom line. In this case a crotch bottom in the shape of only one separate central piece is prepared; the low double lateral edge situated at the ends of the first bottom line is sewn to the portions facing the ends of the second bottom line and the central piece is sewn separate from crotch between the central portion rising higher than the first bottom line and the central portion facing the second bottom line.
[0013] The shape of the two incisions forming a T may admit variations: for example the branches of the T bar may be curves and/or may not be completely at right angle with respect to the T base.
[0014] If the second bottom line is formed by a single incision, normally on the rear face, this second bottom line after lateral extension of the incision is substantially a rectilinear transverse or slightly arched line. Advantageously, the length of the cut at the back is superior to that of the T at the front so as to form, at the back and at the front, two transverse bottom lines which have a substantially equivalent transverse extension.
[0015] In a variant of this same second embodiment, it can be provided that the second bottom line is also formed by two incisions forming a T, in which case a bottom line substantially resembling the first bottom line is formed by extension, with a low edge on either side of a higher central portion. The low edges facing the two bottom lines are sewn to one other, and the central piece separate from the crotch is sewn between the less low central portions of the facing bottom lines. In this variant as in the others, the length of the two cuts at the front and at the back is provided so as to form two transverse bottom lines which have a substantially equivalent transverse extension.
[0016] Thus according to the invention, it is understood that the at least one of the two bottom lines obtained by incisions and lateral stretching is not exclusively rectilinear transverse but on the contrary, though always globally transverse, it comprises, on the one hand, a low transverse edge (in one portion, for example central portion, or in many portions, for example lateral portions) and, on the other hand, a top edge of bottom line rising higher than the low transverse edge (this top edge being possibly in two portions, for example lateral portions, or in one portion, for example central portion), whereby, when this non rectilinear bottom line is placed facing the other bottom line, the low edge can be directly sewn to the other line and the crotch piece(s) can be placed between the top edge and the other line.
[0017] We used here the verb “sew”, but it is clear that this term does not only cover the seam with a thread, but any method allowing to assemble edge to edge two textile pieces.
[0018] As said above, the second bottom line is advantageously substantially rectilinear or arched in shape. It is understood that in this case, said low edge of the second bottom line extends over the entire length of the bottom line.
[0019] The first bottom line is advantageously in the shape of broken line.
[0020] The low edge of first bottom line (for example that of the tab in the first embodiment) may be formed by the low border of the circular knitted fabric itself, after possible unrolling of the lapel which was formed during knitting when appropriate, or long after a transverse complementary cut at the front, between the incisions, to remove the lapels.
[0021] The crotch portion(s) is/are advantageously obtained also by knitting, the two pieces (when there are two) can be easily formed from a common draft, which may be obtained from a transversely cut strip. The crotch portion(s) can also come from another knitted fabric than the knitted fabric of the boxer short itself, another jersey type material. These two portions may, according to their material, possibly bring an additional benefit to the product: ventilation (“mesh” type material), anti-friction type material, anti-irritation treated material, etc.
[0022] The invention also relates to a boxer short obtained by the method above.
[0023] It is about a boxer short formed in a knitted main tube, including a front and a back linked in low portion by a crotch bottom separating two thigh passages, the low portions of the front and of the back ending with a first and a second bottom line globally transverse between which the crotch bottom is sewn, characterized by a first globally transverse bottom line composed, on the one hand, of a low transverse edge and, on the other hand, of a top edge of bottom line rising higher than the low transverse edge, a second bottom line having at least one low transverse edge, in that said low transverse edge of the first bottom line is sewn to a portion facing the low transverse edge of the second bottom line, and in that the crotch bottom is in the shape of at least one separate crotch piece sewn between the top edge of the first bottom line and a portion facing the second bottom line.
[0024] In a particular case of embodiment, it is about a boxer short formed in a knitted main tube, including a front and a back linked in low portion by a crotch bottom separating two thigh passages, the low portions of the front and the back ending with a first and a second bottom line between which the crotch bottom is sewn, characterized by a first bottom line composed, on the one hand, of an edge of front tab and, on the other hand, of two lateral ends of bottom line rising higher than the edge of tab, in that the crotch bottom is in the shape of two separate crotch pieces, and in that that said edge of front tab, situated in the middle of the first bottom line, is sewn in the middle of the second bottom line and in that the two separate crotch pieces are sewn between the ends of the first bottom line and the ends of the second bottom line.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Other features and advantages of the invention will appear from the following description. Reference will be made to the accompanying drawings on which:
[0026] FIG. 1 schematically represents in a front view a knitted tube at the first step of its confection, according to the prior art.
[0027] FIG. 2 schematically represents in a back view a knitted tube at the first step of its confection, according to the prior art.
[0028] FIG. 3 schematically represents in a bottom view the knitted tube of FIGS. 1 and 2 , after sewing of the crotch bottom, according to the prior art.
[0029] FIG. 4 schematically represents in a front view a knitted tube at the first step of its confection, according to the invention.
[0030] FIG. 5 schematically represents in a back view a knitted tube at the first step of its confection, according to the invention.
[0031] FIG. 6 is a view of a crotch draft according to the invention.
[0032] FIG. 7 is a view of a lateral crotch piece according to the invention.
[0033] FIG. 8 schematically represents in a bottom view the knitted tube of FIGS. 4 and 5 , after sewing of the two lateral pieces of the crotch bottom, according to the invention.
[0034] FIG. 9 represents in perspective in a low angle view a particular example of embodiment of a boxer short in accordance with the invention.
[0035] FIGS. 10 to 13 represent various embodiments of the incisions at the front and at the back of the tubular knitted fabric, and FIGS. 10 ′ to 12 ′, similar to FIGS. 3 and 8 , illustrate the shape of the crotch obtained according to the method of the invention. More precisely,
[0036] FIG. 10A describes the first preferred embodiment of the invention, with two front vertical symmetrical incisions, one back vertical incision, with in FIG. 10 ′A the illustration of the corresponding crotch.
[0037] FIGS. 10B and 10C are two variants of this first embodiment, where the frontal symmetrical incisions are oblique.
[0038] FIG. 11A describes an alternative variant of the first preferred embodiment of the invention, two front symmetrical vertical incisions, two back vertical symmetrical incisions, with in FIG. 11 ′A, the illustration of the corresponding crotch.
[0039] FIGS. 11B and 11C are two variants of this first embodiment, where the frontal symmetrical incisions are oblique.
[0040] FIG. 12A describes the second preferred embodiment of the invention, with two front T-shaped incisions, a back vertical incision, with, in FIG. 12 ′A, the illustration of the corresponding crotch.
[0041] FIGS. 12B and 12C are two variants of this second embodiment, where the incision forming the T-bar has a curved or oblique shape on the horizontal, with, in FIG. 12 ′C, the illustration of the crotch corresponding to FIG. 12C .
[0042] FIG. 13A describes an alternative variant of the second preferred embodiment of the invention, with two front and back T-shaped incisions, with, in FIG. 13 ′A, the illustration of the corresponding crotch.
[0043] FIGS. 13B and 13C are two variants of this second embodiment, where the incision forming the front T-bar has a curved or oblique shape on the horizontal, with, in FIG. 13 ′C, the illustration of the crotch corresponding to FIG. 13C .
DETAILED DESCRIPTION
[0044] The enclosed FIGS. 4 to 8 show in detail the confection operation of a boxer short according to the invention according to a first preferred embodiment. As according to the prior art, the boxer short 1 is made in the shape of a knitted tube, with an upper belt 2 and a lower border 3 corresponding to future leg cuffs. The knitted tube comprises a front face 5 and a rear face 6 . It is further represented in hatching on the front face 5 of the portion 4 intended to form the front pocket of the boxer short intended to maintain the genitals. There is defined on the knitted tube a vertical direction going from the belt 2 at the top to the lower border 3 and a transverse direction, orthogonal to the vertical direction, and going from one side of a front or rear face to the other.
[0045] According to the invention, we proceed ( FIGS. 4 and 5 ) to a cut operation creating two parallel vertical incisions 7 and 7 ′ at the front 5 of the boxer short 1 : these incisions have edges 10 , 11 and 10 ′, 11 ′ and form a tab 14 having a lower edge or low edge 16 . The lower edge 16 may be directly the edge of the knitted tube if the lapel is not formed yet, or be the edge of the tab 14 after dismantling the lapel, or even—and preferably—be obtained by the shortening of the tab 14 through an additional transverse cut (not represented) between the two incisions 7 , 7 ′. In practice, the contour portion 4 may advantageously go lower than it has been represented on FIGS. 4 and 8 (to avoid confusing the reading) and come in the tab 14 between the two edges 11 , 11 ′ and almost until to its low edge to ensure more comfort to the genitals.
[0046] We proceed at the back part 6 of the knitted tube to a central vertical incision 8 , creating two edges 12 , 13 .
[0047] We also prepared, preferably in a knitted fabric, two lateral crotch pieces 15 , 15 ′ in one piece 17 represented in FIG. 6 , which can itself be obtained by cutting a long knitted strip. The piece 17 includes, on its two edges, borders 23 , 23 ′ with lapels corresponding to portions 3 of the tubular knitted fabric 1 intended to form the thigh passage. An oblique cut 18 allows to form, from the piece 17 , two pieces 15 and 15 ′ symmetrical in rectangular trapezia. The piece 15 , represented on FIG. 7 , includes, in addition to its reinforced edge 23 , parallel edges 1510 and 1513 and an oblique edge 1511 .
[0048] We then go to the sewing of the crotch pieces 15 , 15 ′ on the knitted tube. For that, each incision 7 , 7 ′ is laterally spaced apart, in the transverse direction, so as to put the edges 10 , 11 and 10 ′, 11 ′ substantially in the shape represented in FIG. 8 , where they are at an obtuse angle together, always with the tab 14 therebetween and the edge 16 thereof at low portion. These elements form a broken front bottom line 10 , 11 , 16 , 11 ′, 10 ′, in which the edge 16 is a low edge and the portions 10 , 11 , 11 ′, 10 ′ a top edge (with respect to the low edge). In the same time, the incision 8 is spaced apart so as to put the edges 12 , 13 substantially in the extension of one another, as represented, so as to form a practically rectilinear rear bottom line 12 , 13 .
[0049] the low edge 16 is then sewn in the middle of the rear bottom line 12 , 13 , in the portion facing the low edge 16 , and the lateral crotch trapezia 15 , 15 ′ are attached and sewn between the lateral portions of front bottom line 10 , 11 and 10 ′, 11 ′ constituting the top edge and the ends of the rear bottom line 12 , 13 . The lateral crotch trapezia 15 , 15 ′ therefore participate in the constitution of each thigh girth 19 by the reinforced edge 23 , 23 ′.
[0050] The shape of the lateral crotch pieces 15 , 15 ′ is not limited to the trapezium. These pieces can also be triangular, or of other shape, and their edges are not necessarily rectilinear, but may be curves. Likewise, the rear bottom line 12 , 13 represented rectilinear on FIG. 8 can be arched, curvilinear or broken.
[0051] An example of a boxer short obtained in accordance with the invention is represented on FIG. 9 . It shows the lateral crotch pieces 15 , 15 ′, placed inwardly and forwardly of each thigh. The front edge 16 forms with the rear bottom line 12 , 13 a seam 20 which extends more or less in an arc between the thighs; two sewing branches go from this seam 20 , sewing the lateral pieces 15 , 15 ′ at the edges 10 , 11 , 10 ′, 11 ′. The fact that the front edge 16 joins the rear bottom line 12 , 13 situated at the back allows to carry to the back the seam and the resulting discomfort in a less sensitive zone, which significantly contributes to the improved comfort of the boxer short of the invention.
[0052] The invention is particularly well combined with an embodiment of the front contoured portion in the more or less oval zone 4 shape surrounded by a peripheral marginal zone 21 made within a mesh different from that of the zone 4 , advantageously a more elastic mesh (higher elasticity module).
[0053] On FIGS. 4 to 8 the preferred embodiment of the invention was described in detail, but it will be seen on FIGS. 10 to 13 that we can, without departing from the spirit of the invention, bring several modifications to what has been described, according to the exact way with which the two incisions are made on the face that receives them, and on the number of incisions on the other face. Figures are too schematic to allow to easily understand the principle of the modifications. The tube 1 is represented with its front face 5 and rear face 6 , either in perspective, or in a bottom view after assembling the crotch.
[0054] On FIGS. 10 A and 10 ′A is resumed the basic construction of FIGS. 4-5 and 8 , with two symmetrical vertical incisions 7 , 7 ′ at the front and one 8 in the middle at the back, which allow to obtain a globally transverse bottom line at the front formed of a low central edge 16 and of a top double lateral edge 10 , 10 ′ (the vertical portion, which passes from one to the other, is neglected). This front bottom line cooperates with a substantially rectilinear rear bottom line to which it is directly sewn at the low edge 16 , and linked by means of the crotch pieces 15 , 15 ′ on the ends.
[0055] The variations of FIGS. 10B and 10C are distinguished by the symmetrical slightly oblique position of the front incisions 7 , 7 ′.
[0056] According to FIGS. 11 A and 11 ′A, we provided two vertical symmetrical incisions 7 , 7 ′ at the front and 8 , 8 ′ at the back, thus this results in two quite similar front and rear bottom lines which are directly sewn to one another by their low edge 16 and on the sides by means of the separate crotch pieces 15 , 15 ′.
[0057] The variations of FIGS. 11 B and 11 C are distinguished by the slightly oblique symmetrical position of the front incisions 7 , 7 ′.
[0058] According to FIGS. 12 A and 12 ′A, a vertical central incision 8 was provided at the back, and two central T-shaped incisions, 7 , 7 ′ were provided at the front, thus this results in that the rear bottom line is still rectilinear and that the front bottom line is characterized by a low edge 16 rejected on the sides while its top edge 10 directly formed by the incision 7 ′ is central. The low edge 10 at the ends is directly sewn to the portion facing the rear bottom line, while the top central edge 10 is sewn to the portion facing the rear bottom line by means of the separate central crotch piece 15 .
[0059] The variations of FIGS. 12B and 12C are distinguished by the curved or oblique shape of the T branches, that is to say, of the second incision 7 ′, which leads as it is seen on FIG. 12 ′C to a slightly modified shape of the top edge 10 and therefore of the separate crotch piece 15 .
[0060] According to FIGS. 13 A and 13 ′A, a double incision in T 7 , 7 ′ and 8 , 8 ′ is provided at the front and at the back, which leads to two bottom lines of identical shape which will be sewn edge to edge at their end portions end forming the low edge 16 and by means of a central crotch piece 15 at their top edge 10 .
[0061] The variations of FIGS. 13B and 13C are again distinguished by the curved or oblique shape of the T branches, that is to say, of the second incision 7 ′, 8 ′ of the incisions of the front face and rear face, which leads as it is seen on FIG. 13 ′C to a slightly modified shape of the top edge 10 and therefore of the separate crotch piece 15 . | These comfortable boxer shorts are formed from a knitted main tube ( 1 ) comprising a front part ( 5 ) and a back part, the lower portions of which end in a first and second bottom line ( 10, 11, 16, 11′, 10; 13, 12 ) consisting of two front incisions and one rear incision. The first bottom line ( 10 ) ( 10, 11, 16, 11′, 10′ ) is composed of an edge ( 16 ) of a front flap ( 14 ) and of two bottom line side ends ( 10, 11; 11′, 10′ ) that rise higher than the edge ( 16 ) of the flap ( 14 ). Said edge ( 16 ) of the front flap ( 14 ) is sown to the middle of the second bottom line ( 13, 12 ), at the rear of the boxer shorts, and two separate crotch parts ( 15, 15′ ) ( 15 ) are sown between the ends ( 10, 11; 11′, 10′ ) of the first bottom line and the ends of the second bottom line ( 13, 12 ). | 3 |
RELATED APPLICATION DATA
[0001] This application claims priority to previously filed U.S. provisional patent application No. 60/801,774, filed on May 19, 2006 and entitled “Protective Space Coatings”, which is incorporated in its entirety herein by reference.
FIELD OF THE INVENTION
[0002] The present invention is related to protective coatings, especially those which are capable of being used to coat space vehicles and/or satellites. In one embodiment, the present invention relates to methyl, cyclopentyl, and/or cyclohexyl polysiloxane ceramer coatings. In another embodiment, the present invention relates to methods for preparing creamer compounds.
BACKGROUND OF THE INVENTION
[0003] In general, low earth orbit (LEO) and/or geosynchronous orbit (GEO) environments are not suitable for organic materials. This is due to the presence of atomic oxygen, high-energy particles, and deep UV light, which are able to degrade polymeric organic resins. Accordingly, inorganic and/or ceramer materials are more appropriate inasmuch as they are more resistant to the harsh conditions of space. Until now, some compounds of this type, for example methyl, cyclopentyl, and/or cyclohexyl polysiloxane ceramer coatings have been unknown in the art. This is due, in part, to a difficulty in preparing such compounds.
[0004] Thermoplastic and thermosetting polymers are used to form a wide variety of structures for which properties such as abrasion resistance, optical clarity (i.e., good light transmittance) and/or the like, are desired characteristics. Examples of such structures include camera lenses, eyeglass lenses, binocular lenses, retroreflective sheeting, automobile windows, building windows, train windows, boat windows, aircraft windows, vehicle headlamps and taillights, display cases, eyeglasses, watercraft hulls, road pavement markings, overhead projectors, stereo cabinet doors, stereo covers, furniture, bus station plastic, television screens, computer screens, watch covers, instrument gauge covers, bakeware, optical and magneto-optical recording disks, and the like. Examples of polymer materials used to form these structures include thermosetting or thermoplastic polycarbonate, poly(meth)acrylate, polyurethane, polyester, polyamide, polyimide, phenoxy, phenolic resin, cellulosic resin, polystyrene, styrene copolymer, epoxy, and the like.
[0005] Many of these thermoplastic and thermosetting polymers have excellent rigidity, dimensional stability, transparency, and impact resistance, but unfortunately have poor abrasion resistance. Consequently, structures formed from these materials are susceptible to scratches, abrasion, and similar damage.
[0006] To protect these structures from physical damage, a tough, abrasion resistant “hardcoat” layer may be coated onto the structure. Many previously known hardcoat layers incorporate a binder matrix formed from free-radically curable prepolymers such as (meth)acrylate functional monomers. Such hardcoat compositions have been described, for example, in Japanese patent publication JP 02-260145, U.S. Pat. Nos. 5,541,049, and 5,176,943. One particularly excellent hardcoat composition is described in WO 96/36669 A1. This publication describes a hardcoat formed from a “ceramer” used, in one application, to protect the surfaces of retroreflective sheeting from abrasion. As defined in this publication, a ceramer is a composition having inorganic oxide particles, e.g., silica, of nanometer dimensions dispersed in a binder matrix.
[0007] Many ceramers are derived from aqueous sots of inorganic oxide particles according to a process in which a free-radically curable binder precursor (e.g., one or more different free-radically curable monomers, oligomers, and/or polymers) and other optional ingredients (such as surface treatment agents that interact with the inorganic oxide particles, surfactants, antistatic agents, leveling agents, initiators, stabilizers, sensitizers, antioxidants, crosslinking agents, crosslinking catalysts, and the like) are blended into the aqueous sol. The resultant ceramer composition may then be dried to remove substantially all of the water. The drying step may also be referred to as “stripping”. An organic solvent may then be added, if desired, in amounts effective to provide the ceramer composition with viscosity characteristics suitable for coating the ceramer composition onto the desired substrate. After coating, the ceramer composition can be dried to remove substantially all of the solvent and then exposed to a suitable source of energy to cure the free-radically curable binder precursor, thereby providing the desired, abrasion resistant hardcoat layer on the substrate.
[0008] Although such ceramer compositions, upon curing, generally provide at least some level of abrasion resistance to a substrate, they generally do not provide appreciable stain resistance or oil and/or water repellency. As a result, substrates comprising a cured ceramer composite are susceptible to staining due to prolonged contact with oil, water or other stain causing agents. Such staining impairs the optical clarity and appearance of the substrate. It is therefore desirable to incorporate agents into ceramer compositions that will provide the ceramer composition, upon, curing, with stain, oil and/or water resistance, while still maintaining the desired hardness and abrasion resistance characteristics of the resultant, cured ceramer composite.
[0009] Thus, there is a need in the art for creamer coatings that, among other things, are suitable for use in space environments.
SUMMARY OF THE INVENTION
[0010] The present invention is generally directed to protective coatings, especially those which are capable of being used to coat space vehicles and/or satellites. In one embodiment, the present invention relates to methyl, cyclopentyl, and/or cyclohexyl polysiloxane ceramer coatings. In another embodiment, the present invention relates to methods for preparing creamer compounds.
[0011] As noted above, the present invention generally relates to protective coatings. More particularly, the present invention relates to protective polysiloxane coatings that are particularly suitable for, among other things, vehicles and/or satellites in low earth and geosynchronous orbits. Some embodiments of the present invention include an inorganic/organic hybrid coating, known as a ceramer, that is fabricated using a polysiloxane binder and nanophase silicon/metal-oxo-clusters derived from sol-gel precursors. Such coatings can be synthesized using hydrolytic polycondensation and hydrosilation methods thereby enabling the synthesis of a wide variety of customized/tailored polysiloxanes. Features of coatings within the scope of the present invention include, without limitation, the ability to self-heal, deflect high-energy particles, protect against deep UV-light, and optical transparency.
BRIEF DESCRIPTION OF THE FIGURES
[0012] FIG. 1 is a diagram of the self-healing mechanism using atomic oxygen;
[0013] FIG. 2 is a Depiction of in situ Silicon/Metal-Oxo-Cluster Formation for Nanoscale Reinforcement in Ceramer Coatings;
[0014] FIG. 3 is an FTIR spectrum of cyclopentyldichlorosilane;
[0015] FIG. 4 is a drawing showing a nanophase reinforced ceramer coating;
[0016] FIG. 5 is a drawing showing the formation and function of protective a silicon oxide layer and silicon/metal-oxo-clusters;
[0017] FIG. 6 is a graph showing the temperature effect on the rate of propagation (R p );
[0018] FIG. 7 is a graph showing the effect of UV light on R p ;
[0019] FIG. 8 is a graph showing the effect of exposure time on R p ;
[0020] FIG. 9 is a graph showing the effect of TEOS concentration on R p ;
[0021] FIG. 10 is a photograph of a sample holder for exposing samples to atomic oxygen;
[0022] FIG. 11 is a graph of thermal gravimetric analysis data from a ceramer coating having a 5% sol-gel precursor content;
[0023] FIG. 12 is a graph showing XPS data from a cross-linked methyl substituted polysiloxane before and after atomic oxygen exposure;
[0024] FIG. 13 is a pair of atomic force microscopy (AFM) images of a sample with 5% (w/w) sol-gel precursor added prior to casting;
[0025] FIG. 14 is a) a pair of photographs showing a ceramer coating on Kapton H and fused silica after atomic oxygen exposure at a moderate fluence level (2.22×10 21 atoms/cm 2 ), and (b) a pair of photographs showing a DC 93-500 coating on Kapton H and fused silica after atomic oxygen exposure at a moderate fluence level (2.22×10 21 atoms/cm 2 );
[0026] FIG. 15 is a) a pair of photographs showing a ceramer coating on Kapton H and fused silica after atomic oxygen exposure at a high fluence level (2.22×10 21 atoms/cm 2 ), and (b) a pair of photographs showing a DC 93-500 coating on Kapton H and fused silica after atomic oxygen exposure at a high fluence level (2.22×10 21 atoms/cm 2 );
[0027] FIG. 16 is a set of plots showing mass loss of various materials as a function of fluence;
[0028] FIG. 17 is a pair of AFM images showing the a) abraded and b) re-oxidized ceramer coating;
[0029] FIG. 18 is a pair of SEM photographs showing the ceramer coating after being a) scratched and b) re-oxidized;
[0030] FIG. 19 is an SEM photograph of a ceramer that has been subjected to high fluence (1.38×10 22 atoms/cm 2 ) and exhibits some delamination and micro-cracking;
[0031] FIG. 20 is a set of plots showing the effect of atomic oxygen exposure on a ceramer coating on fused silica in terms of a) absorbance, b) transmittance, and c) reflectance;
[0032] FIG. 21 is a set of plots showing the effect of atomic oxygen exposure on a DC 93-500 coating on fused silica in terms of a) absorbance, b) transmittance, and c) reflectance; and
[0033] FIG. 22 is a set of plots showing the effect of microcracks on transmittance in samples of a) ceramer on fused silica, and b) DC 93-500 on fused silica.
DETAILED DESCRIPTION OF THE INVENTION
[0034] As used herein, the term ceramer includes inorganic/organic hybrid materials that are part ceramic and part polymer. Ceramers can comprise one or more of a wide range of ceramics such as silica, titania, zirconia, clays, various metal oxides, and mixtures and combinations thereof, both synthetic and naturally occurring. Additionally, ceramers can comprise one or more of a wide range of organic polymers and/or substituents. In another embodiment, ceramers can provide a uniformly distributed nanophase within a continuous organic phase. In some embodiments, ceramers of the present invention can protect space vehicles from atomic oxygen, UV radiation and high energy particles by forming nanophase silicon/metal-oxo-clusters in situ.
[0035] The degradation of carbon-based materials in LEO is due to the presence of ground state atomic oxygen, various forms of radiation, and particulate matter that impacts the vehicle. The UV radiation that is present in LEO can cleave organic bonds, which brings about chain scission and cross-linking reactions in organic polymeric materials. This can lead to changes in thermal conductivity, and optical and mechanical properties, as well as embrittlement, and decreased strength. Other factors that affect organic materials in space include thermal fluctuations, radiation, vacuum, particulate matter, and micrometeoroids and debris. The coatings of the present invention are resistant to some or all of these factors.
[0036] Siloxane polymers in LEO have erosion rates one to two orders of magnitude lower than that of organic polymers under the same conditions. Furthermore, when siloxane polymers are exposed to atomic oxygen they tend to form a protective silicon dioxide barrier, unlike organic polymers, which corrode. For instance, exposure of polyhedral oligomeric silsesquioxanes-siloxane (POSS) copolymer thin films to atomic oxygen results in an initial attack on the tethered organic groups followed by formation of a silica surface layer. The silica layer blocks atomic oxygen thereby preventing further degradation. In addition to providing enhanced atomic oxygen resistance, silica-forming polymers possess a self-healing mechanism whereby the coating can repair itself if it is, for instance, scratched or etched (see FIG. 1 ). The general structure of a T 8 silsesquioxane is shown below:
[0037] In some embodiments of the present invention, silicon/metal-oxo-clusters are formed through a series of hydrolysis and condensation reactions between sol-gel precursors, as illustrated in FIG. 2 . The size of the clusters can be adjusted by controlling the reaction conditions, and/or reaction rate. The siloxane is functionalized through hydrosilation with cycloaliphatic epoxides and alkoxy silanes. The cycloaliphatic epoxide provides a cross-linking site for cationic UV-induced cure. Silanol groups can react with the cycloaliphatic epoxide to further reinforce the network. According to the present invention, the size of the colloidal particles can be adjusted by and/or controlled by adjusting and/or controlling the coupling group, e.g., alkoxysilanes.
[0038] The curing process results in a strong interlocking network comprising a cross-linked organic phase with interconnected silicon/metal-oxo-clusters ( FIG. 4 ). Exposing the coating to atomic oxygen results in forming a protective layer of silicon oxide, which forms an oxide layer that serves as a protective barrier. In some embodiments, incorporation of silicon/metal-oxo-clusters into the coating protects against atomic oxygen erosion, high energy particles, and/or deep ultraviolet (DUV) radiation (see FIG. 5 ).
[0039] In some embodiments, tetraethylorthosilicate (TEOS) is used as a sol-gel precursor. TEOS aids in miscibility and provides a site for interaction with the metal/silicon-oxo-cluster. According to some embodiments, TEOS is oligomerized to avoid volatilization. Additionally, TEOS oligomers are amenable to photo-induced cationic polymerization of cycloaliphatic epoxides.
EXAMPLE PREPARATIONS
[0040] Except where otherwise noted, the following applies to each of the example preparations set forth herein. Octamethylcyclotetrasiloxane, tetramethylcyclosiloxane, tetramethyldisiloxane, dichlorosilane, and vinyl triethoxysilane can be purchased from Gelest, Inc. and are used as supplied. Wilkinson's catalyst, cyclopentene, tetraethylorthosilicate, and 4-vinyl-1-cyclohexene 1,2-epoxide can be purchased from Aldrich and are used as supplied. Toluene, supplied by Aldrich Chemical Co., is distilled in order to eliminate any impurities. The photoinitiator, Iodonium, (4-methylphenyl)[4-(2-methylpropyl)phenyl]hexafluorophosphate(1-) 75% solution in propylene carbonate, is used as received. A structure for this compound is shown below:
This photoinitiator solution can be obtained from Ciba Specialty Chemicals and is sold under the trademark IRGACURE 250. Air sensitive materials are transferred and weighed in an inert atmosphere dry box under argon.
[0041] (1) Synthesis of Compound 1: Poly(dimethylsiloxane-co-methylhydrosiloxane) Hydride Terminated:
[0042] The following components are added to a three neck round bottom flask equipped with a reflux condenser and nitrogen inlet/outlet ports: octamethylcyclotetrasiloxane (90 g), tetramethylcyclosiloxane (5.33 g), tetramethyldisiloxane (0.67 g), and concentrated sulfuric acid (2.5 mL). The solution is stirred at room temperature, under nitrogen, for about eight hours. Sodium bicarbonate is added to neutralize the acid, and the solution is filtered to obtain compound 1. The following M w and polydispersity index (PDI) are obtained by gel permeation chromatography (GPC): M w =47,000, PDI=2.15. H 1 NMR shows a peak at 4.6 ppm and FTIR shows a strong peak at 2160 cm −1 , which are both indicative of the Si-H functionality.
[0043] (2) Cycloaliphatic Epoxide and Alkoxy Silane Functionalization of Compound 1:
[0044] The following are added to a three neck round bottom flask equipped with nitrogen inlet/outlet ports, a reflux condenser, and septum: compound 1 (30 g), 4-vinyl-1-cyclohexene diepoxide (20 g), vinyl triethoxysilane (2 g), and Wilkinson's catalyst (0.004 g). Distilled toluene (30 g) is added via cannula. The reaction is held at about 75° C. with an oil bath, and it is mechanically stirred. The disappearance of the Si—H functionality is monitored through FTIR. The disappearance of the peak at 2160 cm −1 indicates that the reaction is complete. Any solvent and unreacted starting materials are removed under vacuum and the reaction product is verified through H 1 NMR.
[0045] (3) Synthesis of TEOS Oligomers:
[0046] The following materials are added to a single neck round bottom flask: TEOS (100 g), ethanol (88 g) and distilled water (8 g). Hydrochloric acid (0.5 g) is then added dropwise while the mixture is mechanically stirred. The reaction is stirred for 48 hours at room temperature. The solvent is removed under vacuum to yield TEOS oligomers. The products were characterized through H 1 NMR.
[0047] (4) Synthesis of Compound 2: Poly(dicyclopentylsiloxane-co-cyclopentyl-Hydrosiloxane), Hydride Terminated Siloxane:
[0048] (4a) Synthesis of Cyclopentyldichlorosilane:
[0049] A stainless steel bomb is charged with cyclopentene (5 g) and Wilkinson's catalyst (0.06 g), cooled in a liquid nitrogen bath, and evacuated. Dichlorosilane (5 mL) is condensed in a calibrated tube and distilled into the bomb through the inlet valve. The bomb is then allowed to warm to room temperature, and then heated for 15 hours at about 70° C. The bomb is then allowed to cool. The reaction produces a clear, light yellow liquid. The FTIR spectrum shows a strong Si-H peak at about 2100 cm −1 and a Si—Cl 2 peak at about 500 cm −1 as shown in FIG. 3 .
[0050] ( 4 b ) Synthesis of Cyclic n-mers of Compound 2:
[0051] Saturated aqueous sodium bicarbonate (5 mL) is added to a round bottom flask and cooled to about 10° C. Cyclopentyldichlorosilane (5 mL) is added dropwise to yield a thick slurry. Any remaining water is filtered off. The product is added to boiling toluene and then filtered to remove any cross-linked compounds. The solvent is then removed via vacuum to yield a white solid, and analyzed by FTIR. FTIR showed the disappearance of the Si—Cl 2 peak and a slight broadening of the band at 1000 cm −1 which represents cyclic Si—O—Si compounds.
[0000] Reaction Rate; Photo Differential Scanning Calorimetry:
[0052] Photodifferential scanning calorimetry (PDSC) is used herein to show the effects that temperature, UV light intensity, sol-gel precursor concentration, and exposure time have on polymerization rate. According to some embodiments, higher reaction rates produce higher final percent conversions. PDSC is also used to determine heat of reaction exotherms, which can be used to calculate polymerization rate and associated rate constants.
[0053] In some embodiments, the cure kinetics can be studied with a Thermal Analysis Q 1000 DSC equipped with a photocalorimetric accessory. The accessory includes transfer optic cables capable of carrying UV light, and a monochromator capable of selecting specific wavelengths and/or very narrow bands about selected wavelengths. The initiation light source is a 100 W mercury arc lamp. One of ordinary skill in the art is would readily recognize that a variety of wavelengths can be appropriate for such a study, and can be different from one compound to another. In some embodiments, appropriate wavelengths include ultraviolet light below about 300 nm.
[0054] A wide variety of photosensitizers can be used to sensitize samples to UV light. In some embodiments one or more photosensitizers shift the initiating wavelength into the UV or deep UV region. In other embodiments anthracene and/or phenanthrene is used to shift the initiating wavelength into the visible region. In still other embodiments, photosensitizers can include any compound that forms a triplet state in response to visible light exposure. One of ordinary skill in the art is able to readily select particular photosensitizers based on this criterion.
[0055] Polymerization reactions within the scope of the present invention are run isothermally at various temperatures. For the purpose of reaction rate determinations, samples sizes can be between about 1 to 5 mg in order to limit the total heat released. The samples are placed in hermetic uncovered aluminum DSC pans and cured with various UV intensities and exposure times.
[0000] Rate of Polymerization:
[0056] Since PDSC experiments measure the overall heat of reaction, the heat flow is representative of an overall activation energy (E R ), which includes initiation (E I ), propagation (E P ), and termination (E T ):
E R =E P +E I −E T (1)
[0057] Equation (1), presumes that carbocations are produced throughout the reaction, i.e. by photoinitiation. In some embodiments, rate constant determinations for photosensitized reactions show that the photosensitizer is not completely consumed until after the exotherm peak maximum. Thus, equation (1) can be used to represent the overall activation energy for the photopolymerization reaction. Therefore, the rate of propagation (R p ) is proportional to the height of the PDSC exotherm. The propagation rate can be calculated with equation (2). The rate obtained has units of moles of epoxide per second.
R p =( d[E]/dt )=(height of exotherm( Wg −1 )×ρ)/Δ H p (2)
[0058] In equation (2), [E] is the epoxy concentration. The rate of propagation is given by a propagation rate constant (k p ) multiplied by the carbocation concentration [C+] and the epoxy concentration.
R p =( d[M]/dt )
R p =k p [C+][E]
R p =[A] 0 ·( k p k i */k t −k i *)·( e −ki·t −e −kt·t )[ E] (3)
[0059] In equation (3) [A] is anthracene concentration, k i is the initiation rate constant, k i * is the rate constant for carbocation formation, and k t is the termination rate constant. It is possible to have more than one propagating species having different reactivities. Therefore, equation (3) arrives at a general propagation rate constant that accounts for each type of propagating species.
[0060] FIGS. 6, 7 , 8 , and 9 illustrate how temperature, intensity, exposure time, and TEOS concentration affect the rate of polymerization of a single composition. FIG. 6 is an overlay of exotherms for the cationic polymerization of compound 1 with 0.01 wt % anthracene and 3 wt % photoinitiator at temperatures ranging from 50° C. to about −70° C. Some samples also contained 5 wt % TEOS oligomers. FIG. 6 also shows that the rate of polymerization increases with temperature, which is indicated by the fact that the exotherms indicate a larger integrated heat as temperature is increased. The increase in R p results, in part, from increased chain mobility.
[0061] FIG. 7 shows the effect of variations in UV light intensity from about 200 to 1000 mW/cm 2 . Reaction rate increases with UV light intensity. This is a result of the higher intensity producing more protons, which increases the rate of polymerization. It is important to note that the exotherms resulting from 200 and 500 mW/cm 2 UV intensities are very similar and their rates of polymerization differ by approximately 0.030 moles of epoxy/L·s. Intensity needs to be doubled in order to see a substantial difference in the rate of polymerization. The effect of the duration of UV light exposure is shown in FIG. 8 , which displays the results of varying the exposure time from 1 to 30 seconds.
[0062] Increased exposure time produces a greater integrated heat area, and therefore a higher reaction rate. FIG. 8 shows that the rate of polymerization increases with exposure time, which is due to the production of more initiating species. Additionally, FIG. 9 shows that the rate of polymerization (compound 1) also increases with TEOS concentration. Particularly, the rate of polymerization is about 1.5 times greater with 5% TEOS in comparison to samples having no TEOS. This is due in part to the polysiloxane chain undergoing polymerization, and also to additional cross-linking caused by in situ silicon/metal-oxo-cluster formation. Table I summarizes the rates of polymerizations found for compound 1 under various conditions.
TABLE I Compound 1 PDSC Data TEOS Height of Exotherm Rp Exposure Time Intensity Temperature Concentration Exotherm Area (moles of (seconds) (mw/cm 2 ) (° C.) (Wt %) (Wg −1 ) (Jg −1 ) epoxide/L · s) 1 200 25 0 1.84 25.19 0.112 1 500 25 0 2.44 26.08 0.148 1 1000 25 0 12.00 97.39 0.730 5 200 25 0 8.66 106.80 0.527 5 1000 25 0 25.62 246.20 1.558 10 200 25 0 7.13 117.30 0.434 10 1000 25 0 20.80 252.50 1.265 30 200 25 0 10.76 251.20 0.654 30 500 25 0 15.86 324.30 0.965 30 1000 25 0 53.06 1055.00 3.227 5 200 −70 0 0.94 11.84 0.057 5 200 −20 0 3.88 51.54 0.236 5 200 −5 0 3.88 49.84 0.236 5 200 0 0 6.27 78.97 0.382 5 200 50 0 12.14 151.80 0.738 1 200 25 5 4.22 40.15 0.258 5 200 25 5 10.32 143.30 0.630 10 200 25 5 13.14 186.80 0.802 5 200 −20 5 5.18 75.79 0.316 5 200 0 5 5.55 93.19 0.338 5 200 50 5 14.25 198.00 0.869
Coating
[0063] In some embodiments, the coating of the present invention is applied to a substrate by spin coating. For instance, one appropriate spin coating method comprises the following. The functionalized polysiloxane is diluted with toluene (25% wt/wt) thereby sufficiently reducing the viscosity. Sol-gel precursor (5% wt/wt) and photo initiator (3% wt/wt) arc added to the diluted polysiloxane and thoroughly mixed. A substrate (e.g., a piece of Kapton H, fused silica, or the like) of appropriate size (e.g., about 10 cm diameter) is mounted onto a spinning stage and spun at a very high speed. The uncured polysiloxane solution is dropped onto the center of the spinning Kapton sample. The sample is removed from the stage and passed through a UV-curing chamber at a belt speed of about 25 ft/min and an average intensity of about 150 mW/cm 2 . For the purpose of comparison to the present invention, DC 93-500 is coated in the same manner, and placed in an oven at 80° C. for 6 hours to cure. Fused silica panels are also coated by both polymers in the same manner. The coating thickness is measured with a coating thickness gauge and by atomic force microscopy (AFM), and found to be about 2 μm average thickness in each sample.
[0000] Durability Testing
[0064] (a) Thermal Stability:
[0065] The thermal stability of the present invention is compared to DC 93-500 by thermal gravimetric analysis (TGA). Irreversible changes to the cross-linked structure of silicone polymers occur at high temperatures due to chain scission, oxidative cross-linking, and depolymerization. Particularly, depolymerization can occur at about 400° C. in an inert atmosphere. FIG. 11 compares the thermal stability of the present invention to that of DC 93-500.
[0066] As shown in FIG. 11 , thermal gravimetric analysis (TGA) of the cured ceramer coating indicates that low molecular weight oligomers are lost in the early stages of the analysis. This is evident from the gradual decrease in weight percent up to about 400° C. The DC 93-500 does not exhibit this weight loss in the early stages of the analysis because it is vacuum stripped during production, which eliminates any low molecular weight species. Depolymerization occurs in both samples near 400° C. The DC 93-500 sample exhibits a slightly higher degradation temperature. The multiple slopes observed in the ceramer curve can be attributed to a range of molecular weights. Importantly, the ceramer generates a small amount of residue (roughly 11 wt %). This can be attributed to the silicon-oxo-clusters formed during polymerization, and to high molecular weight chains that may not have completely volatized/degraded.
[0067] The thermal degradation of the DC 93-500 is drastically different from the ceramer coating's profile. The major degradation slope starting at approximately 400° C. shows a more thermally stable compound with a broader degradation range from 400 to 730° C. as opposed to that of the ceramers, which range from about 400 to 650° C. The extreme degradation of approximately 35 wt % at 730° C. for the DC 93-500 is very unusual, but it is reproducible. This could be attributed to the sample achieving its absolute highest temperature before total decomposition of the sample. The sharp slope is then followed by a residue segment, which accounts for 50% of the remaining weight. Since the cured DC 93-500 is composed of approximately 40-60% silica of various types (dimethylvinylated, trimethylated, and methylated), these components could account for the residue left after analysis.
[0068] (b) Atomic Oxygen Exposure:
[0069] The atomic oxygen durability of the present invention is assessed in comparison to a DC 93-500 control. The first two samples comprise the ceramer of the present invention spin coated on Kapton H polyamide and fused silica substrates. The second two samples comprise DC 93-500 silicone spin coated on Kapton H and fused silica substrates. All samples are coated on both sides.
[0070] Optical property changes and mass loss are documented at effective atomic oxygen fluence levels of 2.22×10 21 and 1.38×10 22 atoms/cm 2 . Kapton H witness samples are used to determine the effective atomic oxygen fluence as described in ASTM E 2089-00, “Standard Practices for Ground Laboratory Atomic Oxygen Interaction Evaluation of Materials for Space Applications”. All substrates used for the evaluation and fluence witnesses are made of 2.54 cm diameter by 0.127 mm thick Kapton H polyimide.
[0071] The effect of minor abrasions can be observed according to the following process. An additional set of ceramer and DC 93-500 coated samples are made in the foregoing manner, and are scratched with a finger prior to atomic oxygen exposure. Samples of the silicone-coated Kapton H are punched out and vacuum dehydrated for 48 hours prior to weighing to minimize mass uncertainty due to weight loss as recommended by ASTM E 2089-00.
[0072] Atomic oxygen testing is performed in an SPI Plasma Prep II (13.56 MHz) radio frequency plasma asher. The asher is typically operated using air at a pressure of 20 to 26.7 Pa (0.15-0.2 torr), and a Kapton effective flux of 9.21×10 15 atoms·cm −2 /s. The samples are held down by fine wires attached to a metal frame (see FIG. 10 ) lying on a glass plate, which helps to limit sample curling due to atomic oxygen exposure.
[0073] Cross contamination witness samples are placed in the plasma asher next to the silicone coated samples to assess the degree of silicone transport and resulting contamination. This test is performed prior to sample exposures to determine a baseline contamination. The thicknesses of contamination deposits are measured with a Dektak 6M stylus profilometer. The profilometer scans the sample from the contamination deposit to an area that is protected from contamination by means of a tightly fitted aluminum foil mask.
[0000] Verifying the Existence of an Oxide Layer, XPS Data:
[0074] X-ray photoelectron spectroscopy (XPS) is performed to confirm the presence of a protective oxide layer ( FIG. 12 ). Samples are not sputter-coated, thereby ensuring that only the surfaces of the samples are analyzed. The initial XPS spectrum shows high amounts of both silicon and oxygen, which is expected as these elements are present in the polymer backbone. However, after atomic oxygen exposure the oxygen peak increases while the silicon peaks decrease. This is due to the protective oxide layer possessing a high amount of oxygen compared to silicon. The oxide layer should be composed of silicon atoms whose valences are filled by oxygen atoms. Carbon is always present due to surface impurities.
[0075] Another important aspect of the coating is the presence of the silicon-oxo-clusters. It is possible to detect silicon-oxo-clusters in the cross-linked polymer network using an atomic force microscope (AFM) in tapping mode. These clusters provide additional protection against high-energy particles and deep UV-light (200-260 nm).
[0076] FIG. 13 is an AFM image of a ceramer within the scope of the present invention. The ceramer is made with 5% (w/w) sol-gel precursor, which is added prior to casting. The silicon-oxo-clusters are clearly visible in the ceramer sample. The clusters are circled in FIG. 13 . The average size of the methyl substituted clusters is 125 nm. FIG. 13 also reveals a dispersed and uniformly sized nanophase. This can be attributed to the small size of the pendant methyl groups, which provides an unobstructed region for the growing nano-clusters.
[0000] Atomic Oxygen Exposure:
[0077] Micro-cracking and delamination of the ceramer of the present invention due to atomic oxygen is assessed. Photographs of the samples are taken after being subjected to two different fluence levels: 2.22×10 21 and 1.38×10 22 atoms/cm 2 . FIGS. 14 a and 14 b show the ceramer and DC 93-500 coatings on both the Kapton H and fused silica substrates. FIG. 14 a shows no evidence of micro-cracking or other physical damage at 2.22×10 21 atoms/cm 2 , which is a moderate fluence level. This stability is attributed to the coating's homogenously dispersed nano-phase, which allows for a more uniform distribution of the stresses caused by the growing silica layer.
[0078] In contrast, the DC 93-500 coated samples exhibit micro-cracking as shown in FIG. 14 b , which is attributed to a nanophase that is less homogenous than that of the present invention. Such non-uniformity can create weak points that may yield under growing surface stresses. Coating failure is indicated by cracks propagating through the surface, as shown in FIG. 14 b.
[0079] FIG. 15 is further evidence of the relative homogeneity of the present invention in comparison to DC 93-500. Both samples exhibit extreme microcracking and delamination under high fluence conditions. However, FIG. 15 a shows that the present invention fails more uniformly across the entire coating. In contrast, DC 93-500 fails in scattered, isolated., regions. This indicates that the ceramer possesses a more homogenous composition. Conversely, this shows that the DC 93-500 coating has a relatively inhomogeneous composition that results in weak points.
[0080] FIG. 16 illustrates the protection afforded by the ceramer coating of the present invention in comparison to that of DC 93-500 and bare Kapton substrate. Each curve shows sample mass loss as a function of atomic oxygen fluence. The uncoated sample (i.e. bare Kapton) exhibits rapid mass loss as a function of oxygen fluence. In comparison, both the present invention and DC 93-500 substantial improve atomic oxygen resistance. However, the present invention outperforms each of the other samples. Particularly, unscratched ceramer outperforms unscratched DC 93-500, and the same is true in the scratched case.
[0000] Self-Healing:
[0081] The self-healing property of the present invention can be demonstrated according to the following process. Fused silica and Kapton H substrates are coated with either the ceramer of the present invention, or DC 93-500. These samples are oxidized with atomic oxygen at a fluence of about 5.0×10 20 atoms/cm 2 . Then the samples are mildly abraded with dust. Generally, the scratches produced thereby do not penetrate the coating. Thus, the effect is to remove portions of the oxide layer, exposing the underlying non-oxidized coating. The samples are then re-exposed to atomic oxygen at a fluence level of about 1.5×10 21 atoms/cm 2 , thereby oxidizing the scratched surface, and restoring the continuity of the oxide layer. Thus, the coating self-heals.
[0082] Scanning electron (SEM) and atomic force microscopy (AFM) are used to examine the self-healing process. FIG. 17 a is an AFM image of the abraded coating wherein the underlying un-oxidized coating is exposed. FIG. 17 b is an AFM image of the same sample after re-exposure to atomic oxygen. FIG. 17 b clearly shows reformation of the oxide layer, i.e. self-healing.
[0083] FIG. 18 is a pair of SEM images showing the ceramer coating of the present invention, on Kapton substrate, after abrasion and re-exposure to atomic oxygen. The two images are two different locations on the same sample, which are treated identically. The images reveal that no micro-cracking or under-cutting occurred upon re-exposure to atomic oxygen.
[0084] FIG. 19 is an SEM showing the ceramer coating of the present invention after abrasion and re-exposure. However, in this case the sample is subjected to high atomic oxygen fluence (1.38×10 22 atoms/cm 2 ). This image illustrates that delamination and microcracks develop as a result of high fluence. FIG. 19 also shows the underlying Kapton H substrate, which has been damaged by atomic oxygen exposure.
[0000] Oxide Formation:
[0085] The formation of the oxide layer can be shown by UV/Vis spectroscopy. FIG. 20 a shows how the absorption spectrum of a ceramer sample changes as a function of atomic oxygen fluence. Particularly, the region between roughly 250 and 800 nm where silica absorbs. The solid line represents the spectrum of the unexposed ceramer. In this case, the silica absorption is very slight. In comparison, the samples subjected to atomic oxygen, exhibit increased silica absorption as a function of fluence.
[0086] Similarly, the oxide layer produced by the DC 93-500 coating can also be studied by UV/Vis. FIG. 21 a shows how the absorption spectrum of DC 93-500 changes as a function of oxygen fluence. Both samples shown therein are spin-coated on Kapton and have about 2 μm average thicknesses. Unlike the ceramer, the unexposed sample has no UV absorption at all. This is because the ceramer contains silicon-oxo-clusters while the DC 93-500 sample does not. Thus, in the absence of an oxide layer DC 93-500 does not provide the substrate with UV-protection, which could result in severe damage to materials that are sensitive to UV-radiation. Furthermore, the absorbance values for the DC 93-500 are slightly lower than the ceramers due to the lack of silicon-oxo-clusters.
[0087] Similar to the ceramer coating, the DC 93-500 transmittance values decreased with an increasing absorbance and there is no change in the reflectance. The transmittance spectra ( FIGS. 20 b and 21 b ) for both coatings show a decrease in transmittance as atomic oxygen fluence is increased, which could be attributed to micro-cracking.
[0088] In other embodiments compounds 1 or 2 are coated on the surface of a metal part in any of a variety of ways including brushing, spraying, spin-coating, and dip-coating. The part thus coated is then cured. Coated parts can be used in any of a wide variety of applications including, without limitation, space vehicles, orbiters, and satellites. In related embodiments, the coating of the present invention can serve as a protective layer in a wide variety of oxidizing environments including, without limitation, rust-proofing applications, automotive parts, and the like.
[0089] In another embodiment, the compositions of the present invention can be used to form molded parts. Such parts can include, without limitation, parts for space vehicles, orbiters, satellites, automotive parts, and parts that may be subjected to corrosive and/or oxidizing conditions.
[0090] The illustrative embodiments and examples contained herein have been prepared to demonstrate the practice of the present invention. However, the embodiments and examples should not be viewed as limiting the scope of the invention. The claims alone will serve to define the invention. Various modifications and alterations that do not depart from the scope and spirit of this invention will become apparent to those skilled in the art, and are therefore deemed within the scope of the present invention.
[0091] Although the invention has been described in detail with reference to particular examples and embodiments, the examples and embodiments contained herein are merely illustrative and are not an exhaustive list. Variations and modifications of the present invention will readily occur to those skilled in the art. The present invention includes all such modifications and equivalents. The claims alone are intended to set forth the limits of the present invention. | The present invention is generally directed to protective coatings, especially those which are capable of being used to coat space vehicles and/or satellites. In one embodiment, the present invention relates to methyl, cyclopentyl, and/or cyclohexyl polysiloxane ceramer coatings. In another embodiment, the present invention relates to methods for preparing creamer compounds. | 2 |
BACKGROUND OF THE INVENTION
Hydrogen is emerging as one of the primary alternative fuels for the large scale replacement of gasoline and other fossil fuels via its use as automotive fuel or in fuel cells. However, hydrogen is a fuel with one of the lowest molecular weights and energy content among all available fuels. In fact, the hydrogen molecule has a molecular weight of about two atomic mass unit (2 a.m.u.) and the energy content in British Thermal Units (BTU) per standard cubic foot (scf) of about 300 BTU/scf. By comparison, gaseous hydrocarbons can have average molecular weights and energy content up to eight times these values, as in the case of acetylene.
These low values of weights and energy content have caused serious technological, logistic and financial problems which have prevented hydrogen from replacing fossil fuels on a large scale until now, such as:
1) The low average molecular weight implying in a low specific density prevents the automotive use of hydrogen in a compressed form because of insufficient range, or excessively large storage requirements. For instance, gasoline contains about 115,000 BTU per American gallon (g). As a result, the gasoline gallon equivalent of hydrogen is given by 115,000 BTU/300 BTU=383 scf. Therefore, the equivalent of a 20 g gasoline tank would require 7,666 standard cubic feet (scf) of hydrogen which is a prohibitive number of scf for storage in an ordinary car. 2) As proved by the automobiles built by the American auto maker GM, the German auto makers BMW and other car manufacturers, the achievement of a sufficient range for ordinary automotive use requires the liquefaction of hydrogen. By recalling that hydrogen liquefied at a temperature close to the absolute zero degree, it is evident that the liquefaction of hydrogen , its transportation in a liquefied form and the maintainment of such a liquid state in a car implies dramatic expenditures. It then follows that the current automotive use of hydrogen is much more expensive than gasoline. 3) The automotive use of liquid hydrogen is dangerous because of the possible transition of state from liquid to gas in the event of termination of electricity for cryogenic equipment or other malfunctions.
The use of hydrogen in fuel cells is also afflicted by the same problems which are inherent in the low specific density and energy output of conventional hydrogen.
This invention resolves the above problems for the use of hydrogen as a fuel by achieving a new form of hydrogen, called for reasons explained below MagH™ hydrogen fuel which possesses an average molecular weight and energy output bigger than those of conventional hydrogen.
This invention also implies the production of a new form of oxygen, called MagO™ oxygen which also possesses an average molecular weight and energy content much bigger than those of the conventional oxygen.
This invention also implies the production of a new form of oxygen, called MagO™ oxygen which also possesses specific density and energy content much bigger than those of the conventional oxygen.
Therefore, the combustion of MagH™ hydrogen fuel with MagO™ oxygen, whether for automotive use or for a fuel cell, implies a further dramatic reduction of storage tanks, an increase of the energy output, and a consequential reduction of costs.
A scientific notion of paramount importance for this invention is the new chemical species of magnecular clusters discovered by this inventor.
These magnecular clusters are stable clusters generally composed of individual atoms, parts of conventional molecules called dimers (or also radicals) and ordinary molecules under a new internal bond originating in the electric and magnetic polarizations of the orbits of at least some peripheral atomic electrons. There is a dominance of magnetic over electric polarizations.
These magnecular clusters are generally detected via macroscopic peaks in Gas Chromatographic Mass Spectrometric (GC-MS) equipment, which peaks result to be unknown following computer search among all known molecules, while having no signature under InfraRed Detectors (IRD) at the atomic weight of the MS peak. The latter occurrence establishes that the peak detected in the GC-MS cannot possibly be a molecules, particular for the case of large cluster with a weight of the order of hundreds of a.m.u. After eliminating valence bonds, the only remaining possibility for explaining the internal attractive force holding the magnecular clusters together is that such forces are of magnetic and electric nature.
Additional experimental evidence has establish that the attractive bond responsible for the existence of the magnecular clusters originates from the property well established in contemporary science, according to which, when an atom is exposed to a sufficiently strong external magnetic field, the orbitals of its peripheral electrons cannot any longer be distributed in all space directions, and must acquire a toroidal distribution, with consequential creation of a new magnetic dipole moment North-South caused by the rotation of the electron charges in said toroid, which dipole is evidently aligned along the symmetry axes of said toroidal distribution in such a way to have magnetic polarities opposite to the external ones, as illustrated in FIG. 1 .
Atoms, dimers or molecules with toroidal polarization of the orbitals then bond to each other in chains of opposing polarities North-South-North-South- . . . , resulting in the indicated formation of magnecules schematically illustrated in FIG. 2 .
Note that such a toroidal polarization of the orbitals of peripheral atomic electrons creates a magnetic field which is not generally detectable in the conventional space distribution of said orbitals. Simple calculations show that such a field is quite strong since it is generally of the order of 1,415 times the value of the intrinsic magnetic field of the nuclei. As a result, the toroidal polarization of the orbitals of peripheral; atomic electrons creates indeed a new field sufficiently strong to originate a new chemical species.
It should also be noted that the magnetic polarization of an atom also implies the polarization of the intrinsic magnetic moments of electrons and of nuclei. As a result, the magnetic bond between polarized atoms can be composed by three separate attractive forces among opposite polarities originating from the magnetic moments of orbitals, electrons and nuclei, as also illustrated in FIGS. 1 and 2 .
Said magnetic polarizations are individually unstable, because the conventional distribution of the orbitals in all directions in space is reacquired due to rotations caused by temperature as soon as the external magnetic field is terminated. However, the coupling via opposing magnetic polarities of two or more atoms is instead stable because, when the external magnetic field is removed, rotations due to temperature apply to the bonded atoms as a whole and not to the individual atoms. As a result, the clusters are stable at ordinary atmospheric temperatures and pressures.
The above joint stability for coupled magnetic polarization does occur for individual or coupled electric polarizations, as well known. In fact, electric polarizations are essentially reducible to ellipsoidical deformations of orbitals with consequential predominance of one change at one end and the opposite charge at the other end. Whether individual or coupled, such ellipsoidical deformations are evidently terminated by collisions, rotations and other effects due to temperature, and this explains the dominance of magnetic over electric polarizations.
Recall that all magnetic effects are known to cease at a temperature called the Curie Temperature. This is also the case for magnecules which decompose at a certain temperature varying from substance to substance, which temperature is generally of the order of the combustion temperature.
An important feature of the magnecular cluster is that said magnetic polarization occurs in individual atoms rather than in molecules as a whole. This implies that this new chemical species can be formed for all possible gases irrespective of whether they are paramagnetic or diamagnetic.
In fact, the hydrogen molecule H 2 is known to be diamagnetic, namely, clear experimental evidence has established that, when exposed to a magnetic field as strong as desired, the hydrogen molecule does not acquire a total net magnetic polarization North-South. However, by no means this property prevents magnetic polarizations of each individual atom H of the H 2 molecules, which polarizations can then individually bond atom to atom, rather than molecule to molecule, and form in this way the magnecular clusters.
Extensive studies have established that, when subjected to an external magnetic field at absolute zero degree temperature, the hydrogen molecule performs the transition from a spherical distribution of radius equal to the H diameter to a plane distribution in which the rotations of the bonded valence pair in the two atoms are opposite to each other, as illustrated in FIG. 3 . This implies that a fully polarized H 2 molecule is composed by two fully polarized H atom with opposite directions of the polarizations. Due to the very small distances of their symmetry axes, which is of the order of 10-8 cm, opposite adjacent polarizations cancel each other, resulting in said diamagnetic character of the H 2 molecule. The point however persists that each individual polarized H atom of an H 2 molecule can indeed bond to another polarized H atom, as illustrated in FIG. 2 .
The above problem does not exist for the oxygen molecules O 2 which is known to be paramagnetic, thus capable of acquiring a total net magnetic polarity. However, the magnetic field used in this invention exist at the specific level of each individual atoms. Therefore, whether for the hydrogen or the oxygen molecules, a central objective remains that of achieving a magnetic polarization of the individual atoms irrespective of whether the complete molecule is paramagnetic or not.
It is evident that the new chemical species of magnecular clusters implies an increase of the specific weight of any gas, thus including hydrogen and oxygen. In fact, by denoting the valence bond with the symbol—and the magnetic bond with the symbol x, it is evident that the creation of an essentially pure population of magnecular clusters with the structures (H—H)xH, (H—H)x(H—H), (H—H)x(H—H)xH, etc., have respective molecular weights of the order of 3, 4, 5, etc., while the conventional molecular structure H 2 can only have a molecular weight close to 2, as recalled earlier.
It is then evident that the increase of the average molecular weight of the gas, say, of the order of 5 implies a reduction of tank capacities by ⅕ because each cluster in a gas, whether under a valence or magnetic bond, acts as a single entity for pressure, temperature, etc. It then follows that the required 7,666 scf of H 2 for the equivalent of 20 gasoline gallons are reduced in the preceding example to about 1,500 scf which can be easily accommodated in an ordinary tank of about 3.5 scf in volume at about 4,000 pounds per square inch (psi).
It should be stressed that a 5 time increase of the molecular weight of the hydrogen directly implies that its energy content is increased 5 folds, from then original 300 BTU/scf to 1,500 BTU/scf. Alternatively, a first empirical way to verify the achievement of a magnecular structure is that of measuring the BTU content of the gas considered per scf because any increase over conventional values is a general indication of the achievement of a magnecular structure.
As one can see, the creation of hydrogen with a magnecular structure completely eliminates the need for its liquefaction in automotive and other uses because of the achievement of essentially the same range permitted by gasoline via the use of commercially available pressure tanks essentially of the same size as those of gasoline tanks.
A primary objective of this invention is therefore that of achieving the new chemical species of MagH™ hydrogen fuel with an average molecular weight of about 10. a.m.u.
A fully similar situation occurs for oxygen. In fact, the conventional molecule O 2 =O—O has a molecular weight of 32 a.m.u. while clusters (O—O)xO, (O—O)x(O—O), (O—O)x(O—O)xO, etc. have corresponding molecular weights of 48, 64, 80, etc. In this case too the creation of a magnecular structure of the oxygen reduces its storage size by ⅕-th.
Another primary objective of this invention is, therefore, the creation of MagO™ oxygen with an average molecular weight which is at least a multiple that of O 2 , with a corresponding increase of the BTU content. Another important feature of magnecular structures is that they imply an increase of the energy release in thermochemical reactions generally bigger than the increase due to the increased molecular weight. This important feature is due to the following three primary aspects:
i) The presence in magnecular clusters of individual uncoupled atoms, as established by ample experimental evidence, which atoms combine at the time of the combustion, thus releasing energy. For instance, the presence of isolated H atom in a hydrogen magnecular cluster implies the esoenergetic reaction at the time of its combustion H +H→H 2 which releases 104 Kilo calories (Kcal) per mole. It is evident that this additional energy release is completely absent in a conventional molecular structure.
ii) Polarized atoms release energy in their thermochemical reactions in amount greater than that released by unpolarized atoms. Consider, for instance, the water molecule H 2 O=H—O—H where the individual H—O and O—H dimer have the characteristic angle of 104 degrees. As it is well known, the orbitals of the two dimers H—O and O—H have a distribution which is perpendicular to the plane of the molecule H—O—H, as illustrated in FIG. 4 . This implies that, in order to become part of the water molecule, an H atom must necessarily reduce its space distribution to a toroidal one, precisely as needed for this invention. It then follows that a polarized H atom require less energy to couple with the oxygen, or, more generally, the reaction H 2 +O 2 /2−H—O—H, when occurring among magnetically polarized atoms releases more than the conventional value of 57 Kcal/mole. The excess energy is spent by nature precisely for the removal of the space distributions of the orbitals.
iii) Magnetically polarized diatomic molecules with atoms possessing valence and non-valence electrons acquire new internal bonds due to the magnetic polarization of the internal non-valence electrons, with consequential additional energy storage. This feature has been proven for the case of the CO molecule (that with conventional triple valence bonds) exposed to intense magnetic field which shows under scans with IRD the presence of two new peaks which evidently characterize new bonds besides those characterized by conventional valence bonds. Since all available valence bonds are used in the CO molecule, the new bonds can only be explained with the toroidal polarization of the internal non-valence electrons resulting in new internal magnetic bonds North-South-North-South, as illustrated in FIG. 5 . Since every bond of atoms implies an energy storage, it is evident that this third feature implies a third additional means for combustible gas with magnecular structure to have excess energy content.
It is then evident that the combustion of MagH™ hydrogen and MagO™ oxygen releases more energy than the combustion of conventional H and O gases, particularly when all three of the above features i), ii) and iii) are accomplished. Another important objective of this invention is therefore that of achieving magnetic polarizations sufficiently strong to caused said three features.
It is also evident that the same principle outlined above also apply for any other gas, and not necessarily to H and O gases only. In fact, the processing with the apparatus of this invention of any gaseous fossil fuel permits the increase of its molecular weight as well as of its energy output, thus permitting a consequential decrease of storage tanks, increase of performance and decrease of costs.
It should be indicated that the H 3 structure has already been detected in various GC-MS tests, although the structure is generally believed to be due to some form of valence bond. In depth studies have established that a triple valence bond would imply the violation of Pauli's exclusion principle (and other physical laws). In fact, the valence interpretation of the H 3 bond would imply the bond of a third electron to a pre-existing valence pair, resulting in the existence of at least two electrons with the same quantum numbers in the same energy level, an occurrence which would be a clear violation of Pauli's exclusion principle.
This and other violations of fundamental physical laws can be resolved with the interpretation that H 3 has the magnecular structure (H—H)xH. In this case only two electrons are bonded into a pair with the same energy although antiparallel spins as requested for singlet valence couplings, while the electron of the third H atom is magnetically bonded to one of the other two H atoms, thus being in an energy state different than that of the preceding valence pair with consequential lack of applicability of Pauli's exclusion principle.
Consider now the oxygen in which the O 3 molecule has been detected long ago and called ozone. In this case the O 2 molecule possesses free electrons for possible additional bonds into O 3 . Nevertheless, studies have revealed that at least one realization of O 3 has the magnecular structure (O—O)xO with internal coupling similar to those of the magnecular cluster H 3 =(H—H)-xH. This is again due to the fact that valence has been historically established solely for the correlation-coupling of two electrons. The addition of a third electron in the valence couplings generally violates Pauli's exclusion principle and other physical laws which prevent the existence of any possible triple valence bond.
It is evident that the experimental detection of H 3 and O 3 provides major credibility for the creation in this invention of H and O magnecular clusters with a molecular weight greater than 3.
The terminology described in this invention can be defined as follows: magnecular clusters are stable clusters of individual atoms, dimers and molecules bonded together by the attraction between opposite polarities of the toroidal polarization of the orbits of peripheral atomic electrons; “specific density” is the density of a conventional gas composed by the same molecules measured in atomic mass units (a.m.u.) per standard cubic feet (scf); “average specific density” is the density of a gas with magnecular structure, thus having generally different cluster constituents when measured also in a.m.u./scf; the “energy content” is the heat produced by one standard cubic feet (scf) of a combustible gas when measured in British Thermal Units (BTU); an “apparatus” is, for this invention, an equipment permitting the industrial production of gases with magnecular structure; a “piping system” is a set of interconnected pipes permitting a common flow; “electrodes” are a pair of conductors permitting an arc between a gap at their tip; “gas” is referred to a substance which is at the gaseous state when at room temperature and pressure; a “vapor” is referred to a substance which is liquid at room temperature but which acquires its gaseous phase at a sufficiently high temperature; a “gaseous hydrocarbon” is a combustible gas whose chemical composition is that of hydrocarbons, such as natural gas, methane, acetylene; a “slit”, also called in this invention a “Venturi” is a restriction in the flow of a gas with a rectangular sectional area and a minimal width; all other definitions of “electric current”, “pressure”, “volume”, etc. are standard.
SUMMARY OF THE INVENTION
One embodiment of the invention is an apparatus and method for increasing a molecular weight and an energy content of a gas comprising providing a pressure resistant piping system equipped with means for closing and opening said piping system, the means typically being valves; providing means for filling up said piping system with a gas and means for compressing said gas to a desired pressure; providing at least one pair of electrodes placed within said piping system and capable of delivering an electric arc within an interior of the piping system; providing means for delivering an electric power to each of said at least one pair of electrodes; providing means for recirculating said gas through said electric arc; providing means for collecting a resultant processed gas; and filling said piping system with the gas, recirculating the gas through the electric arc generated by the at least one pair of electrodes and collecting the resultant processed gas, wherein the resulting processed gas has an average molecular weight and an energy content bigger than corresponding values of the gas originally first filled into the piping system.
In this embodiment, the electric current of said arc is continuous, alternating or pulsing. The gas can be hydrogen, oxygen, a non-combustible or inert gas, a gaseous hydrocarbon fuel or a liquid vapor. The flow of the gas is preferably restricted with means for restricting the flow of said gas along a slit surrounding said arc.
A still other embodiment is an apparatus and method for increasing a molecular weight and an energy content of a gas comprising providing a pressure resistant piping system equipped with means for closing and opening said piping system; providing means for filling up said piping system with a gas and means for compressing said gas to a desired pressure; providing at least one solenoid acting on a tube or capillary tube in line with said piping system; providing means for delivering an electric current to said at least one solenoid; providing means for cooling said solenoid; providing means for recirculating said gas through said tube; providing means for collecting a resultant processed gas; and filling said piping system with the gas to be processed, compressing said gas to the desired pressure, subjecting said gas to the current of the at least one solenoid acting on the tube while the gas is being recirculated through said tube and with the cooling means activated, and collecting said resultant processed gas, wherein a resulting processed gas has a molecular weight and an energy content bigger than corresponding values of the gas first filled into the piping system.
In this embodiment, the electric current of said solenoid is continuous, alternating or pulsing. The gas may be hydrogen, a non-combustible or inert gas, a gaseous hydrocarbon fuel, or a liquid vapor. A number of solenoids may be placed in series and a number of solenoids may be placed in parallel within the piping system.
The invention also deals with apparatus and a method for producing a hydrogen gas with an increased molecular weight and an increased energy content comprising providing a pressure resistant vessel filled up with a liquid feedstock rich in hydrogen; providing at least one pair of electrodes placed in such a way to create a submerged electric arc; providing means for delivering an electric power to said at least one pair of electrodes; providing means for collecting a combustible gas produced by said submerged electric arc; providing means for separating a hydrogen content of said combustible gas, the hydrogen content comprising the produced hydrogen gas; and subjecting the liquid feedstock to the submerged electric arc, collecting the combustible gas, and separating the hydrogen content of the combustible gas produced to obtain the resultant processed hydrogen gas, wherein the resultant processed hydrogen gas has a molecular weight and energy content greater than a corresponding value for conventional hydrogen gas.
The produced hydrogen gas can be separated from the combustible gas with filtration means or with means for cryogenically liquefaction of remaining components.
Another embodiment of the invention is an apparatus and method for increasing the voltage, power and efficiency of a fuel cell comprising operating a fuel cell with a processed gas which has a molecular weight and an energy content bigger than corresponding values of an original gas prior to being processed. The processed gas is made by recirculating the original gas in a pressure resistant piping system, by compressing said original gas to a desired pressure, and by subjecting the recirculated original gas to generated electric arcs created by at least one pair of electrodes within an interior of the piping system. The original gas is one of hydrogen and oxygen. The processed gas is MagH™ hydrogen fuel when hydrogen is the original gas and MagO™ oxygen gas when oxygen is the original gas.
Another embodiment is an apparatus and method of operating an internal combustion engine with a decreased need for atmospheric oxygen comprising operating the engine with a processed fuel made from a processed hydrogen gas, the processed hydrogen gas having a specific weight and energy content greater than a corresponding value for conventional hydrogen gas. The processed hydrogen gas is made by filling a pressure resistant vessel with a liquid feedstock rich in hydrogen, by subjecting said feedstock to submerged electric arcs between at least one pair of electrodes, by collecting a combustible gas produced by a thermochemical reaction of the electric arcs on the feedstock, and by separating the processed hydrogen gas from said combustible gas.
The processed hydrogen gas is separated with filtration means. The processed hydrogen gas may also be separated using means for cryogenically liquefaction of remaining components. The processed fuel also includes the processed hydrogen gas in the presence of carbon and oxygen, and the processed hydrogen is the magnecular cluster form of hydrogen fuel.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 depicts the toroidal distribution of the orbits of atomic electrons under a strong external magnetic field;
FIG. 2 depicts the bonding of magnetically polarized atoms to each other via opposite magnetic polarities;
FIG. 3 depicts the polarization of a hydrogen molecules with opposite magnetic moments in the two atoms;
FIG. 4 depicts the water molecule with the orbits of valence electron pairs and their opposite rotations in different coupled atoms;
FIG. 5 depicts new internal magnetic bonds in diatomic molecules;
FIG. 6 depicts the strong magnetic field at atomic distances from an electric arc;
FIG. 7 depicts a typical application of a preferred embodiment of this invention;
FIG. 8 depicts a Venturi restricting the flow of a gas through an electric arc;
FIG. 9 depicts a superconducting supercooled solenoid;
FIG. 10 depicts an alternative embodiment of this invention for the production of a hydrogen gas with magnecular structure obtained via filtration;
FIG. 11 depicts an alternative embodiment of this invention for the production of a hydrogen gas with magnecular structure obtained via liquefaction;
FIG. 12 depicts the voltage increase in a fuel cell via the use of oxygen with magnecular structure;
FIG. 13 depicts the power increase in a fuel cell via the use of oxygen with magnecular structure;
FIG. 14 depicts the efficiency increase in a fuel cell via the use of oxygen with magnecular structure;
FIG. 15 depicts the results of analytic measurements of hydrogen with a magnecular structure; and
FIG. 16 depicts mass spectrometric measurements of the same gas depicted in FIG. 15 .
DETAILED DESCRIPTION OF THE INVENTION
As indicated earlier, the magnetic polarization of the orbitals of peripheral atomic electrons requires extremely strong magnetic fields of the order of billions or trillions of Oersteds which are simply not possible with current technologies in large scale, that is at distances of the order of inches or feet, even with the use of superconducting solenoids cooled with the best available cryogenic technologies.
As an illustration, the intensity of the magnetic fields needed to create an industrially meaningful magnetic polarization is of the order of a million times bigger than the most powerful magnets available in a U.S. National Magnetic Laboratory, in Tallahassee, Fla.
The only possible, industrially useful means of achieving magnetic fields of the needed very high intensity are those based on large direct current (DC) measured in Amperes (A) when considered at atomic distances. In fact, with respect to FIG. 6 the magnetic field created by a rectilinear conductor with current I at a radial distance r is given by the law B=kI/r, where the constant k in absolute electromagnetic unit is 1. It then follows that, for current in the range of 10 3 and distances of the order of the size of atoms r=10 −8 cm, the intensity of the magnetic fields H is of the order of 10 13 Oersted, thus having intensity values fully sufficient to cause the magnetic polarization of the orbitals of peripheral atomic electrons.
The main principle of this invention is therefore that of achieving the magnetic polarization of the orbits of peripheral atomic electrons by flowing gases through electric currents as technologically possible. This principle can be best realized by recirculating the gas through one or more electric arcs. The efficiency of the equipment then depends on the achievement of a sufficiently high Amperes as well as of a sufficiently high operating pressure. The achievement of an essentially pure population of a magnecular structure of a given gas with the desired molecular weight then requires its recirculation through said electric arc for a period of time depending on the selected gas, the selected current and the selected operating density.
In fact, under the above conditions schematically represented in FIG. 6 , atoms with the toroidal polarization of their orbitals find themselves aligned one next to the other with opposing polarities. Therefore, the latter attract each other, thus forming the magnecular clusters. The flow of the gas through the electric arc then removes the the magnecular clusters immediately following their creation. The electric arc decomposes the original molecule, thus permitting the presence of isolated atoms in the magnecular structure as needed to increase the energy output.
In this way, the process transforms the original gas with its conventional molecular structure into a new chemical species consisting of individual atoms, dimers and complete molecules all bonded together by the magnetic polarization of their peripheral atomic electrons.
In the event the original gas has a simple diatomic molecular structure, such as H 2 , the magnecular clusters are composed of individual polarized H atom and ordinary polarized molecules H 2 as in FIG. 2 . In the event the original gas has the more complex diatomic structure, the magnecular clusters are composed of individual polarized O atoms, OO single bonds, and O 2 molecules with additional internal bonds as in FIG. 5 . In the event the original gas has the more complex diatomic structure CO, the magnecular clusters are more complex and are generally composed of individual atoms C and O, single and double bond C—O, and conventional molecules CO and O 2 with internal new bonds. Original gases with more complex conventional molecular structure evidently imply more complex magnecular clusters with all possible internal atomic arrangements.
It is also evident that, after completing the processing in the apparatus of this invention, the resulting new species is not composed of all identical magnecular clusters, as it is the case for molecules, but instead of a variety of magnecular clusters from a minimum to a maximum number of atomic components. The molecular weight of the magnecular gas is then given by the average molecular weight of all different magnecular clusters.
A first preferred embodiment of this invention is depicted in FIG. 7 and comprises: one, two or several pairs of positively and negatively charged electrodes 1 and 2 , 3 and 4 , here assumed to be composed of tungsten rods of ½″ outside diameter and 3″ in length with tip configuration depicted in FIG. 8 as described below; commercially available DC power units of 50 Kwh (not shown in the drawings for simplicity), one per each electrode pair; a pipe system 5 typically of ½″ internal diameter and ¾″ outside diameter composed of a diamagnetic metal or other nonconducting material suitable to withstand an internal pressure of least 4, 500 psi; said electrode pairs are placed as a fixed part of piping system 5 via pressure resistant seals 16 in such a way to create the biggest possible gaps 19 , permitted by the selected 50 Kwh power unit and the selected gas at the selected operating pressure, which gap, for the case of hydrogen and oxygen (gas 14 ) at the selected operating features is of the order of ½″; four on-off high pressure valves 6 , 7 , 8 , 9 at the indicated locations; three high pressure pumps 10 , 11 , and 12 ; two tanks 13 , 15 of at least one scf each capable of withstanding at least 4,500 psi and located in line with piping system 5 ; and two commercially available high pressure gas cylinders 17 , 18 connected as shown in the piping system 5 .
FIG. 8 depicts the sectional view of the equipment at the axial line of electrodes pair 1 and 2 , showing: the ½″ by ¾″ pipe 5 ; seals 16 for the high pressure assembly of electrodes 1 and 2 in the piping system 5 ; the ½″ electrode gap 19 ; the ½″ long DC electric arc 20 ; and restriction 80 (also called Venturi) which restricted the flow through arc 20 from the ½″ circular sectional area to a rectangular area surrounding the electric arc 20 for a sectional area of about ½″ in length and 1/16″ in width 81 .
The operations of this first preferred embodiment is as follows. The operation initiate with valve 6 closed and all valves 7 , 8 , 9 open after which a high vacuum is pumped out of the piping system 5 including tank 15 . Then, valve 9 is closed to isolated tank 15 ; tank 13 filled up with the desired gas at 4,500 psi is connected to the system; valve 6 is open so as to fill up the entire system at which point the pressure is equalized everywhere; pump 10 is then operated to empty the content of tank 13 into the piping system 5 and related storage tanks 17 and 18 . At that point, valve 6 is closed; the DC current is sent to all electrode pairs, thus establishing arcs 20 , 21 ; finally, pump 11 is activated for the desired duration of time, generally being of at least one hour.
According to the above apparatus, the selected gas is continuously flown by pump 11 through Venturis 80 in the immediate longitudinal vicinity of DC electric arcs 20 , 21 , by therefore exposing said gas to the DC electric arc according to the main principle of this invention. Assuming that the 50 Kwh power unit has 25% loss in the AC-DC rectification, the equipment has 37.5 Kwh of DC electric power available at each arc. Since another principle of this invention is the maximization of the electric current, the arc is operated at about 37 V, thus permitting 1,000 A in each arc. These operating features can be continuously supported by tungsten electrodes. The continuous recirculation of the gas through Venturis 80 for one hour has the following implications: by exposing the atoms to the extreme magnetic fields in the immediate vicinity of the arc, thus polarizing their electron orbits into toroid; aligned polarized atoms as in FIG. 5 bond to each others; and there is the consequential formation of magnecular clusters with the resulting achievement of the desired increase of the molecular weight and energy content as illustrated in the experimental evidence outlined below.
The increase in the molecular weight and energy content can be achieved in a number of ways, such as: the use of the above described equipment for several hours, e.g., for one full day; the use of AC-DC rectifiers with power much bigger than 50 Kwh; the use of pulse DC power units; the use of a large number of pairs of electrodes sequentially exposed to the same gas flow; a capillary restriction 81 around the electric arcs; and other means, as well as any of their combinations.
Another embodiment is depicted in FIG. 9 consisting of the equipment of FIG. 7 in which the DC electric arc between electrodes is replaced by superconducting solenoid 200 with capillary or tube internal diameter 201 equipped with an adequate cooling systems is schematically represented by vessel 203 with inlet 205 and outlet 206 encompassing the entire solenoid 200 and is filled up by a flowing coolant 204 , such as liquid nitrogen.
The difference between the embodiment of FIG. 9 and that of FIG. 7 is the following. The latter embodiment acts according to the circular configuration of the magnetic field of FIG. 6 , while the former embodiment acts according to a linear configuration of the magnetic field along the symmetry axis of the solenoid with intensity B=nI/r, where n is the number of turns, I is the current in Amps and r is the radius of said tube 201 . It is evident that the linear alignment of magnetically polarized atoms along the direction of its flow favors the creation of magnecular clusters as compared to the circular alignment of FIG. 6 , particularly when the equipment is operated, for instance, at pulses of 50,000 A with a radius of tube 201 of 10 −5 mm.
However, the selection of the preferred equipment depends on the specific needs. For instance, the embodiment of FIG. 9 cannot breakdown the original molecules, thus forming the magnecular clusters essentially composed of molecules with individual polarized atoms. By comparison, the electric arc of the apparatus depicted in FIG. 7 does indeed separate conventional molecules, thus forming magnecular clusters, which generally contains atoms, dimers and molecules.
Needless to say, the embodiment of FIG. 9 can be improved in a variety of ways, e.g., by having several embodiments of the same type connected in series to increase the magnecular structure, all various series being connected in parallel to increase the production. These series and parallel configurations are not indicated in the drawing because quite elementary and definitely known to skilled in the art.
The use of the MagH™ hydrogen fuel and MagO™ oxygen produced by the above embodiments is evidently multifold and include as representative examples without limitations: use of the magnecular clusters of hydrogen fuel and oxygen in fuel cells; use of the magnecular clusters of hydrogen fuel as fuel for internal combustion engines; use of the magnecular clusters of hydrogen fuel as fuel for electric generators; use of the magnecular clusters of hydrogen fuel and oxygen in their liquefied form as fuels for rockets.
In all cases the advantages in the use of the magnecular clusters of hydrogen fuel and oxygen over the use of conventional gases are numerous. For instance, the use of the magnecular clusters of hydrogen fuel and oxygen as liquefied rocket fuel implies: 1) a reduced cost of liquefaction, evidently due to the increases in molecular weight and other factors; 2) an increased energy output; and 3) an increase of the payload or, equivalently, a decrease of the fuel for the same payload. All these advantages evidently depend on the achieved degrees of magnecular structure.
It should be indicated that the apparatus above described is also applicable to conventional gaseous hydrocarbon, such as natural gas, methane, acetylene, etc. In fact, the equipment of this invention can also be filled up with any of these gaseous hydrocarbons and reach the same results, such as an increase of the molecular weight and energy. Moreover, it should be noted that, in this particular case, the electric arc breaks down the polymer chains of hydrocarbons (C—H 2 )—(C—H2)—(C—H 2 )— . . . and rearranges then into magnecular clusters (C—H 2 )x (C—H)xHx(C—H 2 )x(C—H 2 )x with the environmental major advantage of turning the original polluting fuels into a clean burning fuel.
It should be finally indicated that this invention is equally applicable to noncombustible gases, such as helium, nitrogen, argon, etc. in which case the dominant advantage is evidently the increase of molecular weight with consequential decrease of storage volumes, and related logistic advantages. It should be noted that, even though non-combustible, these gases can also store energy via the internal magnetic bonds of the type depicted in FIG. 5 , which energy is evidently released under the form of heat whenever the magnecular structure is removed.
Another embodiment for the production of gases with the desired magnecular structure is given by known means for the production of a combustible gas via electric arcs operating within water or other liquids, and then the separation of a desired gas from said combustible gas via filtering, cryogenic liquefaction or other means. A first embodiment of this type is depicted in FIG. 10 and comprises: carbon-base electrodes 301 and 302 submerged within a liquid 304 which is contained in a pressure vessel 303 with removable lid 305 , said electrodes 301 and 302 being housed in copper holders 306 and 307 which protrude outside of vessel 303 and lid 305 through seals not shown in the figure for simplicity, but which are well known to skilled in the art.
The activation of a DC electric arc within a selected liquid decomposes its molecules and creates a combustible gas with a magnecular structure, as now well established. Said combustible gas exits vessel 303 through opening 308 and then passes through high pressure pipes into a metal container 309 in which there is a special filter 310 selected in such a way to remove the unwanted part of said combustible gas. The remaining gas is released through outlet pipe 311 for collection.
As an example, underwater electric arcs produce a combustible gas which, as far as the atomic percentage is concerned, is composed of 50% H, 25% O and 25% C. These atoms are then combined into magnecular clusters generally composed of H, C and O individual atoms, HO, CH and C—O dimers with one single valence bond, and ordinary molecules of H 2 , CO, H 2 O and O 2 . Since hydrogen is the biggest component of the combustible gas, it can be effectively filtered with various means, resulting in magnecular clusters of hydrogen. In fact, experimental evidence has establishes that magnecular clusters survive filtering.
Numerous micrometric filtering systems 310 are currently available. As an indication without un-necessary limitations, a filtering system recommendable for the separation of in magnecular clusters of hydrogen is given by a 5 Armstrong zeolite consisting of a microporous molecular sieve, which essentially selects a gas via “molecular sieving,” or molecular size exclusion. After a number of hours of operation depending on the DC power unit, the operating pressure and the size of the zeolite filter, the latter is replaced as part of routine service.
An alternative embodiment is depicted in FIG. 11 and essentially consists of the same embodiment of FIG. 10 for the production of a combustible gas via an electric arc submerged within a liquid, plus: a serpentine 312 in which the combustible gas is passed following its exit from vessel 303 through outlet 308 ; a vessel 313 containing said serpentine 312 ; a coolant 318 filling up said vessel 313 ; valves 317 and 314 ; plus outlet 316 for the a liquefied portion of the gas and outlet 315 for its remaining non-liquefied gaseous component.
To illustrate the operation of the alternative embodiment of FIG. 11 , suppose that liquid 304 is ordinary water. In this case, as indicated earlier, the combustible gas has a magnecular structure composed by H, C and O. By recalling that hydrogen liquefied very close to absolute zero degrees temperature, its separation from the combustible gas can be achieved by cooling the gas to about minus 70 degrees F., at which CO is liquefied. Said cooling can be achieved via the use of liquid nitrogen for coolant 318 or other liquid having the needed low temperature or any of the several, commercially available cryogenic equipment not shown in the figure because they are well known to skilled in the art. In this way, the liquefied component of the combustible gas exists at outlet 316 , while magnecular clusters of hydrogen fuel exits at outlet 315 . Valves 317 and 314 are used to optimize operations.
It is evident that the equipment of FIGS. 10 and 11 produce a form of magnecular clusters of hydrogen fuel and other clusters of gases less pure as compared to those produced via the equipment of FIGS. 7 , 8 , 9 , evidently because of impurities containing C and O atoms which should be expected in the production via the equipment of FIGS. 10 and 11 but not with those of FIGS. 7 , 8 , 9 . Therefore, the selection of the equipment depends, again, on the selected application. In fact, for automotive uses of magnecular clusters of hydrogen fuel as fuel for internal combustion engines the presence of C and O atoms is definitely desirable because such presence increases the energy content while decreasing the need of atmospheric oxygen. Therefore, the hydrogen fuel produced via the filtration or cryogenic cooling of the clusters of gases per the equipment of FIGS. 10 and 11 is definitely preferable for use as fuel for internal combustion engine as compared to the forms of hydrogen fuel produced via the equipment of FIGS. 7 , 8 , and 9 . On the contrary, the latter methods are preferable over the preceding ones for use of the process hydrogen fuel and oxygen in fuel cells since the purity of the final form of the process hydrogen fuel and oxygen is guaranteed by that of the original gas.
It is now important to review the experimental evidence on the main results of this invention. First, the inventor constructed an apparatus as per FIG. 7 by using for arcs the sparks produced by four automotive spark plugs placed in series on piping system 5 , said spark plugs being operated by a conventional coil by automotive battery with 12 V, 800 A. The equipment was operated at 15 psi. Two samples of oxygen which were produced, and denoted processed oxygen 1 and processed oxygen 2 , by passing them through said array of four sparks for 30 minutes.
The two samples were tested in lieu of ordinary oxygen in a 2-cell Proton Exchange Membrane (PEM) fuel cell with dimensions 7×11×11 cm, which cell was operated with conventional high purity hydrogen. The membrane material was Nafion 112; the catalyst in the electrodes was platinum acting on carbon; the plates for heat transfer were given by two nickel/gold plated plates; the temperature of the fuel cell was kept constant via ordinary cooling means; current was measured via a HP 6050AA electronic load with a 600 W load module; a flow rate for oxygen and hydrogen was assigned for each current measurement; both oxygen and hydrogen were humidified before entering the cell; the measurements reported herein were conducted at 30 degrees C.
The results of the measurements are summarized in FIGS. 12. 13 and 14 which report relative measurements compared to the same conditions of the cell when working with ordinary pure oxygen. As one can see, these measurements show a clear increase of the voltage, power and efficiency of the maximal order of 5% when the cell was operated with the processed oxygen. To appraise these results, one should note that the samples of the processed oxygen used in the test were reached via an equipment operated with an ordinary automotive battery, powering intermitted sparks as typically the case in automotive engines, and with the pressure limited to 15 psi. By comparison, the processed oxygen of this invention should be produced by an array of arcs each operated by 50 Kwh power unit, with continuous discharges at 1,000 A, the apparatus being operated at 4,500 psi. It is evident that the transition from the conditions of the test to those of this invention imply a significant increase of the performance of the fuel cells when operated with the processed oxygen. Moreover, bigger increases in voltage, power and efficiency are expected when a fuel cell is operated with both the processed oxygen and the processed hydrogen.
In summary, the systematic character of the results combined with the limited capabilities of the equipment confirm the capability of this invention of producing new forms of hydrogen and oxygen with magnecular structure with increase in voltage, power and efficiency of fuel cells with can be very conservatively estimated to be of the order of 20%.
Additional tests were conducted with the processed hydrogen produced with the equipment of FIGS. 10 and 11 . A clean burning combustible gas was first produced by using ordinary tap water as liquid feedstock. The combustible gas then passed through a 5 Armstrong zeolite filter as described above. The filtered gas, was then subjected to the following three measurements:
1) The average molecular weights of the processed hydrogen was measured by two independent laboratories which issued written statements that this particular form of processed hydrogen has an average molecular weight of 15.06 a.m.u., while conventional pure hydrogen has the molecular weight of 2.016, thus implying a 7.47 fold increase over the molecular weight of conventional hydrogen.
2) This type of processed hydrogen was then subjected to analytic measurements by a qualified laboratory via Gas Chromatography (CG) and Fourier transform infrared spectroscopy (FTIR). All measurements were normalized, air contamination was removed, and the lower detection limits were 0.01%. The results are reported in FIG. 15 . As one can see, these measurements indicate that this particular type of processed hydrogen was composed of 99.2% hydrogen and 0.78% methane, while no carbon monoxide was detected.
3) The same type of processed hydrogen used in the preceding tests was submitted to Gas Chromatographic Mass Spectrometric (CG-MS) tests via the use of a HP GC 5890 and a HP MS 5972 with operating conditions specifically set for the detection of the cluster which are different than those for molecules, such as: a feeding line with the biggest possible section of 0.5 mm diameter was selected (to prevent that large magneclusters are not permitted to enter the instrument because of the use of a micrometric feeding line); the feeding line was cryogenic cooled; the operation of the columns at the lowest admitted temperature of 10 degrees C. (to prevent that the column temperature would disintegrate the magnecular clusters); the longest possible ramp time of 26 minutes was selected (to permit the separation of the peaks representing magnecular clusters); and other requirements. The results of this third test are reproduced in FIG. 16 . As one can see, by keeping in mind the results of GC-FTIR of FIG. 15 , the GC-MS measurements should have shown only two peaks, that for hydrogen and that for methane. On the contrary, these GC-MS tests do confirm indeed the existence of a large peak at about a molecular weight of 2 a.m.u. evidently representing hydrogen, but also the presence of a considerable number of additional peaks in macroscopic percentages all the way to a molecular weight of 18 a.m.u. It is evident that these latter peaks establish the existence of a magnecular structure in the type of magnecular cluster of hydrogen here studied. Note, in particular, the existence of well identified peaks in macroscopic percentage with atomic weight of 3, 4, 5, 6, 7, 8 and higher value which, for the gas under consideration here, can only be explained as magnecules cluster composed of individual H atoms as well as H molecules in increasing numbers.
It is evident that the above measurements 1), 2) and 3) confirm in a final form the capability by this invention to produce hydrogen, oxygen and other gases with a large multiple value of their standard specific density, and consequential increase of their energy content per cubic foot. | Apparatus and method for the industrial production of a new form of hydrogen, oxygen and other gases. The invention includes a pressure resistant piping system filled with a gas compressed to a desired pressure. A magnetic field within the piping system is generated using electric power. The gas is circulated through the electric arc causing the magnetic field. | 2 |
[0001] This is a Rule 53b Continuation application of Ser. No. 10/194,687 filed Jul. 24,2002 which is a Rule 53b Divisional application of Ser. No. 09/583,168 filed May 30, 2000 (issued on Mar. 18, 2003, U.S. Pat. No. 6,535,168), which is a Rule 53b Continuation application of Ser. No. 08/283,165 filed Aug. 3, 1994 which is abandoned, which is a Rule 62 Continuation application of Ser. No. 07/671,929 filed Mar. 20, 1991 which is abandoned.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a data processing apparatus provided with a display device.
[0004] 2. Description of the Prior Art
[0005] Among compact and lightweight microcomputers, portable type computers powered by batteries are now used extensively. Particularly, one of them known as a note-size computer is lighter in weight and smaller in size, yet provides equal capabilities to those of a desktop or laptop computer. The note-size computer powered by batteries is handy for use in a place where a power supply facility is rarely available, e.g. a meeting room or a lecture hall.
[0006] However, the disadvantage of such handy use is that the life of batteries is short and limited. When used to record a business meeting or a college lecture, the service duration of such a note-size computer with fully charged batteries is preferably 10 hours nonstop; more preferably, 20 to 30 hours. If possible, more than 100 hours—a standard of hand calculators—is most desired.
[0007] So far, the service operation of a commercially available note-size computer lasts 2 to 3 hours at best. This results in battery runout in the middle of a meeting or college lecture causing an interruption during input work. As a result, troublesome replacement of batteries with new ones will be needed at considerable frequency.
[0008] Such a drawback of the note-size computer tends to offset the portability in spite of its light weight and compactness.
[0009] It is understood that known pocket-type portable data processing apparatuses including hand calculators and electronic notebooks are much slower in processing speeds than common microcomputers and thus, exhibit less power requirements. They are capable of servicing for years with the use of a common primary cell(s) of which life will thus be no matter of concern. The note-size computer, however, has a processing speed as high as that of a desktop computer and consumes a considerable amount of electric energy-namely, 10 to 1000 times the power consumption of any pocket-type portable data processing apparatus. Even with the application of up-to-date high quality rechargeable batteries, the serving period will be 2 to 3 hours at maximum. This is far from a desired duration demanded by the users. For the purpose of compensating the short life of batteries, a number of techniques for energy saving have been developed and some are now in practical use.
[0010] The most well known technique will now be explained.
[0011] A “resume” function is widely used in a common note-size computer. It works in a manner that when no input action continues for a given period of time, the data needed for restarting the computer with corresponding information is saved in a nonvolatile IC memory and then, a CPU and a display are systematically turned off. For restart, a power switch is closed and the data stored in the IC memory is instantly retrieved for display of the preceding data provided before disconnection of the power supply. This technique is effective for extension of the battery servicing time and suitable in practical use.
[0012] However, a specified duration, e.g. 5 minutes, of no key entry results in de-energization of the entire system of the computer and thus, disappearance of display data. Accordingly, the operator loses information and his input action is interrupted. For reviewing the display data or continuing the input action, the power switch has to be turned on each time. This procedure is a nuisance for the operator. The resume technique is advantageous in saving energy of battery power but very disadvantageous in operability of the note-size computer.
[0013] More specifically, the foregoing technique incorporates as a means for energy saving a system which de-energizes all the components including a processing circuit and a display circuit. The operator is thus requested to turn on the power switch of the computer at considerable frequencies during intermittent data input action because each no data entry duration of a given length triggers automatic disconnection of the switch. In particular, the data input operation with a note-size computer is commonly intermittent and thus, the foregoing disadvantage will be much emphasized.
SUMMARY OF THE INVENTION
[0014] It is an object of the present invention to provide an improved data processing apparatus capable of substantially reducing power consumption while performing required data processing operations.
[0015] A data processing apparatus according to the present invention comprises: a data input unit for input of external data; a first processing unit for processing the data inputted through the data input unit; a second processing unit for processing the data inputted through the data input unit and/or an output data of the first processing unit; and a display unit for displaying an output data of the first and/or second processing units, wherein the display unit has a memory function for maintaining a display state without being energized, and the first processing unit has a means for actuating the second processing unit according to a timing or a kind of the input data.
[0016] For example, when no data entry continues, the second processing unit or the display unit is inactivated or decreased in clock rate thus diminishing power consumption. Also, the present invention allows the display of data to remain intact. Upon occurrence an input data, the first processing unit activates the second processing unit to process the data. Thus, the operator can prosecute his job without knowledge of an interrupted de-energization. As a result, an appreciable degree of energy saving is guaranteed without affecting the operability and thus, the service life of batteries will largely be increased.
[0017] In another aspect, the first processing unit may activate the second processing unit according to the kind of the input data. When the input data is such a data that requires a processing in the second processing unit, the first processing unit activates the second processing unit. The second processing unit, after completing a required operation or processing, may enter an inactive state by itself or may be forced into the inactive state by the first processing unit. Thus, the power consumption will be reduced to a considerable rate without affecting the operability.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a block diagram of a data processing apparatus showing a first embodiment of the present invention;
[0019] [0019]FIG. 2 is a timing chart;
[0020] [0020]FIG. 3 is a view showing the arrangement of a display unit;
[0021] [0021]FIG. 4 is a cross sectional view explaining the operating principle of the display unit;
[0022] FIGS. 5 ( a ) and 5 ( b ) are views showing displayed images on the display unit;
[0023] [0023]FIG. 6 is a flow chart;
[0024] [0024]FIG. 7- a is a block diagram showing an arrangement of components;
[0025] [0025]FIG. 7- b is a block diagram showing another arrangement;
[0026] [0026]FIG. 7- c is a block diagram showing a further arrangement;
[0027] [0027]FIG. 7- d is a flow chart;
[0028] [0028]FIG. 8( a ) through 8 ( f ) illustrate the operating principle of a reflective device with the use of different reflecting plates;
[0029] [0029]FIG. 9 is a block diagram showing a second embodiment of the present invention;
[0030] [0030]FIG. 10- a is a block diagram associated with a first processing unit;
[0031] [0031]FIG. 10- b is a block diagram associated with a second processing unit;
[0032] FIGS. 11 - a and 11 - b are flow charts:
[0033] [0033]FIG. 12 is a timing chart;
[0034] [0034]FIG. 13 is a view explaining the representation of a cursor;
[0035] [0035]FIG. 14 is a view showing a sequence of translation procedures;
[0036] [0036]FIG. 15 is a view explaining data insertion;
[0037] [0037]FIG. 16 is a view explaining a copy mode;
[0038] [0038]FIG. 17 is a block diagram showing a modification of the second embodiment;
[0039] [0039]FIG. 18 is a block diagram showing a third embodiment of the present invention;
[0040] [0040]FIG. 19 is a flow chart;
[0041] [0041]FIG. 20 is a block diagram showing a fourth embodiment of the present invention;
[0042] [0042]FIG. 21 is a timing chart of the fourth embodiment;
[0043] [0043]FIG. 22 is a block diagram showing a fifth embodiment of the present invention;
[0044] [0044]FIG. 23 is a timing chart of the fifth embodiment;
[0045] [0045]FIG. 24 is a block diagram showing a data input unit; and
[0046] [0046]FIG. 25 is a block diagram showing a combination of the first and second processing units.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] Preferred embodiments of the present invention will be described referring to the accompanying drawings.
[0048] Embodiment 1
[0049] [0049]FIG. 1 is a block diagram of a data processing apparatus showing a first embodiment of the present invention.
[0050] The data processing apparatus comprises a data input unit 3 , a first processing block 1 , a second processing block 98 , and a display block 99 .
[0051] In operation, a data input which is fed to the data input unit 3 of the data processing apparatus by means of key entry with a key-board or communications interface is transferred to the first processing block 1 in which a first processor 4 examines which key in key entry is pressed or what sorts of data are input from the outside and determines the subsequent procedure according to the information from a first memory 5 .
[0052] If no input is supplied to the data input unit 3 throughout a given period of time as shown in FIG. 2- a and also, the action of a second processor 7 has been completed, the feeding of clock signals to the second processor 7 and a display circuit 8 is halted by an interruption controller 6 and/or a process of energy saving is systematically executed.
[0053] The energy saving process will now be described referring to FIG. 2.
[0054] As shown in FIG. 2- a , a data input entered at t1 using an n-th key of the key-board is transferred from the data input unit 3 to the first processor 4 .
[0055] The first processor 4 when examining the data input and determining that further processing at the second processor 7 is needed delivers a start instruction via the interruption controller 6 and a start instruction line 80 to the second processor 7 which thus commences receiving the data input from the first processor 4 . The second processor 7 starts processing the data input when t=t3 as shown in FIG. 2- c and upon finishing, sends an end signal to the first processor 4 . In turn, either the first processor 4 or the interruption controller 6 delivers a stop instruction to the second processor 4 via the startup instruction line 80 . Accordingly, the second processor 4 transfers finally processed data from its RAM memory or register to the second memory for temporary storage and then, stops processing action when t=t5 as shown in FIG. 2- c or enters into an energy saving mode where a consuming power is sharply attenuated. After t5 where the actuation of the second processor 7 is ceased, the data remains held in the second memory 9 due to its nonvolatile properties or due to the action of a backup battery. If display change is needed, the second processor 4 sends a display change signal to the first processor 4 . The first processor 4 then delivers a display start instruction via a display start instruction line 81 to the display circuit 8 for starting actuation. When t=t4 as shown in FIG. 2- d , the command signal is transmitted to the display circuit 8 which in turn retrieves the data of a previous display text from a video memory 82 or the second memory 9 and displays a new image corresponding to the display change signal and data from the second processor 7 . When t=t6, the display circuit 8 sends its own instruction or an end signal via the interruption controller 6 to the first processor 4 and upon receiving an instruction from the first processor 4 , stops or diminishes clock generation to enter a display energy saving mode. Thereafter, the power consumption of the display circuit 8 will largely be declined as illustrated after t 6 in FIG. 2- d.
[0056] After t6, the display circuit 8 stays fully or nearly inactivated but a display 2 which is substantially consisted of memory retainable devices, e.g; ferroelectric liquid crystal devices, continues to hold the display image. The arrangement of the display 2 will now be described. The display 2 , e.g. a simple matrix type liquid crystal display, contains a matrix of electrodes in which horizontal drive lines 13 and vertical drive lines 14 coupled to a horizontal driver 11 and a vertical driver 12 respectively intersect each other, as best shown in FIG. 3. FIG. 4 illustrates a pixel of the display 2 in action with a voltage being applied.
[0057] In each pixel, a ferroelectric liquid crystal 17 is energized by the two, horizontal and vertical lines 13 , 14 which serve as electrodes and are provided on glass plates 15 and 16 respectively.
[0058] More particularly, FIG. 4- a shows a state where light is transmitted through. When a signal is given, the ferroelectric liquid crystal 17 changes its crystalline orientation and acts as a polarizer in which an angle of polarization is altered, thus allowing the light to pass through.
[0059] When a voltage is applied in the reverse direction, the ferroelectric liquid crystal 17 causes the angle of polarization to turn 90 degrees and inhibits the passage of light with polarization effects, as shown in FIG. 4- b . The ferroelectric liquid crystal 17 also has a memory retainable effect as being capable of remaining unchanged in the crystalline orientation after the supply of voltage is stopped, as shown in FIG. 4- c . Accordingly, throughout a duration from t=t6 to t=t14, explained later, the display remains intact without any operation of the display circuit 8 . While the energy saving mode is involved after t6, both the data input unit 3 and the first processor 4 are only in action.
[0060] The first processor 4 performs only conversion of key entry to letter code or the like. In general, the key entry is conducted by a human operator and executed some tens times in a second at best. The speed of data entry by a human operator is 100 times or more slower than the processing speed of any microcomputer. Hence, the processing speed of the first processor 4 may be as low as that of a known hand calculator and the power consumption will be decreased to hundredths or thousandths of one watt as compared with that of a main CPU in a desktop computer. As shown in FIG. 2- b , the first processor 4 continues operating while a power switch 20 of the data processing unit 1 is closed. However, it consumes a lesser amount of energy and thus, the power consumption of the apparatus will be low.
[0061] When n+1-th key entry is made at t11, the first processor 4 examines the data of the entry at t12 and if necessary, delivers a start instruction via the interruption controller 6 or directly to the second processor 7 for actuation. Upon receiving the start instruction, the second processor 7 starts processing again with the use of clock signals so that the data stored in the second memory 9 , i.e. data at a previous stop when t=t5, such as memory data, register information, or display data, is read out and the CPU environment when t=t5 can fully be restored. When t=t13, the data in the first processor 4 is transferred to the second processor 7 for reprocessing. The second processor 7 is arranged to operate at high speeds and its power consumption is as high as that of a desk-top computer. If the second processor 7 is continuously activated, the life of batteries will be shortened as well as in a known note computer. The present invention however provides a series of energy saving mode actions during the operation, whereby the energy consumption will be minimized.
[0062] The energy saving mode is advantageous. For example, the duration required for processing the data of a word processing software is commonly less than 1 ms while the key entry by a human operator takes several tens of milliseconds at maximum. Hence, although the peak of energy consumption during a period from t13 to t15 is fairly high in the second processor 7 as shown in FIG. 2- c , the average is not more than a tenth or a hundredth of the peak value. It is now understood that the energy saving mode allows lower power consumption.
[0063] When t=t14, the second processor 7 sends a desired portion of the display data to the display 2 . Before t14, the display 2 continues to display the text altered at t6 due to the memory effects of the ferroelectric liquid crystal 17 while the display circuit 8 remains inactivated. The desired data given through the key entry at t11 is written at t14 for regional replacement. The replacement of one to several lines of display text is executed by means of voltage application to corresponding numbers of the horizontal and vertical drive lines 13 and 14 . This procedure requires a shorter period of processing time and thus, consumes a lesser amount of energy as compared with replacement of the entire display text.
[0064] The second processor 7 then stops operation when t=t15 and enters into the energy saving mode again as shown in FIG. 2- c.
[0065] At the moment when the operation of the second processor 7 has been finished before t15 or when a stop instruction from the first processor 4 is received, the second processor 7 saves the latest data in the second memory 9 .
[0066] When t=t14, the second processor 7 stops operation or diminishes an operating speed and enters into the energy saving mode.
[0067] When the input data is fed at short intervals, e.g. at t21, t31, t41, and t51, through a series of key entry actions or from a communications port, the second processor 7 shifts to the energy saving mode at t23, t33, and t43 as shown in FIG. 2- c . If the first processor 4 detects that the interval between data inputs is shorter than a predetermined time, it delivers an energy saving mode stop instruction to the second processor 7 which thus remains activated without forced de-energization and no longer enters into the energy saving mode. The energy saving mode is called back only when the interval between two data inputs becomes sufficiently long.
[0068] Also, when the first processor 4 detects that the key entry is absent during a given length of time, it actuates to disconnect the power supply to primary components including the first processor 4 for shift to a power supply stop mode. The memory data is being saved by the back-up battery while the power supply is fully disconnected.
[0069] Before disconnection of the power supply, the first processor 4 however sends a power supply stop display instruction directly or via the second processor 7 to the display circuit 8 for display of an “OFF” sign 21 shown in FIG. 5- b and then, enters into the power supply stop mode. The OFF sign 21 remains displayed due to the memory effects of the display 2 after the power supply is disconnected, thus allowing the operator to distinguish the power supply stop mode from the energy saving mode.
[0070] In the energy saving mode, the operation can be started again by key entry action and thus, the operator will perceive no interruption in the processing action.
[0071] In the power supply stop mode, the OFF sign 21 is displayed and the operator can restart the operation in succession with the previous data retrieved from the second memory 9 by the second processor 9 when the power switch 20 is turned on. This procedure is similar to that in the conventional “resume” mode.
[0072] The foregoing operation will now be described in more detail referring to a flow chart of FIG. 6. When the power switch 20 is turned on at Step 101 , the first processor 4 starts activating at Step 102 . The input data given by key entry is transferred from the data input unit 3 to the first processor 4 at Step 103 . At Step 104 , it is examined whether the duration of no-data entry lasts for a predetermined time or not. If the no-data entry duration t is greater than the predetermined time, the procedure moves to Step 105 where the actuation of the second processor 7 is examined. If the second processor 7 is in action, the procedure moves back to Step 103 . If not, the entire apparatus is de-energized, at Step 106 , and stops actuating at Step 107 before restarting with Step 101 where the power supply switch 20 is closed.
[0073] If the no-data entry duration t is greater than the predetermined time, but is as short as a few minutes, the procedure is shifted from Step 104 to Step 108 . When the processing frequency in the first and second processors 4 and 7 is low, the procedure moves from Step 108 to Step 109 where a back light is turned off for energy saving.
[0074] If the no-data entry duration t is not greater than the predetermined time, the operation in the first processor 4 is prosecuted at Step 110 . Also, it is examined at Step 110 a whether the data of text is kept displayed throughout a considerable length of time or not. If too long, refreshing action of the data display is executed at Step 110 b for prevention of an image burn on the screen. At Step 110 c , the processing frequency in the second processor 7 is examined and if it is high, the second processor 7 is kept in action at Step 110 d . If the processing frequency is low, the procedure moves to Step 111 . When it is determined at Step 111 that no further processing in the second processor 7 is needed, the procedure returns to Step 103 .
[0075] When further processing in the second processor 7 is required, the procedure moves from Step 111 to Step 112 a where the actuation of the second processor 7 is examined. If the second processor 7 is not in action, a start instruction is fed at Step 112 b to the second processor 7 which is in turn activated at Step 113 by the first processor 4 and the interruption controller 6 . The second processor 7 then starts processing action at Step 114 . If it is determined at Step 115 that a change in the text of display is needed, the procedure moves to Step 116 a where a display change instruction is supplied to both the interruption controller 6 and the first processor 4 . Then, the interruption controller 6 delivers a display energizing instruction to the display block 99 at Step 116 b . The display circuit 8 is activated at Step 116 c and the display change on the display 2 including the replacement of a regional data with a desired data is carried out at Step 117 . After the display change is checked at Step 118 , a display change completion signal is sent to the first processor 4 at Step 117 a . When the display change completion signal is accepted at Step 117 b , the display 2 is turned off at Step 119 .
[0076] If no change in the display text is needed, the procedure moves from Step 115 to Step 120 where the completion of the processing in the second processor 7 is examined. If yes, a processing completion signal is released at Step 120 a . As a result, the second processor 7 stops operation at Step 121 upon receiving a stop signal produced at Step 120 b and the procedure returns back to Step 103 .
[0077] FIGS. 7 - a and 7 - b are block diagrams of a note-size computer according to the first embodiment of the present invention.
[0078] As shown in FIG. 7- a , a data input block 97 comprises a keyboard 201 , a communication port 51 with RS232C, and a floppy disk controller 202 . Also, a hard disk unit 203 is provided separately. A first processing block 1 is mainly consisted of a first processor 4 . A second processing block 98 contains a second processor 7 which is a CPU arranged for shift to and back from the energy saving mode upon stopping and feeding of a clock signal respectively and is coupled to a bus line 210 . Also, a ROM 204 for start action, a second memory 9 of DRAM, and a backup RAM 205 which is an SRAM for storage of individual data of returning from the resume mode are coupled to the bus line 210 . Both ends of the bus line 210 are connected to the first processor 4 and a display block 99 respectively. The display block 99 has a graphic controller 206 and a liquid crystal controller driver 207 arranged in a display circuit. There are also provided a video RAM 209 and a liquid crystal display 208 . For energy saving operation, corresponding components only in the arrangement are activated while the remaining components are de-energized. This energy saving technique is illustrated in more detail in Table 1. In general, input operation for e.g. word processing involves an intermittent action of keyboard entry. Hence, the power supply is connected to every component except the communications I/O unit. While a clock signal is fed to the first processing block 1 , no clock signals are supplied to the second processing block 98 and the display block 99 . Power is thus consumed only in the first processing block 1 . If necessary, the second block 98 and/or the display block 99 are activated within a short period of time. If more frequent operations are needed, the second processing block 98 is kept activated for acceleration of processing speeds.
[0079] When the key entry is absent for a given time, the second processing block 98 is disconnected and simultaneously, its processing data is stored in a backup memory for retrieval in response to the next key entry.
[0080] [0080]FIG. 7- b is similar to FIG. 7- a , except that the first processor 4 having a lower clock frequency is used as a “monitor” for the total system and the processing will be executed by the second processor 7 having a higher clock frequency. The first processor 4 is adapted for operating an event processing method by which the second processor 7 is activated for processing action corresponding to data of the keyboard entry. The second processor 7 stops operation for the purpose of energy saving when the processing action is finished and remains inactivated until another key entry commences. The display block 99 starts operating in response to a display signal from the second processor 7 and stops automatically after completion of display. This procedure can be executed with a common operating system similar to any known operating system, thus ensuring high software compatibility. For example, MS-DOS is designed to run with the use of one complete CPU. Hence, the energy saving effect will hardly be expected during operation with conventional application software programs. It is then a good idea that a specific operating system and a corresponding word processing software which are installed in two CPUs are provided in addition to the conventional operating system. Accordingly, a word processing job can be performed using the specific software with the operating system of the present invention and thus, the power consumption will be reduced to less than a tenth or hundredth. Also, general purpose software programs can work with the conventional operating system-although the energy saving effect will be diminished. It would be understood that about 80% of the job on a note-size computer is word processing and the foregoing arrangement can contribute to the energy saving.
[0081] [0081]FIG. 7- c is a block diagram of another example according to the first embodiment and FIG. 7- d is a flow chart showing a procedure with the use of a conventional operating system such as MS-DOS. The second processor 7 is a CPU capable of holding data from its register and internal RAM during actuation of no clock or de-energization. When key entry is made at Step 251 , a keyboard code signal from the keyboard 201 is transferred by the first processor 4 to a start device 221 which remains activated, at Step 252 . At Step 253 , the start device 221 delivers a clock signal to a main processor 222 which is de-energized. Both of the register 223 and the internal RAM 224 are coupled to a backup source and thus, start operating upon receipt of the clock signal. At Step 254 , the main processor 222 starts the program which has been on stand-by for key entry. The program is then processed for e.g. word processing according to data of the key entry, at Step 255 . At Step 257 , a display instruction is released for replacement of display text if required at Step 256 . At Step 258 , the graphic controller 206 is activated. The data in the video RAM 209 is thus rewritten at Step 259 . After the liquid crystal controller driver 207 is activated at Step 261 , a desired change in the display text is made on the liquid crystal display 208 formed of ferroelectric liquid crystal. Then, the video RAM 209 is backup energized at Step 262 and the display block 99 is de-energized, at Step 263 , thus entering into the energy saving mode. When the processing in the second processor 7 is completed at Step 270 , the program stops and moves into a “keyboard entry stand-by” stage at Step 271 . At Step 272 , the data required for re-actuation of the register 223 and the internal RAM 234 is saved and the second memory 9 is backup energized before a clock in the CPU is stopped. Then, the second processor 7 stops operation, at Step 273 , thus entering into the energy saving mode. As the start device 221 remains activated, the second processor 7 stays on stand-by for input through keyboard entry at Step 251 or from the communications port 5 . As understood, the start device 221 only is kept activated in the second processing block 98 . The CPU shown in FIG. 7- c provides backup of registers with its clock unactuated and ensures instant return to operation upon actuation of the clock. As a single unit of the CPU is commonly activated, a conventional operating system can be used with equal success. Also, existing software programs including word processing programs can be processed with less assignment and thus, private data stock will be permitted for optimum use. Consequently, it would be apparent that this method is eligible. In addition, the consumption of electric energy will be much decreased using a technique of direct control of the first processor 1 on display text change which will be described later with a second embodiment of the present invention. As understood, the resume mode allows most components to remain de-energized when no keyboard entry lasts for a long time.
[0082] As a ferroelectric liquid crystal material has a memory effect, permanent memory results known as protracted metastable phenomenon will appear when the same text is displayed for a longer time. For prevention of such phenomenon, a display change instruction is given to the first processor 4 and the power switch 20 upon detection with the timer 22 that the display duration exceeds a predetermined time in the energy saving mode or power supply stop mode. Accordingly, the display circuit 8 actuates the display 2 to change the whole or a part of the display text, whereby permanent memory drawbacks will be eliminated.
[0083] If it is happened that the persistence of such permanent memory effects allows no change in the display text on the display 2 , the crystalline orientation of liquid crystal is realigned by heating up the display 2 with a heater 24 triggered by a display reset switch 23 . Then, arbitrary change in the display text on the display 2 will be possible.
[0084] Energy saving can be promoted by stopping the clock in the second processor 7 during the energy saving mode. When more or full energy saving is wanted, the power supply to the second processor 7 or the display circuit 8 is disconnected by the interruption controller 6 .
[0085] As understood, the power supply stop mode requires a minimum of power consumption for backup of the second memory 9 .
[0086] As shown in FIG. 1, the back light 25 is turned off when the power source is a battery and a reflective device 27 is activated by a reflection circuit 26 for display with a reflection mode.
[0087] The reflective device 27 is composed of a film of ferroelectric liquid crystal which provides a transparent mode for transmission of light, as shown in FIG. 8- a , and an opaque mode for reflection as shown in FIG. 8- b , for alternative action. Incoming light 32 is reflected on the reflective device 27 and runs back as reflected light 33 . At this time, polarization is also effected by the polarizers in the display 2 and the reflective device 27 , whereby the number of components will be reduced. Also, a film-form electrochromic display device may be used for providing a transmission mode and a white diffusion screen mode in which it appears like a sheet of white paper.
[0088] The reflective device 27 may be of fixed type, as shown in FIGS. 8 - c and 8 - d , comprising a light transmitting layer composed of low refraction transmitting regions 28 and high refraction transmitting regions 29 and a reflecting layer 31 having apertures 30 therein.
[0089] As shown in FIG. 8- c , light emitted from the back light 25 enters the high refraction transmitting regions 29 where it is fully reflected on the interface between the high and low refraction transmitting regions 29 , 28 and passes across the apertures 31 to a polarizer plate 35 . The polarized light is then transmitted to a liquid crystal layer 17 for producing optical display with outwardly emitted light.
[0090] During the reflection mode in battery operation, outside light 32 passes the liquid crystal layer 17 and is reflected by the reflecting layer 31 formed by vapor deposition of aluminum and reflected light 33 runs across the liquid crystal layer 17 again for providing optical display.
[0091] The reflective device 27 requires no external drive circuit, thus contributing to the simple arrangement of a total system. It is known that such a combination of high and low refraction transmitting regions is easily fabricated by a fused salt immersion method which is commonly used for making refraction distributed lenses.
[0092] Although such a transmission/reflection combination type liquid crystal display is disadvantageous in the quality of a display image as compared with a transmission or reflection speciality type liquid crystal display, the foregoing switching between transmission and reflection allows display of as good an image as of the speciality type display in both the transmission and reflection modes. This technique is thus suited to two-source, battery and AC application.
[0093] When the external power source is connected, the back light 25 is lit upon receiving an instruction from the first processor 4 which also delivers a transmission instruction to the reflection circuit 26 and thus, the reflective device 27 becomes transparent simultaneously. Accordingly, transmitting light can illuminate the display as shown in FIG. 8- a.
[0094] When the battery is connected, the first processor 4 delivers a reflection signal to the reflection circuit 26 and the reflective device 27 becomes opaque to cause reflection and diffusion. As a result, the display is made by reflected outside light as shown in FIG. 8- b while an amount of electric energy required for actuation of the back light 25 is saved.
[0095] Also, the same result as shown in FIGS. 8 - c and 8 - d may be provided with the use of a transmitting reflective plate 34 which is formed of a metal plate, e.g. of aluminum, having a multiplicity of tapered round apertures therein, as illustrated in FIGS. 8 - e and 8 - f.
[0096] As set forth above, the CPU in this arrangement provides intermittent actuation in response to the intermittent key entry and the average power consumption of the apparatus will be declined to an appreciable rate.
[0097] Also, the text remains on display during the operation and thus, the operator can perceive no sign of abnormality when the processing unit is inactivated. More particularly, a great degree of energy saving will be ensured without affecting the operability.
[0098] More particularly, each key entry action takes several tens of milliseconds while the average of CPU processing durations in word processing is about tens to hundreds of microseconds. Hence, the CPU is activated 1/100 to 1/1000 of the key entry action time for accomplishing the task and its energy consumption will thus be reduced in proportion. However, while the energy consumption of the CPU is reduced to 1/1000, 1/10 to 1/20 of the overall consumption remains intact because the display unit consumes about 10 to 20%, namely 0.5 to 1 W, of the entire power requirement. According to the present invention, the display unit employs a memory effect display device provided with e.g. ferroelectric liquid crystal and thus, its power consumption will be minimized through intermittent activation as well as the CPU.
[0099] As the result, the overall power consumption during mainly key entry operation for e.g. word processing will be reduced to 1/100 to 1/1000.
[0100] Embodiment 2
[0101] [0101]FIG. 9 is a block diagram showing a second embodiment of the present invention.
[0102] In the second embodiment, the first processor 4 is improved in the operational capability and the second processor 7 of which energy requirement is relatively great is reduced in the frequency of actuation so that energy saving can be encouraged.
[0103] As shown in FIG. 9, the arrangement of the second embodiment is distinguished from that of the first embodiment by having a signal line 97 for transmission of a display instruction signal from the first processing block 1 to the display block 99 . In operation, the first processor 4 of the first processing block 1 delivers a display change signal to the display circuit 8 of the display block 99 for change of the display text on the display 2 . As understood, the second processor 7 delivers such a display change signal to the display circuit 8 according to the first embodiment.
[0104] [0104]FIG. 10- a is a block diagram showing in more detail the connection of the first processor 4 , in which the first memory 5 comprises a first font ROM 40 for storage of dot patterns of alphabet and Japanese character fonts or the like in a ROM, an image memory 41 , and a general memory 42 .
[0105] As shown in FIG. 10 b , the second memory 9 may contain a second font ROM 43 which serves as a font memory.
[0106] In operation, a series of simple actions for display text change can be executed using the first processor 4 . Character codes are produced in response to the key entry and font patterns corresponding to the character codes are read from the first 40 or second font memory 43 for display on the display 2 after passing the display circuit 8 . The second memory 9 may also contain a second general memory 44 .
[0107] During input of a series of data characters which requires no large scale of processing, the first processor 4 having less energy requirement is actuated for operation of the display text change. If large scale of processing is needed, the second processor 7 is then utilized. Accordingly, the frequency of actuation of the second processor 7 is minimized and energy saving will be guaranteed. Also, as shown in FIG. 11, the memory size of the first memory 5 can be decreased because of retrieval of font patterns from the second font ROM 43 of the second memory 9 .
[0108] The operation according to the second embodiment will now be described in more detail referring to flow charts of FIGS. 11 - a and 11 - b . FIG. 11- a is substantially similar to FIG. 6 which shows a flow chart in the first embodiment.
[0109] A difference is that as the first processor 4 directly actuates the display circuit 8 , a step 130 and a display flow chart 131 are added. When the first processor 4 judges that the display is to be changed in Step 130 and that a desired data for replacement in the display text is simple enough to be processed by the first processor 4 at Step 111 , the procedure moves to the display flow chart 131 . The display flow chart 131 will now be described briefly. It starts with Step 132 where the display block 99 is activated. At Step 133 , the display text is changed and the change is examined at Step 133 . After the confirmation of the completion of the text change at Step 134 , the display block 99 is de-energized at Step 135 and the procedure returns back to Step 103 for stand-by for succeeding data input. FIG. 11- b illustrates the step 133 in more detail. After the display block 99 is activated, at Step 132 , by a start instruction from the first processing block 1 , the movement of a cursor with no restriction is examined at Step 140 . If yes, data input throughout the cursor movement is executed at Step 141 . If not, it is then examined whether the desired input area on the display 2 is occupied by existing data or not at Step 142 . This procedure can be carried out by reading the data in the image memory 41 with the first processor 4 . If no, partial text replacement with desired data is executed at Step 143 . If yes, the procedure moves to Step 144 where the existing data in the input area of the display block 99 is checked using the image memory 41 and examined whether it is necessarily associated or not with the desired data to be input. If no, overwriting of the desired data is executed at Step 143 . If yes, the existing data is retrieved from the image memory 41 or read from the second font ROM 9 and coupled with the desired data for composition, at Step 145 . At Step 146 , it is examined whether a black/white inversion mode is involved or not. If yes, the data is displayed in reverse color at Step 147 . If no, the text change with the composite data is carried out at Step 148 . Then, the completion of the text change is confirmed at Step 134 and the display block 99 is turned off at Step 99 .
[0110] For a more particular explanation, the processing action of corresponding components when the key entry is made is illustrated in FIG. 12. When the key entry with “I” is conducted at t1 as shown in FIG. 12- e , the first processor 4 shifts input data into a letter “I” code, reads a font pattern of the letter code from the first font ROM 40 shown in FIG. 10, and actuates the display circuit for display of the letter “I” on the display 2 . With the memory effect display having ferroelectric crystal liquid, partial replacement in a character can be made. The partial replacement is feasible in two different manners; one for change dot by dot and the other for change of a vertical or horizontal line of dots at once. The dot-by-dot change is executed with less energy requirement but at a higher voltage, thus resulting in high cost. The line change has to be done in the group of dots at once even when one dot only is replaced but at relatively lower voltages. Both manners in this embodiment will now be explained.
[0111] When the horizontal and vertical drivers 11 , 12 shown in FIG. 3 accept higher voltages, it is possible to fill the dots forming the letter “I” one by one. Accordingly, the letter “I” can be displayed by having a font data of a corresponding character pattern supplied from the first processor 4 . However, ICs accepting such a high voltage are costly. It is thus desired for cost saving that the operating voltage is low. It is now understood that every data processing apparatus is preferably arranged, in view of capability of up-to-date semiconductors, for providing line-by-line text change operation.
[0112] It is also necessary that the first memory 5 of the first processor 4 carries at least data of one text line.
[0113] For Japanese characters, the one text line data is equal to 640×24 dots. The writing of the letter “I” thus involves replacement of 24 of 640-dot lines.
[0114] In operation, the previous data of a target line is retrieved from the image memory 41 of the first memory 5 and also, the pattern data of the letter “I” is read from the first font ROM 40 . Then, the two data are combined together to a composite data which is then fed to the display circuit 8 for rewriting of one text line on the display 2 . Simultaneously, the same data is stored into the image memory 41 . The input of “I” is now completed.
[0115] None of the first font ROM 40 and the image memory 41 is needed when the second font ROM 43 is employed for the same operation, which is capable of processing coded data. In particular, the same text line can be expressed with about 40 of 2-byte characters and thus, 40×2=80 bytes per line. Therefore, the first memory 5 may carry coded data of the entire screen image.
[0116] During the processing of data input “I” in either of the two foregoing manners, the second processor 7 provides no processing action as shown in FIG. 12- c.
[0117] Similarly, a series of key inputs are prosecuted by the first processor 4 , “space” at t2, “L” at t3, “i” at t4, “v” at t5, and “e” at t6. Although the first processor 4 is much slower in the processing speed than the second processor 7 , the replacement of one text line on display can be pursued at an acceptable speed with less energy consumption.
[0118] As shown in FIG. 12, t7 represents the key input of an instruction for processing a large amount of data, e.g. spelling check in word processing, translation from Japanese to English, conversion of Japanese characters into Chinese characters, or calculation of chart data.
[0119] When the first processor 4 determines that the processing at the second processor 7 is needed, the second processor 7 is turned on at t71. The start-up of the second processor 7 is the same as of Embodiment 1. As shown in FIG. 12- c , the second processor 7 upon being activated at t71 returns to the original state prior to interruption and starts processing the data of text lines fed from the first processor 4 . As the processing is prosecuted, each character of changed text is displayed on the display 2 through the display circuit 8 as shown at t72 in FIG. 12- d.
[0120] This procedure will now be explained in the form of data entry for translation from Japanese to English. After the letter k is input at t1, as shown in FIG. 12- f , and displayed on the screen, as shown in FIG. 12- h . Then, the letter a is input at t2 and the display reads “ka” as shown in FIG. 12- h.
[0121] By then, the second processor 7 remains inactivated as shown in FIG. 12- c . When a key of translating conversion is pressed at t7, the second processor 7 starts processing at t71. Accordingly, the Japanese paragraph “kareha” is translated to “He is” in English. The resultant data is sent to the display circuit 8 for dot-by-dot replacement for display.
[0122] Now, the display reads “He is” as shown in FIG. 12- h . The dot-by-dot character replacement shown in FIG. 12- g requires less electric energy than the text line replacement shown in FIG. 12- d.
[0123] For the purpose of saving energy during the movement of the cursor, the black/white inversion or negative mode is used as shown in FIGS. 13 - a and 13 - b . This however increases the power consumption in the line replacement. When a bar between the lines is used for display of the cursor as shown in FIGS. 13 - c and 13 - d , the replacement of the full line is not needed and thus, energy saving will be expected. Also, the speed of processing is increased and the response will speed up during processing with the low speed first processor 4 . This advantage is equally undertaken in the dot-by-dot replacement.
[0124] As shown in FIG. 14- a , the movement of the cursor is expressed by the bar. For ease of viewing, the bar may be lit at intervals by means of control with the first processor 4 . When a key data input is given, a corresponding character is displayed in the reverse color as shown in FIG. 14- b . This technique will also reduce the energy consumption at least during the cursor movement.
[0125] FIGS. 14 - a to 14 - g illustrate the steps of display corresponding to t1 to t7. FIG. 14- h shows the conversion of the input text.
[0126] FIGS. 15 - a to 15 - f shows the insertion of a word during dot-by-dot replacement. It is necessary with the use of the second font ROM 43 in the arrangement shown in FIG. 10 that the data of one text line is saved in the image memory 41 because the first font ROM 40 does not carry all the Chinese characters. When the cursor moves backward as shown in FIGS. 15 - c and 15 - d , the letter n is called back from the image memory 41 . Accordingly, the data prior to insertion can be restored without the use of the second processor 7 or the second front ROM 43 as shown in FIG. 15- d.
[0127] FIGS. 16 - a to 16 - g show the copy of a sentence “He is a man”. The procedure from FIG. 16- a to FIG. 16- f can be carried out with the first processor 4 . The step of FIG. 16- g involves an insertion action which is executed by the second processor 7 .
[0128] According to the second embodiment, most of the job which is processed by the second processor 7 in the first embodiment is executed by the low power consuming first processor 4 . Thereby, the average energy consumption will be much lower than that of the first embodiment.
[0129] The optimum of a job sharing ratio between the first and second processors 4 and 7 may vary depending on particulars of a program for e.g. word processing or chart calculation. Hence, a share of the first processor 4 in operation of a software program can be controlled by adjustment on the program so as to give an optimum balance between the energy consumption and the processing speed. Also, a video memory 82 may be provided in the display block 99 for connection via a connecting line 96 with the first processor 4 . This allows the data prior to replacement to be stored in the video memory 82 and thus, the image memory 41 shown in FIG. 10- a will be eliminated.
[0130] Embodiment 3
[0131] [0131]FIG. 18 is a block diagram showing a third embodiment of the present invention. The difference of the third embodiment from the first and second embodiments will now be described. As shown in FIG. 1, the first embodiment has the display start instruction line 81 along which both a start instruction and a stop instruction are transferred from the first processing block 1 to the display block 99 while equal instructions are transferred by the start instruction line 80 from the same to the second processing block 98 .
[0132] The third embodiment contains no display start instruction line 81 to the display block 99 as shown in FIG. 18. Also, the start instruction line 80 of the third embodiment allows only a start instruction but not a stop instruction to be transmitted from the first processing block 1 to the second processing block 98 .
[0133] The second processor 7 stops itself upon finishing the processing and enters into the energy saving mode. When the second processor 7 determines that the display change is needed, it delivers a display start instruction via a data line 84 to the display block 99 which is then activated. After the display change on the display 2 is completed, the display block 99 stops operation and enters into the display energy saving mode. This procedure will be explained in more detail using a flow chart of FIG. 19. The flow chart is composed of a first processing step group 151 , a second processing step group 152 , and a third processing step group 153 . At first, the difference of this flow chart will be described in respect to the sequence from start to stop of the second processing block 98 .
[0134] There is no control flow from the second processing step group 152 of the second processing block 98 to the first processing step group 151 , unlike the flow chart of the first embodiment shown in FIG. 6. More specifically, the first processor 4 delivers, at Step 112 , a start instruction to the second processor 7 which is then activated. This step is equal to that of the first embodiment. However, the second processor 7 is automatically inactivated at Step 121 , as compared with de-energization by an instruction from the first processor 4 in the first embodiment. At Step 103 , the second processor 7 is turned to a data input stand-by state.
[0135] The difference will further be described in respect to the sequence from start to stop of the display block 99 .
[0136] In the first embodiment, a display start instruction to the display block 99 is given by the second processor 7 after completion of display data processing. According to the third embodiment, the start instruction is delivered by the second processing block 98 to the display block 99 , at Step 115 a shown in FIG. 19. Then, the display block 99 is activated at Step 116 and the display change is conducted at Step 117 . After the display change is examined at Step 118 , the display block 99 stops itself at Step 119 .
[0137] As understood, the third embodiment which is similar in the function to the first embodiment provides the self-controlled de-energization of both the second processing block 98 and the display block 99 .
[0138] Also, a start instruction to the display block 99 is given by the second processing block 98 . Accordingly, the task of the first processing block 1 is lessened, whereby the overall processing speed will be increased and the arrangement itself will be facilitated.
[0139] Embodiment 4
[0140] [0140]FIG. 20 is a block diagram showing a fourth embodiment of the present invention, in which an energy saving manner is disclosed with the use of an input/output port for communications with the outside. A data processing apparatus of the fourth embodiment incorporates an input/output unit 50 mounted in its data input block 97 . The input/output unit 50 contains a communications port 51 and an external interface 52 . In operation, the unit 50 performs actions as shown in a timing chart of FIG. 21 which is similar to the timing chart of key data entry shown in FIG. 12. When a series of inputs from the communications port are introduced at t1 to t74, as shown in FIG. 21- a , the input/output unit 50 delivers corresponding signals to the first processing block 1 . The first processor 4 sends an input data at t1 to the display circuit 8 which in turn actuates, as shown in FIG. 21- d , for display of a data string as illustrated in FIG. 21- e . If an input at t7 is bulky, the second processor 7 is activated at t71 as shown in FIG. 21- c.
[0141] The second processor 7 delivers a start instruction at t72 to the display circuit 8 which is then actuated for data replacement on the display 2 . If the input through the communications port is not bulky, it is processed in the first processor 4 or the input/output unit 50 while the second processor 7 remains inactivated. Accordingly, energy saving during the input and output action will be ensured.
[0142] Embodiment 5
[0143] [0143]FIG. 22 is a block diagram showing a fifth embodiment of the present invention, in which a solar battery 60 is added as an extra power source. The first processor 4 operates at low speeds thus consuming a small amount of electric energy. Accordingly, the apparatus can be powered by the solar battery 60 . While the action is almost equal to that of the first embodiment, the solar battery however stops power supply when the amount of incident light is decreased considerably. If the supply is stopped, it is shifted to from the source 61 . When no key entry is made throughout a length of time and no power supply from the solar battery 60 is fed, the source stop mode is called for as shown in FIG. 23- b . The first processor 4 saves processing data into the first memory 5 and then, stops operation. Thus, the power consumption will be reduced. When a power supply from the solar battery 60 is fed again at t71 or another key input data is fed from the data input unit 3 , the first processor 4 starts actuating for performance of an equal action from t72.
[0144] One example of the start procedure of the first processor 4 will now be described. As shown in FIG. 24, a key input device 62 of the data input unit 3 feeds a voltage from the battery 64 to a hold circuit 63 . The hold circuit 63 upon pressing of a key connects the power source to the first processor 4 for energization. Simultaneously, the key input device 62 transfers a key input data to the first processor 4 and processing will start.
[0145] Each key of the key input device 62 may have a couple of switches; one for power supply and the other for data entry.
[0146] Accordingly, as the solar battery is equipped, the power consumption will be minimized and the operating life of the apparatus will last much longer.
[0147] The solar battery 60 , which becomes inactive when no incoming light falls, may be mounted on the same plane as of the display 2 so that no display is made including text and keyboard when the solar battery 60 is inactivated.
[0148] Hence, no particular trouble will arise in practice. In case of word processing in the dark e.g. during projection of slide pictures in a lecture, a key entry action triggers the hold circuit 3 for actuation of the first processor 4 .
[0149] As the data processing apparatus of the fifth embodiment provides more energy saving, it may be realized in the form of a note-size microcomputer featuring no battery replacement for years. Also, the first and second processors in any of the first to fifth embodiments may be integrated to a single unit as shown in FIG. 25.
[0150] It was found through experiments of simulative calculation conducted by us that the average power consumption during a word processing program was reduced from 5 w of a reference value to as small as several hundredths of a watt when the present invention was associated. This means that a conventional secondary cell lasts hundreds of hours and a primary cell, e.g. a highly efficient lithium cell, lasts more than 1000 hours. In other words, a note-size computer will be available which lasts, like a pocket calculator, over one year in use of 5-hour a day without replacement of batteries. As understood, intensive attempts at higher-speed operation and more-pixel display are concurrently being prosecuted and also, troublesome recharging of rechargeable batteries needs to be avoided. The present invention is intended to free note-size computers from tangling cords and time-consuming rechargers.
[0151] The advantages of high speed and high resolution attributed to ferroelectric liquid crystal materials have been known.
[0152] The present invention in particular focuses more attention on the energy saving effects of the ferroelectric liquid crystal which have been less regarded.
[0153] No such approach has been previously made. The energy saving effects will surely contribute to low power requirements of portable data processing apparatuses such as note-size computers.
[0154] Although the embodiments of the present invention employ a display device of ferroelectric liquid crystal for utilization of memory effects, other memory devices of smectic liquid crystal or electrochromic material will be used with equal success. The liquid crystal display is not limited to a matrix drive as described and may be driven by a TFT drive system. | A data processing apparatus has a first processing unit for processing an input data, a second processing unit responsive to the data processed by the first processing unit for executing a processing dependent on the data and producing a display data, and a display unit having a display drive unit and a display device for displaying the display data. The second processing unit is selectively inactivated and activated under control of the first processing unit to reduce power consumption in the second processing unit. The display drive unit is also selectively inactivated and activated under control of the first processing unit to reduce power consumption in the display unit. The display device has a memory function that maintains its display image even when supply of a display drive signal from the display drive unit is stopped, so that a latest image before inactivation of the second processing unit and/or the display drive unit for power consumption reduction is visible by an operator during the inactivated and low power consumption state of the apparatus. | 8 |
BACKGROUND OF THE INVENTION
The invention relates to devices and methods for making plumbness measurements of building frame structures, especially when the measurements must be made of the plumbness of bowed or warped vertical studs of the frame structures and when the vertical studs are of various lengths.
By way of background, those skilled in the art of constructing building frames know that the studs of framed walls are rarely truly vertical immediately after the frames are erected. The studs therefore must be measured and adjusted for "plumbness", or true verticalness". The typical approach of erecting frame walls is to utilize premarked horizontal lower plates that are attached to the top of the foundation or floor structure. The lower ends of the vertical studs are attached to the lower plates at the spaced, premarked locations thereof. The upper ends of the studs are attached to similarly spaced, premarked locations of a horizontal (or, in some cases, sloped, "top plate". The frame wall is temporarily held in place by braces. The studs may be of the same or varying lengths, depending on the type of roof structure utilized. In any case, the studs, whether they are of metal or wood, but especially if they are of wood, are rarely perfectly straight, and they are rarely perfectly vertical. One reason the studs are rarely vertical is non-levelness of the floor or foundation to which the bottom premarked plates are attached. Furthermore, even if wood studs are initially straight, a few hours of exposure to sunlight usually causes them to warp, sometimes severely. This warpage makes it difficult for a worker to subsequently make measurements indicative of the plumbness of individual studs and of the framed wall as a whole. Nevertheless, the plumbness must be measured and adjustments of the "verticalness" of the measured studs and the wall must be made in the most efficient and accurate way that is practical, because otherwise numerous difficulties will be encountered in subsequent construction of the building.
If a typical carpenter's level having flat, parallel opposed edge surfaces and also having both a horizontal bubble vial and a vertical bubble vial is used, a number of difficulties may be encountered. Usually, the carpenter's level is considerably shorter than the studs which must be measured in order to adjust plumbness. To measure plumbness of a warped stud, the flat edge surface of the carpenter's level must be placed against either the convex or the concave surface of the warped stud. Those skilled in the art know that the resulting measurements and adjustments of plumbness of the warped stud is therefore based on "guesswork" as to against which portion of the warped stud the relatively short carpenter's level should be abutted to obtain an accurate indication of the stud's plumbness. Due to the inherent inaccuracy of this approach, the common practice is for the worker whose responsibility it is to measure plumbness to find the straightest unused stud of the needed length that he can and nail two equal thickness blocks to the upper and lower ends respectively, of that stud. In order to make the needed plumbness measurement, the worker then holds the nailed-on block of the modified stud against the end points of the stud to be plumbed. He then holds a flat edge surface of the carpenters level against the straight stud.
Although this technique provides the needed accuracy of measurement, it is quite inconvenient, especially if no adequately straight stud can be found. Furthermore, if the roof structure of the building under construction is of the type sometimes referred to as a "shed roof", the studs of a wall may be all of different lengths. In this case, it is obviously inconvenient and impractical to use the above technique. However, it may be difficult to obtain accurate plumbing measurements without making a number of the above-described makeshift devices.
It is clear that the unavailability of a readily made, easily used, extendable length plumbing device results in inefficient use of workers' time in constructing and using the above makeshift devices, and also leads to imprecision in the plumbness of the walls of the completed structure and lower than desirable quality of construction.
A variety of plumbing tools and aids are known, including those disclosed in U.S. Pat. Nos. 686,360; 3,328,887; 1,780,344; 945,275 which are listed in order of decreasing relevance to the present invention. U.S. Pat. No. 686,360 discloses an extendable device with two offset elements 10 attached to members that are respectively extendable from opposite ends of the main body, which includes a vial for making plumb measurements. This device is of rather imprecise construction, and is extendable to a length that is only less than twice the length of the main body. Furthermore, the device does not have a flat edge surface that is useful for simultaneously making flatness, as well as plumbness measurements. But those skilled in the art know that both types of measurements must be made in "plumbing up" a newly erected frame structure, especially in "plumbing up" and shimming door jambs. Typically, a prefabricated door is perfectly rectangular, but a door jamb erected in a frame structure usually is not straight, and instead is warped in one or two directions, and it also usually is "out of plumb" in one or two directions. The device disclosed in U.S. Pat. No. 686,360 is not suitable for measuring both plumbness and flatness of door jambs. Furthermore, it is not easily extendable, because set screws must be loosened to allow extension of the device and then must be tightened to maintain the extended length. Furthermore, the device shown in U.S. Pat. No. 686,360 is not easily retrofittable to standard commercially available carpenter's levels.
It is clear that there is an unmet need for a single inexpensive, highly accurate device which can be used as a plumbness measurement tool that is easily and quickly extendable to many desired practical working lengths, is easily locked into an extended configuration, has a flat surface that enables accurate measurements of both flatness and plumbness, and is easily attachable to carpenter's levels of conventional design.
Accordingly, it is an object of the invention to provide an improved extendable apparatus for efficient working of plumbing measurements.
It is another object of the invention to provide an apparatus that makes it easy for a worker to quickly make plumbness measurements and flatness measurements to "plumb up" a frame structure of walls of a building before continuing further construction of the walls.
It is another object of the invention to provide a plumbing device which is extendable and has a quick release mechanism for allowing extension and locking of the device into an extended configuration or allows rapid collapsing of the extended device into a compact configuration.
It is another object of the invention to provide a device that is useful in making accurate plumbness measurements of warped studs and flatness measurements of door jambs.
SUMMARY OF THE INVENTION
Briefly described and in accordance with one embodiment thereof, the invention provides an apparatus and method for efficiently and accurately making measurements of the plumbness of warped vertical studs in a frame structure and also for making measurements of flatness and plumbness of door jambs, wherein the apparatus is conveniently extendable by means of a quick release locking mechanism from a compact configuration to a configuration of arbitrary length.
In the described embodiment of the invention, the device includes first and second vertical members each having a modified, I-beam shaped cross section, the inner end of which has a pair of groove-forming flanges in which the opposed parallel surfaces of a main body member are slideable. The main body member is a conventional carpenter's level which includes a bubble vial that is calibrated for aiding measurements of plumbness and a pair of quick-release locking mechanisms that normally engage both the main body member and respective ones of the first and second extension members to lock them to the main body member, but are releasable by means of handles to allow extension of the first and second members to a convenient length. A first offset member is attached to the end of the first vertical extension member and extends beyond the flat outer plate thereof to an imaginary plane that is parallel to the opposed parallel surfaces of the main body member. A second offset member extends from the bottom of the second vertical extension member horizontally outward to the surface of the imaginary plane. One or both of the extension members can be extended so that the upper and lower offset elements contact the top and bottom end portions of a warped stud that is to be "plumbed", so that the vial indicator indicates the plumbness of the major axis of the stud. In the described embodiment of the invention, the quick release locking mechanisms includes first and second dog members that are attached to the main body member and are spring loaded to engage the groove-forming flanges of the first and second extension members, respectively, to prevent sliding movement thereof relative to the main body member. Upon depressing of the first and second handles, the dogs move away from the groove-forming flanges, allowing extension or collapsing of the device. An outer surface of the second extension member is flat, allowing measurement of both flatness and plumbness of a door jamb.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view of the extendable plumbness/flatness measuring device of the present invention.
FIG. 2 is an enlarged partial cutaway elevation view of the upper quick-release mechanism shown in the device of FIG. 1.
FIG. 3 is an elevation view illustrating partial extension of the device of FIG. 1.
FIG. 4 is a partial cutaway perspective exploded view useful in illustrating the construction and operation of the embodiment of the invention shown in FIG. 1.
FIG. 5 is another partial cutaway perspective view of the device shown in FIG. 1.
FIG. 6 is a section view of an extension member of an alternate embodiment of the invention.
DESCRIPTION OF THE INVENTION
Referring now to the drawings, plumbing device 1 includes a standard "level" device, referred to herein as a carpenter's level. Carpenter's level 3 is typically approximately three to four feet long. Carpenter's level 3 includes 3 vials designated by reference numerals 4, 5 and 6. Vial 5 is used to indicate when the carpenter's level 3 is level by means of an air bubble in a liquid-filled, slightly arcuate tube, as is well known. Vials 4 and 6 are used to determine when carpenter's level 3 is perfectly vertical.
As best seen from the partial cutaway-exploded view of FIG. 4, carpenter's level 3 includes a web 8 having a plurality of handholds 9 therein. A perpendicular flange 11 is attached to one side of web 3 and a second similar opposed flange 12 is attached to the other side of level 3, so that the cross-section of carpenter's level 3 has the appearance of an I-beam. The outer opposed surfaces of flanges 11 and 12 are planar.
In accordance with the present invention, two additional vertical members, namely left extension member 14 and right extension member 16 slidably engage the opposed flat surfaces of flanges 12 and 11, respectively, of carpenter's level 3. As best seen in FIG. 4, the cross section of each of extension members 14 and 16 is generally I-beam shaped. Extension arm 14 has an inner flange 14A and an outer flange 14B.
Similarly, extension member 16 has an inner flange 16A and an outer flange 16B. A channel member 18 has one side wall 18A that slidably engages the flange 12 of carpenter's level 3. A second channel 19 has a side wall 19A that slidably engages the flange 12 of carpenter's level 3 on the opposite side of web 3. The opposite side walls of channels 18 and 19 are attached to the inner sections of flange 14A of left extension member 14, so carpenter's level 3 is vertically slidable within the groove formed by channels 18 and 19 and surface 14A of extension member 14. The planar outer flange surface 14A of left extension member 14 slides against the outer planar surface (not shown) of flange 12 of carpenter's level 3.
Similarly, a channel member 20 has an inner side wall 20A that slidably engages to the inner surface of the inner flange of carpenter's level 3. Channel 20 also has an outer wall 20B that extends along and is attached to the inner surface of flange 16A of extension member 16 so that the outer surface of flange 16A slides smoothly against the flat outer surface of flange 11 of carpenter's level 3. Another channel similar to channel 20, but not shown herein, is attached to the inner surface of flange 16A on the opposed side of the web of extension member 16, and forms the other side of the groove in which flange 11 of carpenter's 11 slides.
Although channels 18, 19 attached to flange 14A of extension member 14 and channel 20 attached to flange 16A of extension member 16 are shown in the embodiment of the inventions illustrated in the drawings, it is deemed preferable that extension members 14 and 16 have the cross sectional configuration shown in FIG. 6, which includes a web 22, a perpendicular outer flange 23, and a lower flange 24 integrally formed with two L-shaped members 25 and 26, as shown. This forms a wide groove 27 in which either flange 11 or flange 12 of carpenter's level 3 can slide.
Opening 28 is wide enough to accommodate the web 3 of carpenter's rule 3. Preferably, the extension members 14 and 16, having the cross section shown in FIG. 6, are composed of extruded, lightweight aluminum.
Referring to FIGS. 1, 3 and 5, at the upper end of extension arm 16 a horizontal end piece 30 is attached to the web of extension arm 16 by means of suitable rivets or bolts generally designated by reference numeral 32 and a plate 32'. A notch 31 is provided in the lower part of the left end of end piece 30 into which the plumbness measurement device 1 is in the retracted configuration shown in FIG. 1. At the right end of upper end piece 30 an offset portion 33 of end piece 30 extends approximately one inch beyond the flat surface 16B of extension member 16. Arrow 34 illustrates the directions in which extension arm 16 can move vertically relative to carpenter's level 3.
Similarly, a lower end piece 35 is rigidly attached by means of plate 37 and rivets or bolts 36 to the lower end of left extension arm 14. A notch 38 is cut in the upper right end portion of piece 35 to accommodate the lower end portion 39 of right extension member 16 when device 1 is in the retracted configuration shown in FIG. 1. The extreme right end portion of lower end piece 35 extends the same distance (approximately one inch) beyond the plane of surface 16B of extension arm 16 as above-mentioned offset section 33. Dotted line 41 designates an imaginary plane parallel to the plane of flat surface 16B. Arrow 42 indicates the direction in which extension arm 14 can vertically move relative to carpenter's level 3.
In accordance with the present invention, one or more quick release mechanisms such as 44 in FIG. 2 are provided to effectively lock each of extension members 14 and 16 to carpenter's level 3. Referring to FIGS. 2 and 4, each quick release mechanism includes a handle 45 which is connected by means of a bolt and nut 46 to a dog member 47. Dog member 47 includes an arm 47A, an arm 47B, and a hole 47C at the junction of arms 47A and 47B. As indicated by dotted line 49, a bolt (not shown) and a nut 50 pivotally attach dog member 47 by means of hole 51 to one side of web 3 of carpenter's level 3. Similarly, on the opposite side of web 3, a second dog member 53 having an arm 53A and an arm 53B is pivotally connected by means of bolt and nut 54 extending through hole 55 in web 3 and hole 56 to carpenter's level 3. Bolt and nut 58 connect the free end of arm 53A to handle 45. A flared, generally V-shaped piece of steel spring 61 has an outer portion 62. The left end of outer portion 62 fits into a notch 64 that is cut in web 3 along the left edge of hole 9 therein. Two additional adjacent notches 66 are cut in web 3 on either side of notch 64 to accommodate movement of bolts 46 and 58 as handle 45 is pressed against spring 61. As easily seen in FIG. 4, handle 45 consists of a piece of channel material, and the material of web 3 and spring 61 extends into the channel of handle 45. Holes 60A and 60B have counterpart holes which are drilled in the opposite side of handle 45. These holes are drilled in tabs which cause handle 45 to have a somewhat T-shaped appearance.
The operation of quick release mechanism 44 can be best understood with reference to FIG. 2, wherein it can be seen that if the user extends his fingers through opening 9 and presses handle 45 in the direction indicated by arrows 69, handle 45 moves to the left. This causes arms 47A and 53A of dog members 47 and 53 to rotate in the directions indicated by arrows 71 and 72, respectively. This, of course, causes arms 47B and 53B to rotate in the direction indicated by arrows 74 and 75, respectively. It can be seen that with handle 45 pressed as far as it will go to the left against spring 61 (FIG. 4), the extreme ends of arms 53B and 47B no longer engage the flange of right extension arm 16, thereby allowing it to slide freely in the directions indicated by arrow 34 in FIG. 3. However, when handle 45 is not depressed, the force of spring 61 on handle 45 causes dog members 47 and 53 to be rotated in the directions opposite to the respective arrows 74 and 75 in FIG. 2. The resulting forces urge the extreme ends of dog arms 53B and 47B against the flanges (i.e., the channels such as 20) of extension arm 16. Any attempt to slide extension arm 16 in either of the directions indicated by arrow 34 causes one of the two dog members to rotate in a direction that tightens the locking engagement of extension arm 16 with carpenter's level 3. For example, if extension arm 3 is urged upward, the frictional engagement of flange surface 20A (FIG. 2) causes dog arm 53B to rotate in the direction opposite to arrow 75, forcing the free end of dog arm 53 more tightly against surface 20A. Downward motion of extension arm 16 will be resisted in the same manner by rotation of dog arm 47B in the direction opposite to 74, unless handle 45 is depressed in the direction indicated by arrow 69.
A second dog mechanism 77 which is essentially identical to quick release mechanism 44 maintains left extension member 14 locked in fixed relationship with carpenter's level 3 unless its handle is depressed to move the free ends of the dog arms away from surfaces 18A and 19A.
Thus, it can be seen that the two quick release mechanisms 44 and 77 allow a construction worker to very easily extend the plumb measurement device 1 to a length that is considerably greater than twice the length of main body 3. The device remains rigid in its extended configuration, and is easily collapsible to the closed configuration shown in FIG. 1 by simply depressing the two handles such as 45 and sliding the two end pieces 30 and 35 toward each other until each engages the opposed extension member end piece.
The device is extremely useful in "plumbing up" a wall frame structure. The worker simply quickly extends the plumb measurement device to the length of the particular warped stud to be measured by using the quick release mechanisms, positions the upper offset end 33 against the upper end of the stud and places the protruding offset end 40 of the lower end piece 35 against the lower end of the stud to be plumbed. Dotted line 41 represents the surface of a perfectly straight stud. However, dotted line 79 indicates the position of a typical warped stud, the plumbness of which could not be measured accurately by an ordinary flat surface carpenter's level.
The flat surface 81 on the left side of left extension member 14 is perfectly flat, so that it can be used both to "plumb up" door jambs and also to measure them for flatness, so that the jambs can be adjusted by use of shims until they are flat.
Thus, using the single tool described herein, a worker can quickly walk through an entire frame structure and quickly make all of the necessary measurements needed to enable workers to "plumb up" the entire structure, even if a "shed type" roof structure requiring numerous different length vertical studs is required. The same worker can quickly plumb door frames and shim the door jambs until they are flat by using the surface 81.
While the invention has been described with reference to a particular embodiment thereof, those skilled in the art will be able to make various modifications to disclosed structure and method without departing from the true spirit and scope of the invention. It is intended that all apparatus elements and method steps which accomplish substantially the same work in substantially the same way to obtain substantially the same result be encompassed within the scope of the invention. | An apparatus for measuring the plumbness of vertical studs of building structure frames includes a vertical main body member with a horizontal vial therein and having first and second opposed, plane, parallel surfaces, first and second vertical extension members being connected to said main body member and slidably engaging said first and second plane, parallel surfaces, respectively, first and second quick-release mechanisms releasably locking said first and second vertical extension members to said main body member, a first offset member connected to the upper end of the first vertical extension member and extending to an imaginary plane that is parallel to the first surface, and a second offset member extending from the bottom of the second vertical extension member to the imaginary plane. The device is rapidly extensible to any length up to nearly three times the length of the main body member in order to allow a worker to quickly plumb an outwardly warped stud by aligning the first and second offset members against the upper and lower ends of the stud. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a divisional application of U.S. Ser. No. 11/671,181, filed Feb. 5, 2007, the contents of which are incorporated by reference herein in their entirety.
BACKGROUND OF THE INVENTION
For a variety of reasons there are occasions when tubular structures such as casings and production tubing, for example, positioned downhole in wellbores need to be cut. Some examples are for removal of a damaged section of tubing or to provide a window for diagonal drilling.
Cutters have been developed that have rotating portions with knives that are pivoted radially outwardly to engage the inner surface of the tubular structure to perform a cut. Such cutters have a multitude of pivoting joints, cams and actuators that interact to rotate the knives between the noncutting and cutting configurations. The complexity of such cutters increases fabrication costs and potential failure modes.
Accordingly, the art is in need of less complex cutting tools.
BRIEF DESCRIPTION OF THE INVENTION
Disclosed herein relates to a single piece tubular member. The tubular member having a non-radially displaceable portion and a radially displaceable portion, the radially displaceable portion being movable to a position of similar radial displacement as that of the non-radially displaceable portion and a position of relatively large radial displacement in comparison to the non-radially displaceable portion. The tubular member also having at least one cutting arrangement disposed at the radially displaceable portion.
Further disclosed herein relates to a cutting tool. The cutting tool having a deformable tubular member having an inside surface and an outside surface and a plurality of lines of weakness thereat. At least one of the lines of weakness being positioned closer to one of the outside surface and the inside surface and at least one other of the plurality of lines of weakness being positioned closer to the other of the outside surface and the inside surface. The cutting tool also having at least one cutting element disposed at a portion of the tubular member most radially displaceable from an undeformed position of the tubular member.
Further disclosed herein relates to a method of cutting a downhole tubular. The method includes delivering a tubular cutting tool, with a plurality of lines of weakness thereon, to a downhole position within a downhole tubular that is to be cut, rotating the tubular cutting tool, and actuating the tubular cutting tool. The actuating causing a radially deformable portion of the tubular cutting tool to radially deform compared to an unactuated position of the tubular cutting tool. The actuating also causing a cutting element attached to the radially deformable portion to contact a downhole tubular to be cut.
Further disclosed herein relates to a method for making a cutting tool. The method includes configuring a deformable tubular member with a plurality of lines of weakness, with at least one of the plurality of lines of weakness disposed at each of an inside dimension and an outside dimension of the tubular member. The method also includes locating the plurality of lines of weakness relative to each other to facilitate deforming a portion of the tubular member to a greater radial dimension than the undeformed tubular member, and locating a cutting arrangement on the portion.
BRIEF DESCRIPTION OF THE DRAWINGS
The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
FIG. 1 depicts a partial cross sectional view of a cutting tool disclosed herein in an unactuated configuration;
FIG. 2 depicts a partial cross sectional view of the cutting tool of FIG. 1 in an actuated configuration;
FIG. 3 depicts a partial cross sectional view of the cutting tool of FIG. 2 taken at arrows 3 - 3 ;
FIG. 4 depicts a partial cross sectional view of another embodiment of a cutting tool disclosed herein in an unactuated configuration;
FIG. 5 depicts a partial cross sectional view of the cutting tool of FIG. 4 in an actuated configuration; and
FIG. 6 depicts a partial cross sectional view of the cutting tool of FIG. 5 taken at arrows 6 - 6 .
DETAILED DESCRIPTION OF THE INVENTION
A detailed description of several embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
Referring to FIGS. 1 and 2 , a partial cross sectional view of an embodiment of the cutting tool 10 is illustrated. The cutting tool 10 includes a tubular member 14 that has a radially displaceable portion 18 and a non-radially displaceable portion 20 . As illustrated in FIG. 1 the radially displaceable portion 18 is in an unactuated configuration and as illustrated in FIG. 2 the radially displaceable portion 18 is in an actuated configuration. In the actuated configuration the radially displaceable portion 18 forms two frustoconical sections 22 and 26 . The greatest radial deformation 30 of the tubular member 14 occurs where the two frustoconical sections 22 and 26 meet. Thus, an annular flow area 34 is defined by the greatest radial deformation 30 and an outside surface 38 of the non-radially displaceable portion 20 . At least one axial groove 42 in the outside surface 38 forms a first fluid passage through which fluid can flow between an uphole annular area 44 and a downhole annular area 46 when the radially displaceable portion 18 is in the actuated configuration. A second fluid passage 50 is formed through the center of the tubular member 14 defined by an inside surface 52 of the tubular member 14 .
The greatest radial deformation 30 contacts an inner surface 60 of a tubular structure 62 that is to be cut by the cutting tool 10 . A cutting arrangement positioned at the greatest radial deformation 30 engages with and cuts through the tubular structure 62 . The cutting arrangement can include a hardened portion of the metal of which the tubular member 14 is made, which can include sharpened portions of the metal, for example. Alternately the cutting arrangement can include an insert 16 of another material into the tubular member 14 . A cutting arrangement insert 16 can be made of such materials as tungsten carbide or diamonds, for example, which can be used separately or in combination.
The radially displaceable portion 18 is reconfigurable between the unactuated configuration and the actuated configuration. In the unactuated configuration the frustoconical sections 22 and 26 are configured as cylindrical components having roughly the same inside dimension as the tubular member 14 in the uphole annular area 44 and a downhole annular area 46 . Reconfiguration from the unactuated to the actuated configuration is effected, in one embodiment, by the application of an axial compressive load on the tubular member 14 . Conversely, reconfiguration from the actuated to the unactuated configuration is effected by the application of an axial tensile load on the tubular member 14 .
Reconfigurability of the radially displaceable portion 18 between the actuated configuration and the unactuated configuration is due to the construction thereof. The radially displaceable portion 18 is formed from a section of the tubular member 14 that has three lines of weakness, specifically located both axially of the tubular member 14 and with respect to the inside surface 52 and the outside surface 38 of the tubular member 14 . In one embodiment, a first line of weakness 66 and a second line of weakness 70 are defined in this embodiment by diametrical grooves formed in the outside surface 38 of the tubular member 14 . A third line of weakness 74 is defined in this embodiment by a diametrical groove formed in the inside surface 52 of the tubular member 14 . The three lines of weakness 66 , 70 and 74 each encourage local deformation of the tubular member 14 in a radial direction that tends to cause the groove to close. It will be appreciated that in embodiments where the line of weakness is defined by other than a groove, the radial direction of movement will be the same but since there is no groove, there is no “close of the groove”. Rather, in such an embodiment, the material that defines a line of weakness will flow or otherwise allow radial movement in the direction indicated. The three lines of weakness 66 , 70 and 74 together encourage deformation of the tubular member 14 in a manner that creates a feature such as the radially displaceable portion 18 . The feature is created, then, upon the application of an axially directed mechanical compression of the tubular member 14 such that the radially displaceable portion 18 is actuated as the tubular member 14 is compressed to a shorter overall length. Other mechanisms can alternatively be employed to actuate the tubular member 14 between the unactuated relatively cylindrical configuration and the actuated configuration presenting the frustoconical sections 22 and 26 . For example, the tubular member 14 may be reconfigured to the actuated configuration by diametrically pressurizing the tubular member 14 about the inside surface 52 in the radially displaceable portion 18 .
Referring to FIG. 3 , a cross sectional view of the cutting tool 10 of FIG. 2 is shown taken at arrows 3 - 3 . The fluid passages between the cutting tool 10 and the inside surface 52 , of the tubular structure 60 , created by the axial grooves 42 , is illustrated. Although the axial grooves 42 are illustrated herein as V-shaped, it should be appreciated that alternate embodiments can have grooves of any shape. It should also be noted that in alternate embodiments the cutting tool 10 could be used to cut through any downhole tubular structure such as a casing 78 for example.
Referring to FIGS. 4 and 5 , an alternate exemplary embodiment of the cutting tool 110 is illustrated. The cutting tool 110 includes a tubular member 114 and a radially displaceable portion 118 . The radially displaceable portion 118 includes a plurality of extension members 120 attached thereto. As illustrated in FIG. 4 the radially displaceable portion 118 is in an unactuated configuration and as illustrated in FIG. 5 the radially displaceable portion 118 is in an actuated configuration. In the actuated configuration the radially displaceable portion 118 forms two frustoconical sections 122 and 126 . The extension members 120 are fixedly attached to the first frustoconical section 122 at a first portion 128 . A second portion 129 of the extension members 120 is positioned radially outwardly of the second frustoconical section 126 but is not attached to the second frustoconical section 126 . As such when the radially displaceable portion 118 is actuated the extension members 120 remain substantially parallel to the first frustoconical section 122 causing the second portion 129 of the extension members 120 to extend radially outwardly of the outermost portion of the frustoconical members 122 , 126 . As such the greatest radial deformation 130 of the cutting tool 110 occurs at an end 132 of each of the extension members 120 . Control of the relationship of the greatest radial deformation 130 to the radial dimension of the end 132 in the unactuated configuration is completely controllable by setting the lengths of the second portions 129 . An annular flow area 134 is defined by the greatest radial deformation 130 and an outside surface 138 of a non-radially displaceable portion 140 . At least one axial space 142 between adjacent extension members 120 forms a first fluid passage through which fluid can flow between an uphole annular area 144 and a downhole annular area 146 when the centralizer 110 is in the actuated configuration. A second fluid passage 150 is formed through the center of the tubular member 114 defined by the inside surface 162 in the outside surface 138 forms a first fluid passage through which fluid can flow between an uphole annular area 144 and a downhole annular area 146 when the radially displaceable portion 118 is in the actuated configuration. A second fluid passage 150 is formed through the center of the tubular member 114 defined by an inside surface 152 of the tubular member 114 .
The greatest radial deformation 130 contacts an inner surface 60 of a tubular structure 62 that is to be cut by the cutting tool 110 . A cutting arrangement positioned at the greatest radial deformation 130 of the extension members 120 engages with and cuts through the tubular structure 62 . The cutting arrangement can include a hardened portion of the metal from which the extension members 120 are made. Alternately the cutting arrangement can include an insert of another material into the extension members 120 . A cutting arrangement insert can be made of such materials as tungsten carbide or diamonds, for example, which can be used separately or in combination.
The radially displaceable portion 118 is reconfigurable between the unactuated configuration and the actuated configuration. In the unactuated configuration the frustoconical sections 122 and 126 are configured as cylindrical components having roughly the same inside dimension as the tubular member 114 in the uphole annular area 144 and a downhole annular area 146 . Reconfiguration from the unactuated to the actuated configuration is effected, in one embodiment, by the application of an axial compressive load on the tubular member 114 . Conversely, reconfiguration from the actuated to the unactuated configuration is effected by the application of an axial tensile load on the tubular member 114 .
Reconfigurability of the radially displaceable portion 118 between the actuated configuration and the unactuated configuration is due to the construction thereof. The radially displaceable portion 118 is formed from a section of the tubular member 114 that has three lines of weakness, specifically located both axially of the tubular member 114 and with respect to the inside surface 152 and the outside surface 138 of the tubular member 114 . In one embodiment, a first line of weakness 166 and a second line of weakness 170 are defined in this embodiment by diametrical grooves formed in the outside surface 138 of the tubular member 114 . A third line of weakness 174 is defined in this embodiment by a diametrical groove formed in the inside surface 152 of the tubular member 114 . The three lines of weakness 166 , 170 and 174 each encourage local deformation of the tubular member 114 in a radial direction that tends to cause the groove to close. It will be appreciated that in embodiments where the line of weakness is defined by other than a groove, the radial direction of movement will be the same but since there is no groove, there is no “close of the groove”. Rather, in such an embodiment, the material that defines a line of weakness will flow or otherwise allow radial movement in the direction indicated. The three lines of weakness 166 , 170 and 174 together encourage deformation of the tubular member 114 in a manner that creates a feature such as the radially displaceable portion 118 . The feature is created, then, upon the application of an axially directed mechanical compression of the tubular member 114 such that the radially displaceable portion 118 is actuated as the tubular member 114 is compressed to a shorter overall length. Other mechanisms can alternatively be employed to actuate the tubular member 114 between the unactuated relatively cylindrical configuration and the actuated configuration presenting the frustoconical sections 122 and 126 . For example, the tubular member may be reconfigured to the actuated configuration by diametrically pressurizing the tubular member 114 about the inside surface 152 in the radially displaceable portion 118 .
Referring to FIG. 6 , a cross sectional view of the cutting tool 110 of FIG. 5 is shown taken at arrows 6 - 6 . The fluid passages between the cutting tool 110 and the inside surface 60 , of the tubular structure 62 , created by the axial spaces 142 between the extension members 120 , is illustrated. Although the extension members 120 depicted herein are rectangular prisms, it should be noted that alternate embodiments could have extension members of any shape. It should also be noted that in alternate embodiments the cutting tool 110 could be used to cut through any downhole tubular structure such as a casing 78 for example.
While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. | Disclosed herein relates to a single piece tubular member. The tubular member having a non-radially displaceable portion and a radially displaceable portion, the radially displaceable portion being movable to a position of similar radial displacement as that of the non-radially displaceable portion and a position of relatively large radial displacement in comparison to the non-radially displaceable portion. The tubular member also having at least one cutting arrangement disposed at the radially displaceable portion. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to a circuit and particularly to an LED drive circuit.
BACKGROUND OF THE INVENTION
[0002] Conventional LED drive circuits typically are designed by adopting a switch-type power converter. Referring to FIG. 1 , it employs a semiconductor power switch to switch low frequency AC or DC power signals to high frequency DC drive signals usable for LEDs. Such a high frequency conversion wastes a lot of energy on different converter elements and results in power loss. Moreover, the high frequency switch creates signal interference that requires more elements to suppress. As the prevailing trend of products mainly focuses on energy-saving and miniaturization, the structure of the switch-type power converter cannot fully meet the requirement of LED drive circuits.
[0003] Furthermore, the common voltage regulator circuit is typically used for constant current control that is widely adopted. The voltage regulator must share significant energy with the controlled constant current load to get desired control effect. As a result, it also consumes a lot of power that becomes a great concern for designing the power converter. When in use, in the voltage regulator circuits, the more power consumption of the elements, the higher the temperature. If the voltage regulator circuit is adopted in the LED drive circuits, the greater cooling mechanism is needed. This disobeys the requirements of energy-saving and miniaturization of the products. Thus there are still rooms for improvement.
SUMMARY OF THE INVENTION
[0004] The primary object of the present invention is to solve the problems of excessive power loss and easy interference occurring to the conventional LED drive circuits that adopt switch-type power converters.
[0005] Another object of the invention is to solve the problem of the conventional LED drive circuits that adopt a voltage regulator circuit that renders higher temperature caused by too much power loss and results in difficulty in product miniaturization because of the constraint of the cooling mechanism.
[0006] To achieve the foregoing objects, the present invention provides an LED drive circuit comprising a power supply unit, a first LED lamp string, a first voltage control unit, a second LED lamp string and a first power transfer unit. The power supply unit includes an output end to output drive power. The first LED lamp string is connected to the output end to receive the drive power to be driven, and includes a first anode end connected to the output end and a first cathode end. The first voltage control unit is connected to the first cathode end to get the drive power and stabilize and provide the voltage to the first LED lamp string. The first voltage control unit includes a power switch. The drive power generates a power loss on the power switch. The second LED lamp string is connected to the first voltage control unit. The first power transfer unit bridges the second LED lamp string and first voltage control unit.
[0007] The first power transfer unit transfers the power loss generated on the power switch to the second LED lamp string for driving thereof.
[0008] Thus, through the technique set forth above, the invention can provide at least the following advantages:
[0009] 1. Through the first voltage control unit, the problems of excessive power loss and easy interference occurring to the conventional switch-type power converter can be averted.
[0010] 2. By connecting the first power transfer unit and second LED lamp string to the first voltage control unit, the power loss originally consumed at the power switch is transferred and output to drive the second LED lamp string. This not only resolves the problem of providing an extra cooling mechanism due to the high temperature caused by too much power loss of the power switch, the product also can be miniaturized. With the power loss used for lighting the second LED lamp string, lighting efficiency of the drive circuit is enhanced. Hence it also can utilize energy resources more efficiently and save energy.
[0011] 3. By dispensing with the switch-type power converter, the invention can be structured simpler at a lower cost, and also can be operated at a lower temperature and stably.
[0012] The foregoing, as well as additional objects, features and advantages of the invention will be more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic circuit diagram of a conventional LED drive circuit.
[0014] FIG. 2 is a schematic circuit block diagram of the invention.
[0015] FIG. 3 is a schematic circuit diagram of a first embodiment of the invention.
[0016] FIG. 4 is a schematic circuit diagram of a second embodiment of the invention.
[0017] FIG. 5 is a schematic circuit diagram of a third embodiment of the invention.
[0018] FIG. 6 is a schematic circuit diagram of a fourth embodiment of the invention.
[0019] FIG. 7 is a schematic circuit diagram of a fifth embodiment of the invention.
[0020] FIG. 8 is a schematic circuit diagram of a sixth embodiment of the invention.
[0021] FIG. 9 is a schematic circuit diagram of a seventh embodiment of the invention.
[0022] FIG. 10 is a schematic circuit diagram of an eighth embodiment of the invention.
[0023] FIG. 11 is a schematic circuit diagram of a ninth embodiment of the invention.
[0024] FIG. 12 is a schematic circuit diagram of a tenth embodiment of the invention.
[0025] FIG. 13 is a schematic circuit diagram of an eleventh embodiment of the invention.
[0026] FIG. 14 is a schematic circuit diagram of a twelfth embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Please refer to FIG. 2 for a circuit block diagram of the invention. It is an LED drive circuit comprising a power supply unit 10 , a first LED lamp string 20 , a first voltage control unit 30 , a second LED lamp string 40 and a first power transfer unit 50 . The power supply unit 10 includes an output end 11 to output drive power. The first LED lamp string 20 is connected to the output end 11 to receive the drive power to be driven, and includes a first anode end 21 connected to the output end 11 and a first cathode end 22 . The first voltage control unit 30 is connected to the first cathode end 22 to get the drive power and stabilize and provide the voltage to the first LED lamp string 20 . The first voltage control unit 30 includes a control end 32 , a feedback end 33 and a power switch 31 connecting to the control end 32 and feedback end 33 . The drive power generates a power loss on the power switch 31 . The second LED lamp string 40 is connected to the first voltage control unit 30 . The first power transfer unit 50 bridges the second LED lamp string 40 and first voltage control unit 30 to form a serial connection with the second LED lamp string 40 , and also bridges the control end 32 and feedback end 33 with the second LED lamp string 40 . Thereby, the first power transfer unit 50 transfers and outputs the power loss generated on the power switch 31 to the second LED lamp string 40 for driving thereof.
[0028] Please refer to FIG. 3 for the circuit diagram of a first embodiment of the invention. In this embodiment the first LED lamp string 20 is coupled in parallel with a first capacitor 23 and a first resistor 24 to filter out ripple waves and get a stable DC current. The first anode end 21 is connected to the output end 11 of the power supply unit 10 . The power supply unit 10 includes a full bridge rectifier 12 and an AC power source 13 connected to the full bridge rectifier 12 . The first voltage control unit 30 is connected to the first cathode end 22 of the first LED lamp string 20 . The second LED lamp string 40 is connected to the first voltage control unit 30 , and includes a second anode end 41 and a second cathode end 42 . In this embodiment the second anode end 41 is connected to the first voltage control unit 30 via a rectification diode 45 , and the second LED lamp string 40 also is coupled in parallel with a second capacitor 43 and a second resistor 44 . The first power transfer unit 50 bridges the second cathode end 42 of the second LED lamp string 40 and the first voltage control unit 30 , and has the same circuit structure as the first voltage control unit 30 .
[0029] In this embodiment, the first voltage control unit 30 includes the power switch 31 a and a control circuit 34 connecting to the power switch 31 a. The power switch 31 a is an N-type power switch in this embodiment. The control circuit 34 includes a Zener diode 342 , a third resistor 343 , a voltage stabilization element 341 a, a fourth resistor 344 and a fifth resistor 345 . The Zener. diode 342 is connected to the gate of the power switch 31 a to provide voltage stabilization protection for the power switch 31 a. The third resistor 343 bridges the gate of the power switch 31 a and control end 32 . The voltage stabilization element 341 a is an NPN transistor here and connected to the gate of the power switch 31 a . The fourth resistor 344 is connected to the emitter of the NPN transistor. The fifth resistor 345 is connected to the gate of the NPN transistor. The AC power source 13 is rectified through the full bridge rectifier 12 to generate a DC voltage supplied to the first LED lamp string 20 for emitting light. The control current of the first voltage control unit 30 is a constant current, hence the first LED lamp string 20 can stably emit light a constant luminosity. The power loss on the power switch 31 a is transferred to the second LED lamp string 40 and first power transfer unit 50 to drive the second LED lamp string 40 .
[0030] Please refer to FIG. 4 for the circuit diagram of a second embodiment of the invention. It differs from the first embodiment by replacing the NPN transistor by a three-end voltage regulator to be the voltage stabilization element 341 b . The three-end voltage regulator has a gate connecting to the fifth resistor 345 to provide a stable voltage for the fifth resistor 345 .
[0031] Please refer to FIG. 5 for the circuit diagram of a third embodiment of the invention. It differs from the first embodiment by replacing the NPN transistor by serial-connected diodes to be the voltage stabilization element 341 c. The serial-connected diodes provide a stable voltage for the fifth resistor 345 as well.
[0032] Please refer to FIG. 6 for the circuit diagram of a fourth embodiment of the invention. It differs from the first embodiment by replacing the NPN transistor by a Zener diode to be the voltage stabilization element 341 d. The Zener diode also can provide a stable voltage for the fifth resistor 345 .
[0033] Please refer to FIG. 7 for the circuit diagram of a fifth embodiment of the invention. It differs from the first embodiment by replacing the N-type power switch by an NPN transistor to be the power switch 31 b.
[0034] Please refer to FIG. 8 for the circuit diagram of a sixth embodiment of the invention. It differs from the fifth embodiment by including an integration circuit in the control circuit 34 of the first voltage control unit 30 and replacing the NPN transistor in the integration circuit by an operational amplifier to be the voltage stabilization element 341 e. The operational amplifier is connected to the base of the power switch 31 b, the cathode of the Zener diode and a third capacitor 346 . The third capacitor 346 has another end connecting to the inverse end of the operational amplifier and a sixth resistor 347 connecting to the fifth resistor 345 . The sixth resistor 347 and the anode of the Zener diode 342 are connected to the feedback end 33 . The non-inverse ends of the operational amplifier are connected to a seventh resistor 348 connecting to a DC voltage end and an eighth resistor 349 connecting to a ground end.
[0035] Please refer to FIG. 9 for the circuit diagram of a seventh embodiment of the invention. It differs from the first embodiment by using a transistor 51 as the first power transfer unit 50 which is a current limit resistor, thus has a circuit structure different from the first voltage control unit 30 .
[0036] Please refer to FIG. 10 for the circuit diagram of an eighth embodiment of the invention. It differs from the first embodiment by replacing the N-type power switch 31 by a P-type power switch to be the power switch 31 c. The structure of the control circuit 34 can be changed according to the characteristics of the power switch 31 c being used. In addition, NPN transistor or PNP transistor also can be adopted.
[0037] Please refer to FIG. 11 for the circuit diagram of a ninth embodiment of the invention. It differs from the first embodiment by including a second voltage control unit 60 and a second power transfer unit 70 in the drive circuit that are coupled in parallel with the first voltage control unit 30 and first power transfer unit 50 . Thus, when the power loss cannot be fully transferred and output from the first power transfer unit 50 to the second LED lamp string 40 , the second power transfer unit 70 can aid to output the residual power loss to the second LED lamp string 40 . It is to be noted that in this embodiment a third voltage control unit and a third power transfer unit, a fourth voltage control unit and a fourth power transfer unit and so on that are coupled in parallel with the second LED lamp string 40 also can be provided according to the amount of the power loss without limitation.
[0038] Please refer to FIG. 12 for the circuit diagram of a tenth embodiment of the invention. It differs from the first embodiment on the power supply unit 10 which is merely an AC power source 13 . Hence, the drive circuit, according to the characteristics of AC power output from the AC power source 13 , is coupled in series with the first LED lamp string 20 , first voltage control unit 30 , second LED lamp string 40 and a first circuit 80 the same as the first power transfer unit 50 to form an AC LED drive circuit
[0039] Please refer to FIG. 13 for the circuit diagram of an eleventh embodiment of the invention. It differs from the first embodiment on the power supply unit 10 which is merely a DC power source 14 . Hence, the drive circuit, according to the characteristics of DC power output from the DC power source 14 , is coupled in parallel with the first LED lamp string 20 , first voltage control unit 30 , second LED lamp string 40 and a second circuit 90 the same as the first power transfer unit 50 to form a DC LED drive circuit.
[0040] Please refer to FIG. 14 for the circuit diagram of a twelfth embodiment of the invention. It differs from the first embodiment by further including a first expansion unit 100 which has a circuit structure the same as that of the second LED lamp string 40 and first power transfer unit 50 . In this embodiment, the first power transfer unit 50 is structured the same as the first voltage control unit 30 by having a first control end 52 and a first feedback end 53 corresponding respectively to the control end 32 and feedback end 33 . The expansion unit 100 bridges the first control end 52 and first feedback end 53 . Thus, when a first power switch 54 of the first power transfer unit 50 generates a first power loss, the first power loss is further transferred to the first expansion unit 100 to reduce the heating temperature of the first power switch 54 and also drive an LED lamp string 101 to emit light. Through the first expansion unit 100 , total transfer efficiency can be enhanced. It is to be noted that a second expansion unit having the same structure as the first expansion unit 100 can be provided to couple with the first expansion unit 100 , and a third expansion unit having the same structure as the second expansion unit also can be provided to couple with the second expansion unit, and so on to get improved transfer efficiency.
[0041] As a conclusion, the invention provides at least the following advantages:
[0042] 1. Through the first voltage control unit, the problems of excessive power loss and easy interference occurring to the conventional switch-type power converter can be avoided.
[0043] 2. By coupling the first power transfer unit and second LED lamp string with the first voltage control unit, the power loss generated on the power switch of the first voltage control unit is transferred and output to drive the second LED lamp string. Thus not only the problem of adding an extra cooling mechanism due to the high temperature caused by the power loss can be averted, the power loss also can be used for lighting the second LED lamp string to improve lighting performance of the drive circuit, thereby utilize energy resources more efficiently and save energy.
[0044] 3. The invention does not require the switch-type power converter, thus can be simply structured at a lower cost to make, and also can be operated in a lower temperature and has improved stability.
[0045] 4. Through the second voltage control unit and second power transfer unit, the amount of power loss can be regulated to get improved output transfer effect.
[0046] 5. The invention further can effectively use the power loss to generate light through the first expansion unit to achieve improved transfer efficiency.
[0047] While the preferred embodiments of the invention have been set forth for the purpose of disclosure, they are not the limitation of the invention, modifications of the disclosed embodiments of the invention as well as other embodiments thereof may occur to those skilled in the art. Accordingly, the appended claims are intended to cover all embodiments which do not depart from the spirit and scope of the invention. | An LED drive circuit comprises a power supply unit, a first LED lamp string, a first voltage control unit, a second LED lamp string and a first power transfer unit. The power supply unit outputs a drive power to drive the first LED lamp string. The first voltage control unit gets the drive power and stabilizes and provides the voltage to the first LED lamp string. The first voltage control unit includes a power switch where the drive power generates a power loss. The second LED lamp string and first power transfer unit are coupled in series with the first voltage control unit so that the power loss is transferred and output to drive the second LED lamp string. Thus loss of the drive power is reduced and lighting efficiency of the LED improves. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to various coated fabric articles of manufacture that glow in the dark. More specifically, the invention preferably relates to coated fabric toys and similar articles, especially stuffed animal or other figure toys, that have specific general body luminescence or anatomic parts that void or attenuate general luminescence and emit visible light in low light or in the dark. The invention describes toys of various sizes, shapes and designs. In a most preferred embodiment, the invention provides stuffed fabric toys.
[0003] 2. Description of the Prior Art
[0004] Toys and various articles of manufacture that have light emitting elements from external natural or artificial light sources are known in the art. Also, toys and articles that selectively phosphoresce and/or, fluoresce have been described. Various human and animal toys that glow or emit light, and gloves that glow are described in U.S. Pat. Nos. 5,374,192, 6,360,693, 4,655,721 and 5,580,154.
[0005] What is needed are toys or other items that are capable of storing light energy when struck by light and selectively emitting visible light over extended periods in low light or in the dark. Preferably, what is needed are various coated fabric toys, including but not limited to stuffed animals and the like, that glow in the dark and selectively emit light so as to delineate recognizable overall form and/or selected body parts. The present invention is directed toward solving this need.
[0006] By way of background, luminescence is a general term applied to all forms of cool light (i.e., light that is usually occurs at low temperatures in contrast to incandescent light emitted by hot incandescent bulbs or the like). There are several kinds of luminescence: chemoluminescence (including bioluminescence from living organisms such as sea plankton, fireflies, glowworms, certain fungi etc.; produced by chemical reactions, primarily oxidations, at low temperatures), crystalloluminescence; electroluminescence (i.e.,cathodoluminescence; produced by electric discharges that occur when silk or fur is stroked, when adhesive surfaces are separated, etc.); photoluminescence (i.e., phosophorescence; fluorescence); radioluminescence; sonoluminescence; thermoluminescence (i.e., produced by crushing crystals); and triboluminescence. Luminescence can be caused by chemical or biochemical changes, electrical energy, subatomic motions, various reactions in crystals, or by stimulation of an atomic system. Although phosphorescence is a specific type of photoluminescence related to fluorescence, they are sometimes confused. Also, the term phosphorescence is often incorrectly used synonymously with luminescence. The process of coating dials, fabric, signs, aviation and navigations instruments, etc. with luminescent materials is known as luminising.
[0007] A wide variety of non-radioactive photoluminescent products that glow in the dark are known, including luminescent powders, paints, waxes, gels, polishes, inks, plastics, yarns, signs, sheets, and the like. A wide variety of organic and inorganic compositions are known to effect luminescence. Zinc sulfide based material has been commonly used to produce glow in the dark items and paints. However, zinc sulfide based compositions and related materials have limited glow in the dark characteristics after exposure to natural or artificial light, typically glowing for only an hour or so after exposure to light. More recently, a new generation of luminescent materials containing rare earth metals has been developed that provide extended glow in the dark luminescent after exposure to light. Such rare earth metal compositions (i.e., containing Europium etc.) provide bright and long lasting luminescence (i.e., sometimes glowing in the dark for 12 hours or more after being exposed to light).
[0008] A major limitation of the use of rare earth metal composition coating on fabric is that luminising provides a surface coating exposed to the light that is rough or coarse to the touch. Hence, items with fabrics that are coated with these compositions that touch the skin of the user have a texture that is unacceptable. Luminescent coating are generally applied to the surface of articles that re exposed to light sot that maximum light exposure will be provided to the coating material for maximal generation of luminescence
[0009] Accordingly, it is an object of the present invention to provide improved luminescent fabric having glow in the dark capability;
[0010] Another object of the present invention is to provide luminescent fabric coated glow in the dark toys;
[0011] Yet another object of the present invention is to provide glow in the dark luminescent fabric coated articles that do not have a coarse texture.
SUMMARY OF THE INVENTION
[0012] The present invention provides a system and method for articles of manufacture that have luminescent or glow in the dark features. Preferred embodiments are fabric-coated toys, sports equipment, household items, clothing, and the like, that absorb daylight or artificial light and emit light in the dark. Articles that may be coated with luminescent-coated fabric of the invention include but are not limited to: animal and character slippers; animal and character and decorative pillows; key chains; squishy pillows; character animal pens; plush cars, trains boats, bats, ball and beds; glow fabric picture frames; glow fabric picture frames with characters/animals; purses; coin purses; books; puzzles; notepad covers; Halloween costume accessories, tails, masks, ears; Halloween fabric trick or treat bags; fabric coated buttons; Christmas ornaments; shoe laces; shoes; scarves; hats; visor hats; fabric books; fabric rattles; puppets; magnets with plus toy attached or in plus toy; backpacks; barrettes; hair pony tails; ribbon; bibs; belts; socks; cell phone holders; and ear muffs. Luminescent capability is preferably provided by coating fabric with doped or rare earth metal activated photo-luminescent materials (i.e., Strontium Aluminates, Sr:Al:Eu, and related products). Organic as well as inorganic luminescent compositions may be applied to fabric. Luminescent material is applied to only one side of the fabric.
[0013] The present invention is directed to fabric-coated articles, preferably toys that glow in the dark, including especially stuffed toys that exhibit luminescence in the dark after exposure to natural or artificial light. The toys may be any variety of animal or plant or specific form of any object. Toys that are animal variants are preferred, including mammals, reptiles, birds and insects. The toys exhibit glow patterns in the dark that generally show the entire glowing form of the toy with distinguishable, generally lower or non-glowing intensity of specific organs, body parts and the like giving life-like appearance to the toy. Toys and other fabric-coated items that luminesce are preferred, but toys and other fabric-coated items that phosphoresce or fluoresce are also within the scope of the invention.
[0014] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. Although any methods, materials, and devices similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present invention, the preferred methods, materials, and devices are now described. All publications mentioned herein are incorporated by reference. Nothing herein is to be construed as an admission that the invention is not entitled to antedate such disclosure by virtue of prior invention. In case of conflict, the present specification, including definitions, will control. In addition, the materials, methods and examples are illustrative only and not intended to be limiting.
[0015] Other features and advantages of the invention will be apparent from the following description and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The accompanying drawings, which are incorporated in and form a part of the specification, illustrate embodiments of the present invention and, together with the description serve to explain the principles of the invention. The embodiments illustrated in the drawing should not be read to constitute limiting requirements, but instead are intended to assist the reader in understanding the invention.
[0017] FIG. 1 is a photograph of four stuffed toys with luminescent fabric and embroidered eyes, nose, ears, fingers, and toes.
[0018] FIG. 2 is diagrammatic cross sectional view of a stuffed doll member having luminescent coated fabric.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The present invention includes any and all fabric coated articles, including in a preferred embodiment toy stuffed animals, mammals, reptiles, birds, insects preferably made to glow in the dark with fluorescent coated fabric. Preferably, the fabric of the invention is coated on one side with luminescent material doped with Europium and other rare earth elements. Any fabric that has some natural porosity, including cotton, polyester and other synthetic fibers, wool, and combinations thereof to which luminescent coating adheres may be used. Multiple layer fabrics or very tightly woven fabrics may not be suitable materials. In the fabrication of stuffed toys and other fabric coated articles, the coated side that has a rough texture is faced inward with the untreated side of the fabric facing outward. By placing the untreated side of the casing fabric outward, the toy or other fabric coated article has a natural feel to the touch while still providing luminescent properties. Normally the treated side of fabric would be faced outward to maximize light absorption and luminesce. It was surprising to learn that the luminescent glow in the dark capabilities were retained when the treated side of the fabric was turned “inside-out” away from the light. Optionally, toys or other articles may have embroidered or embroidered features (i.e., eyes, nose, mouth, nails, ears, paws, claws and other markings) with untreated fabric, threads, or fiber. With such embroidered or other features on the base luminescent fabric, the glow in the dark or luminescent characteristics of the base fabric are negated thereby leaving the features without any glow in the dark capability emphasizing the features. Alternatively, if eyes, nose, mouth or other feature markings are made with treated fabric, threads, or fibers, the features will luminesce along with the base fabric.
[0020] The glow patterns of the articles and toys of the invention may preferably be obtained by use of by coating one side of the chosen casing fabric with rare earth doped luminescent material or other luminescent material that will still provide glow in the dark capability. Alternatively, luminescent coating may be added to the stuffing of the article or toy as the case may be. For example, pellets that are luminescent, preferably super high intensity glow pellets, may be used as toy stuffing or placed in a layer underneath casing fabric of toys or other articles. With luminescent stuffing (pellets, etc.) it is preferred that the casing fabric be loosely woven fabric so as to permit light penetration. Thus, the toy will show the same glow pattern as if one-side-luminescent-material-treated fabric used inside-out were used. A stuffed bear toy was prepared using loosely woven fabric and stuffed with high intensity glo pellets. This stuffed bear glowed successfully in the dark. Glo stuffing should be directly underneath the outer casing or fabric.
[0021] The articles of the invention, preferably stuffed toys with luminescent one-side-coated casing fabric with the coated side facing inward, will take on the appearance, touch and feel of a traditionally stuffed toy but when exposed to darkness will glow in the dark creating a ghost like image of the stuffed toy. Stuffed toys of the invention are preferably fabric coated and in the case of stuffed animals, preferably have fur or fur-like fabric. However, toys may alternatively be made of solid material.
[0022] Referring now to FIG. 1 , shown are four stuffed dolls of the invention. The dolls have a polyester fabric casing 101 that is treated on one side with Europium doped luminescent material with the treated (coarse textured) side facing inward. The dolls have embroidered facial features (eyes, nose, mouth, cheeks, whiskers, ears) that use untreated thread or fabric Eye 102 is shown.
[0023] Referring now to FIG. 2 , shown is a diagrammatic cross section of a member of a doll of FIG. 1 . The diagram shows a schematic cross section of a representative member of a doll (i.e., head, arm, leg, etc.) to show the interior location of the luminescent coating on the casing fabric of the doll. Shown is the casing fabric 201 with the untreated side facing outward, the luminescent material on the inward side of the casing 202 , and stuffing of the doll 203 .
[0024] Stuffed toys of the invention may be manufactured by coating one side of any traditional casing fabric with luminescent material, preferably doped with Europium and other rare earth elements. Any luminescent coating that is able to provide glow in the dark capability after exposure to light may be used, but material comprising Europium is preferred. The casing fabric may be spray coated, brush coated, or otherwise applied to one side of the fabric by methodology known in the art. In addition most animal toys of the invention will be accented with features and markings with fibers or other material that may or may not be luminescent treated. For example, add-on features may use untreated materials.
[0025] The present invention comprises the treating of one side of fabric with luminescent material and use of the treated fabric for covering or casing of various articles of manufacture, preferably stuffed toys, to provide nighttime or glow in the dark luminescence when articles are placed in the dark after exposure to natural or artificial light. Various ornamental features may optionally be applied to the fabric casing of the doll or other articles using standard luminescent threads or materials or untreated threads or materials. Optionally, in addition to whole body luminescence provided by use of treated casing fabric, dolls or other articles may use one-side-treated fabric similarly placed (“inside out”) for just certain portions of the items placed on untreated casing. For example, in the case of dolls, just the eyes, nose, mouth, ears or other features may use the treated fabric thereby providing nighttime luminescent to just the features after exposure to light. With use of rare earth doped luminescent material, the dolls or other articles will glow in the dark for extended periods of time. Children will be comforted in the night by luminescent dolls of the invention.
[0026] In the manufacture of stuffed toys of the invention, glow in the dark dolls, or dolls with just luminescent features and/or markings will provide a ghost-like image when exposed to darkness. The invention is novel and will provide the child with a traditional cuddle toy with a special effect. The invention provides novel stuffed toys and luminescent products.
[0027] There are a number materials that can be mixed or melted with paint, waxes, plastics, gels etc. to provide luminescence. For example, newly developed Europium-based materials, or older Zinc Sulfide based materials, are available. The Europium-based materials are sometimes known as phosphorescent powders, but function as luminescent products. These phosphorescent powders come in blue or green colors. Europium-based paints and powders are available commercially. Luminescent or phosphorescent glow is produced after exposure to sunlight, artificial light (incandescent or fluorescent), or ultra violet light. Also, photo-luminescent (glow-in-the-dark) yarns and films are available commercially having luminescent materials consisting mainly of crystals of Strontium Aluminates (Sr:Al:Eu). Strontium Aluminates provide luminescent glow that lasts several times longer than traditional crystals of Zinc Sulphide and are used in a wide variety of products (i.e., photo-luminescent pigments, PVC film, paints, signs, etc.). Strontium Aluminates or Europium-based materials are preferred for coating the fabrics of the invention.
[0028] Photo-luminescent self-adhesive films and tapes containing Strontium Aluminates may be cut into various shapes and applied to surfaces (walls, ceilings, etc.) or used on sporting goods, stationary, telephones, electronic equipment, indoor and outdoor emergency lines and signs, and the like. In such applications, it is desirable to have maximum light exposure provided to the luminescent material. Generally with luminescent films and paints a film thickness in the range of 100-150 μm is provided.
[0029] With photo-luminescent glow-in-the-dark articles of the invention, any convenient natural or synthetic fabric that may be coated on one side with luminescent material, preferably coated with Europium based material, may be used. Cotton, polyester, nylon, rayon, wool, etc. or any combinations of natural and/or synthetic fabric may be used. Acceptable glow-in-the-dark functionality is optimally provided by light colored fabrics (i.e., white, yellow, beige, etc.) that have acceptable weaves. Acceptable weaves of fabric is interpreted to mean fabrics wherein sufficient light can penetrate the fabric when light is exposed to the untreated side to activate the luminescent coating on the treated side of the chosen fabric. Dark colors (i.e., black) are not preferred and seem to absorb luminescent light and produce attenuated glow-in-the-dark functionality. Very thick or tightly woven fabrics may not work optimally or work poorly. Coating and testing samples of desirable fabrics can conveniently enable evaluation of the suitability of various fabrics.
[0030] Preferred luminescent materials are Strontium Aluminates (Sr;Al;Eu) or rare earth activated silicate aluminates (strontium aluminates-silicates). These materials may contain addition materials such as rare earth elements or metals (i.e., Europium Oxide; Dysprosium Oxide, Aluminum Oxide). Zinc sulfide-based luminescent materials may be used but are not preferred. Any photo-luminescent coating that can produced acceptable luminescence when applied to fabric on one side and used inside-out (coated side inside; light exposed to the untreated side of the fabric) to avoid coarse feel of the coating to the touch may be used.
EXAMPLE
Fabrication of Glow-In-The-Dark Stuffed Toys
[0031] Various stuffed animals shown in FIG. 1 were fabricated. The casing of the dolls is white polyester fabric that was coated with photo-luminescent rare earth-based material on one side by Jiang Su Guo Da Group, Jiangsu Province, China. The coating material, that has a green color, contained SrAl 2 O 4 :Eu (45%); Al 2 O 3 (42%); Eu 2 O 3 (8%); and Dy 2 O 3 . The dolls are approximately 8½ inches in length and have non-luminescent embroidered features. Non-luminescent material (i.e., thread or fabric), was sewn on to provide certain dress or anatomical features (i.e., inner ear; belts; boots, gloves, eyes, nose, mouth). The treated side of the casing fabric was on the inside surface with the natural fabric side on the outside. The filling of the dolls is polyester. Antennae are constructed with foil coated wire stiffeners. Following exposure to light, the dolls all provide a long-lasting green glow pattern. Black polyester fibers were sewn to mark the eyes, nose and paw markings.
[0032] Although the present invention describes in detail certain embodiments, it is understood that variations and modifications exist known to those skilled in the art that are within the invention. Accordingly, the present invention is intended to encompass all such alternatives, modification and variations that are within the scope of the invention as set forth in the following claims. | Toys and other fabric coated articles that glow in the dark. The present invention is preferably directed to a variety of articles, especially stuffed toys, that exhibit luminescence in the dark following light exposure. The toys may be any variety of animal, plant or specific form, including but not limited to mammals, reptiles, birds and insects. Methods of manufacture are described that use fabric coated with luminescent material on one side that is used as casings with the rough coating side facing inwardly for toys and other items. | 0 |
BACKGROUND OF THE INVENTION
In recent years beans have come to be utilized over a wide range of applications and accordingly their effective utilization and treatment has become an important endeavor.
For example, the effective utilization of the soybean refuse generated during tofu production is one of these endeavors. However, there are various qualities of bean refuse. Thus there are considerble differences in the practicality of utilizing refuse such as, for example, bean refuse from hulled soybeans compared to bean refuse from soybeans still having their hulls on. The hulled soybean refuse has the potential possibility of being utilized to a rather higher degree as a food.
Prior U.S. patent application Ser. No. 804,435 relates to a device for the production of food products by utilizing whole-grain soybeans. The present invention is intended to provide an apparatus for treating various beans, particularly soybeans comprising apparatus for hulling the soybeans and for separating the outer hulls from the beans which may be utilized in the invention of said prior application.
SUMMARY OF THE INVENTION
The present invention is a bean treating apparatus comprising means for hulling beans, such as a disk-type hulling device having two disks, one fixed and the other rotating, set in a position parallel and opposing to each other with a clearance being provided between the disks which can be freely adjusted to accomodate and trap the soaked beans which are dropped between the disks and then split into halves as they are moved in the direction of the rotation with the hulling action being simultaneously carried out. A running-water-type hull and seed separating device which is a water tank has the aforementioned hulls and seeds introduced into one end thereof. These hulls and seeds are separated by water having varying flow rates which is caused to flow from one side of the tank.
The apparatus of the present invention will be described by referring to the attached drawings.
BRIEF EXPLANATION OF THE DRAWINGS
FIG. 1 (a) shows a side view of a disk-type hulling device according to the present invention.
FIG. 1 (b) shows a vertical cross section of the device shown in FIG. 1 (a).
FIG. 2 (a) shows a cross section of a running-water-type hull and seed separating device of the present invention.
FIG. 2 (b) shows a perforated plate used in the rectifying device used in the separation tank used in the present invention.
FIG. 3 (a) shows rectifying control plate used in the separation tank according to the present invention.
FIG. 3 (b) to FIG. 3 (d) show positions of the rectifying control plate.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, 1 is the material feed hopper, and the raw material beans, together with water, drop into the space 6 between the fixed disk 3 and the revolving disk 5 through an opening in the disk 3 shown in dotted line in FIG. 1(a), these beans being moved as the revolving disk rotates, and being split into halves and simultaneously hulled. A scraper 4 scrapes off hulled material from the disk 3 and clears space 6. The disk clearance 6 is adjusted by means of a disk clearance control bolt 2 in accordance with the size of the beans, but usually a value of 70 to 80% of the bean diameter is appropriate. 7 is a bolt for adjusting the scraper.
The hulled beans exiting from the above device and operation are washed down by water from a water sprayer 9 and pass through a collection chute 10, dropping into a hull and seed separating tank 11 as shown in FIG. 2 (a). This water tank is rectangular and the hull fraction and the cotyledon fraction from the seeds split into halves fall into this tank at one end A of it and are then separated from each other due to the difference in their specific gravities as they float in water flowing from the rectifying tank 12. The rectifying tank 12 comprises a perforated plate 12-a as shown in FIG. 2 (b), through which the water is spouted under pressure to cause a water flow in the separation tank. It is preferable that the total area of the perforation is not more than 2/3 of the cross sectional dimension of the pipe 17 which is provided for returning water to the rectifying tank 12.
The cotyledon fraction falls inside a screw conveyor 14 driven by a motor M and is then stored in a stock tank 15. On the other hand, the hulls float up and enter the hull collection pan 18 together with the overflowing water, and the water enters a water storage tank 19 and excessive water is exhaused from the exhaust pipe 20. This water, by virtue of a pump 21 driven by a motor M, is used again for the separation. Since there is likely to be a bit of hulls contaminating the cotyledons at the far end of the screw conveyor 14, an auxiliary water jet 24 is preferably employed to blow them up and toward the overflow. This is regulated by an auxiliary water jet control valve 25.
The rectifying control plate 13 is preferably composed of four separated plates as shown in FIG. 3 (a), each being designed to slide up and down along guide rails 26 provided on the side walls of the separation tank 11.
By adjustment of the position, a lower, upper or middle position, for example, of the rectifying control plate 13, the water flow from the rectifying tank 12 can be partially changed into varied states as shown in FIGS. 3b-3d in the vicinity of the plate 13.
Thus, when the plate 13 is at a lower position as shown in FIG. 3 (b), a quicker water flow is obtain in the upper portion, while when the plate 13 is positioned at an upper position as shown in FIG. 3 (c), a quicker water flow is obtained in the lower portion of the tank.
Meanwhile, when the plate 13 is separated into the upper portion and the lower portion as shown in FIG. 3 (d), a quick water flow is obtained at the middle portion of the tank.
With regard to the question of why water flow must be varied by the rectifying or control plate 13, it is noted that the cracked soybeans and hulls coming from the hulling machine are arranged to fall into the separation tank 11.
Soybeans are allowed to sink to the bottom part of the separation tank while the hulls are arranged to overflow the tank 11 for separation of the hulls from the soybeans. However, the size and specific gravity of each soybean or hull will differ from those of other soybeans or hulls. Therefore the material will sink in varied degrees. Particularly, the distribution of the hulls flowing within the tank 11 from the rectifying tank 12 toward the area or the vicinity of the control plate 13 will vary to a substantial degree. Therefore, the control plate is adjusted into a position, as shown in FIG. 3(b), whereby many of the hulls in the vicinity of the plate 13 will be in a relatively higher area within the separation tank. The control plate 13 may also be adjusted as shown in FIG. 3(c) when the hulls are in a relatively lower area within the separation tank. Another state shown in FIG. 3(d) indicates the condition when the hulls are in a middle area so that they may be allowed to overflow as desired. In general, the control plate 13 will operate to enable varying control of the flow of the hulls to the overflow portion of the tank for collection within the pan 18.
The quantity of water flowing from the tank 12 into the separation tank 11, and overflowing the tank 11 into the pan 18, is maintained to be generally unvarying. Therefore, adjustment of the plate 13 as shown in FIGS. 3(b) 3(d) will not cause change in the velocity of the water which is flowing between the tank 12 and the opposite side of the tank 11. What is changed by the adjustment of the plate 13, as shown in FIGS. 3(b)-3(d) is the manner of flow in which the water will pass through the vicinity of the control plate 13.
The cotyledons are stored in the stock tank 15 until a fixed amount is obtained; then a valve 16 opens and these are flushed out together with water and enter a collection pan 23 where the water is drained off. When a high level of separation is required due to the application, it is possible to increase the separability by employing salt water instead of plain water. The level of water in the tank 11 is adjusted by opening and closing the valve 27.
As described above, the hulling apparatus of the present invention is one which carries out hulling and separation of the hulls and seeds by means of an extremely simple hulling device having only 2 disks, and a water tank which has water flowing in it at different flow rates at the top and bottom. This apparatus, furthermore, has the special feature that the cotyledons are not damaged or finely ground during operation and so there is no drop in the yield.
With regard to the entry of beans between the discs 3 and 5, as shown in FIGS. 1(a) and 1(b), there is shown an opening extending through the disc 3. This opening is shown in dotted line form in FIG. 1(a) and it is shown at the centrally upper portion of FIG. 1(b) as a square opening extending through the face of the disc 3. The beans from the feed hopper 1 enter into the clearance space 6 through this opening and they are thus brought into position within the clearance 6. It will be apparent that this will insure that the beans are properly engaged within the clearance 6 between the discs 3 and 5.
Although the space between the discs 3 and 5 is less than the thickness of the beans at the opening, the beans will nevertheless be forced into the space by the scraper 4 where they will be split and hulled by the discs inasmuch as the beans will be watered in the feed hopper 1 prior to entry between the discs.
With reference to the drawings, it will be seen that in the operation of the invention the raw material feed hopper 1 is attached to the fixed disc 3 with the beans entering into the clearance space 6 through an opening or channel V extending through the disc 3. Thus, raw soybean material in the hopper 1 will pass through the channel V of the disc 3 and as the revolving disc 5 rotates, most of the soybeans will be cracked into halves within the space 6 between the disc 3 and the revolving disc 5 by the friction therebetween with the space 6 between the discs 3 and 5 being maintained at only about 70 to 80 percent of the soybean diameter. The hulls of the soybeans are peeled there and the cracked soybeans and their hulls will drop into a collection chute or cover 10. Some of the cracked soybeans and their hulls will stick or accumulate between the discs 3 and 5. Sticking soybeans and their hulls which cannot be readily removed will be forced or wiped off and caused to fall on the collection cover 10 by means of the scrape 4.
The scraper 4 is attached to the revolving disc 5 and is arranged to sweep the cracked soybeans and hulls from the space 6 by coming into contact with the fixed disc 3 while the disc 5 rotates. However, since the diameter of the soy bean material varies, it may become necessary to adjust the spacing 6 in accordance with the diameter of the soybean material. When the space 6 is adjusted, the scraper 4 must also be adjusted accordingly be means of the scraper adjustment bolts 7 in order to allow the scraper 4 to come into close contact with the fixed disc 3. For this adjustment, the scraper 4 is arranged either to be moved toward or away from the fixed disc 3 and parallel with the shaft of the revolving disc 5.
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles. | Apparatus for treating beans such as soybeans, comprising means for hulling the beans, such as a disk-type hulling device, and a running-water-type hull and seed separating device in which the hull and the seed are separated by water flows having different velocities. | 0 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This is a division of U.S. application Ser. No. 10/990,818, filed Nov. 16, 2004, which is incorporated herewith by reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to an MPEG-4 streaming system, and more specifically to an MPEG-4 streaming system with adaptive error concealment scheme to improve the overall quality of the transmitted video contents over error prone environment.
BACKGROUND OF THE INVENTION
[0003] It has been a constant challenge for the research community and the industry to search for a better service quality for video streaming over the error-prone environment such as Internet, as the video bitstreams may be corrupted by random error or suffer packet loss in the channels.
[0004] To address the aforementioned problem, the MPEG-4 video coding standard is developed to provide users a new level of performance for various video communication services, such as video-on-demand (VOD) over the Internet or mobile multimedia applications. An MPEG-4 video system uses a robust encoded bitstream and a resilient decoding process. The robust encoded bitstream is used in the encoder to help, with some coding overhead, the recovery from error corruption. One of the methods for creating a robust bitstream is to insert additional intra blocks to stop error propagation in decoder. But the insertion of intra blocks will slightly decrease coding efficiency. Thus, the trade-off of the error propagation and coding efficiency must be built to achieve a good performance for MPEG-4 video encoders.
[0005] Cote, Shirani and Kossentini proposed an adaptive intra refreshment (IR) scheme for H.263 under the consideration of rate distortion optimization (IEEE Journal on Selected Areas in Communications, vol. 18, pp. 952-965, No. 6, 2002). The rate distortion optimization is to improve the timing of intra block insertion to achieve the optimized usage of IR based on the Internet conditions.
[0006] Another method is to use an error resilient decoding process, which can locate errors and then conceal the lost slices. The error location methods utilize useful header information available at the decoder for coding process resynchronization. For error resilience, MPEG-4 provides several tools, including the resynchronization marker (RM), the data partition (DP), and the reverse variable length coding (RVLC). The optimal usage of the error resilient tools is not specified in the video specification. To further enhance the error-resilient ability, the selection of the optimal parameters, intra refreshment, advanced error detection and concealment methods are required to improve the reconstructed video quality.
[0007] Several error concealment methods are developed for either spatial error concealment (SEC) or temporal error concealment (TEC). The SEC techniques exploit the spatial redundancy within a picture, while the TEC techniques exploit the temporal similarity of frames in a sequence. For spatial error concealment, various interpolation methods, such as multi-directional interpolation (Valente, et al., IEEE Transaction On Consumer Electronics, vol. 147, No. 3, 2001), and quadri-linear interpolation (Kwok, et. al., IEEE Transaction On Consumer Electronics, vol. 39, No. 3, 1993), are developed in addition to the widely used bi-linear interpolation (Kaiser, et. al., Signal Processing: Image Communication, vol. 14, No. 6-8, 1999). The multi-directional interpolation needs all neighboring macro blocks (MB) to correctly decide the edge direction in the lost MB and requires much more computational complexity. The quadri-linear interpolation is an area-based interpolation which takes the nearest four pixels to interpolate the recovered pixel. Two refinements are introduced by Kwok et. al. One is to increase the weight of nearer direction and the other is to take average of nearest pixels and their neighboring two pixels instead of nearest pixels only. The refinements will make the visual quality smoother.
[0008] For temporal error concealment, blind selection of motion vector such as mean, medium, nearest motion vector of surrounding motion vectors have been used. Boundary matching algorithm (BMA) is the most common method that uses the boundary properties to choose a best motion vector. There are two kinds of BMA. One is using boundary gradient to choose a result which makes the boundary match between lost MB and its neighbors. This method can be called a spatial BMA because it uses the spatial boundary correlation. The other BMA method is using boundary difference between the current frame and the previous frame. This method can be called a temporal BMA because it uses the temporal boundary correlation. Other temporal concealment method, such as decoder motion vector estimation (DMVE), uses search range and surrounding area to find a best motion vector according to temporal BMA or uses search range to refine the best motion vector of neighbors. It is obvious that the DMVE costs much more computational complexity due to testing more motion vectors and surrounding lines used for motion estimation.
[0009] As spatial concealment is suitable for the area in which spatial correlation is higher than temporal correlation, and temporal concealment is suitable for the area in which temporal correlation is higher than spatial correlation, several hybrid error concealment methods are developed to take advantages of their respective strength. A general hybrid scheme is that spatial concealment is used for I-VOP and temporal concealment is used for P-VOP. Further refinement strategies are also developed to improve the performance of the hybrid concealment methods. For example, the majority of I-VOPs excluding the first VOP have temporal correlation; thus, the temporal methods are used to conceal the VOP. For pictures having conditions, such as scene change, fad in, or fad out, and less temporal correlation, the spatial methods are used to conceal the VOP. The approach proposed by Kraiser et. al. uses spatial activity and temporal activity to decide the use of spatial concealment or temporal concealment. Spatial activity is calculated by computing the variance of nearest neighboring macro-block. Temporal activity is calculated by computing the mean square error between co-located macro-blocks. When the temporal activity is larger than spatial activity, spatial concealment is used, and vice versa. Other approaches use the boundary smoothness property. The ratio of boundary gradient of lost macro-block to boundary gradient of above and below macro-blocks is used to decide if the boundary gradient of lost macro-block is too large and requires the use of spatial concealment instead of temporal method.
[0010] However, as more and more applications and activities are brought to the Internet, the competition for bandwidth and the fluctuation of the bandwidth availability is more severe than before. It is, therefore, necessary to device an MPEG-4 streaming system with adaptive error concealment capability in order to deliver performance to the video services.
SUMMARY OF THE INVENTION
[0011] The present invention has been made to overcome the aforementioned drawback of conventional techniques used in MPEG-4 delivery in an error-prone environment. The primary object of the present invention is to provide an MPEG-4 system with error concealment for video service under the network with packet loss.
[0012] The second object of the present invention is to provide an encoder for use in an MPEG-4 video streaming system. The encoder uses an intra-refreshment technique is used to make coded bitstream more robust against noise in order to stop error propagation. The rate-distortion optimization criterion is also introduced to adaptively update in synchronization with intra-coded blocks adaptively based on the true network condition with minimal overhead. The Lagrange multiplier is modified to achieve the best rate distortion balance. In addition, a decoder loop is used in the encoder and is synchronized with the true decoder to achieve the best performance and avoid mismatch with the decoder used in the MPEG-4 system.
[0013] The third object of the present invention is to provide a decoder which is able to achieve resilient decoding from any kind of noise and enhance the reconstructed image quality with spatial and temporal hybrid concealment method. The result shows that a 3.65-9.71 dB further improvement on peak-signal-to-noise-ratio (PSNR) can be achieved in comparison with the existing methods that adopt spatial copy and zero motion concealment in decoding.
[0014] The fourth object of the present invention is to provide a rate distortion optimized intra-refresh (RDIR) method for improving the bit-stream structure according to the network condition to an encoder system with least overhead.
[0015] The fifth object of the present invention is to provide an error concealment method combining hybrid concealment scheme and block-based refinement.
[0016] The foregoing and other objects, features, aspects and advantages of the present invention will become better understood from a careful reading of a detailed description provided herein below with appropriate reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The present invention can be understood in more detail by reading the subsequent detailed description in conjunction with the examples and references made to the accompanying drawings, wherein:
[0018] FIG. 1 shows an MPEG-4 system with error concealment according to the invention;
[0019] FIG. 2 shows an embodiment of an encoder according to the invention;
[0020] FIG. 3 shows an embodiment of a decoder according to the invention;
[0021] FIG. 4 shows an RDIR encoding flowchart used in an embodiment of the invention;
[0022] FIG. 5 shows a schematic view of bi-directional error concealment used in the embodiment of the invention;
[0023] FIG. 6 shows three different concealment orders;
[0024] FIG. 7 shows a flowchart of an embodiment of error concealment of the invention 1 ; and
[0025] FIG. 8 shows a 3×3 first order smoothing filter used in an embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] FIG. 1 shows a schematic view of an MPEG-4 system of the present invention, including an encoder 102 and a decoder 104 . The details of encoder 102 and decoder 104 are illustrated in FIG. 2 and FIG. 3 , respectively.
[0027] As shown in FIG. 2 , an encoder includes an intra-coding module 202 , an inter-coding module 204 , a rate-distortion (R-D) cost decision module 206 , a motion search module 208 , an MV module 210 , a mode module 212 , a mode modified module 214 , a motion compensation (MC) module 216 , a discrete cosine transform (DCT) module 218 , a quantization (Q) module 220 , an inverse discrete cosine transform (IDCT) module 222 , an inverse quantization (IQ) module 224 , and a variable length coding (VLC) module 226 . For the encoder to generate error resilient bitstreams, an error probability model is built for passing each macro-block (MB) of the bitstream through the model. The distortion of the MB is calculated from the reconstructed images with and without errors and the weighting follows the accumulated error probability. If the R-D cost to encode the current MB as inter-coding mode is lower than that of the intra-coding mode, the inter-coding mode is selected; otherwise, the intra-coding mode is selected. Such a criterion will bring the most efficient usage of intra blocks insertion under similar service quality. After the coding mode is decided, the current MB is encoded and the coded bitstream is passed to a transmitter.
[0028] As shown in FIG. 3 , the decoder of the present invention includes a decoding VOP header module 302 , a decoding VOP module 304 , a timing check and correction module 306 , an error detection module 308 , an error recovery module 310 , an error localization module 312 , a frame buffer 314 , a hybrid scheme module 316 , a spatial concealment module 318 , a temporal concealment module 320 , a smooth filter 322 , and an output buffer 324 . First, a received bitstream is parsed to look for continuous resynchronization markers (RM). A successful bitstream parsing indicates that no syntactic errors occur, and the normal decoding resumes. If there is any syntactic error, the decoder will jump to the next RM to resume the decoding processes. After one frame is fully reconstructed, the proposed error concealment algorithm is applied based on the available information from the received bits.
[0029] To enhance the ability of error resilience, matching solutions over both the encoder and decoder end are provided. At the encoder, the rate distortion optimized intra-refresh (RDIR), originally developed as a more effective solution for error propagation, is provided to improve the bit-stream structure according to the network condition. The intra-refresh technique inserts intra-blocks instead of inter-blocks in P frame to prevent serious error propagation over error-prone network. Since the intra-coding block sacrifices more bits, it will become inefficient when the network condition varies over time. To improve this situation, intra block insertion with R-D optimization adaptive to channel condition can provide the most compact encoder system with least overhead.
[0030] The RDIR design flow is shown in FIG. 4 . Starting with step 401 , the begin of the i-th P frame is read, and for each i-th MB (step 402 ), the cost for intra and inter blocks, denoted as J intra and J inter , can be computed, as shown in step 403 , by the following Lagrangian formula:
[0000]
J=D
q
+λ·R
[0000] where
[0031] J: Lagrangian cost
[0032] λ: Parameter used to control coding bit rate in encoding process
[0033] D q : Distortion induced from residue quantization
[0034] R: Bits used in coding a macroblock
[0000] A better mode for individual MB can be found by taking both distortion and bitrate into consideration. Not only quantization distortion but concealment error must be included for transmission over packet switch network without reliable quality of service (QoS). Therefore, the distortion with concealment combined with packet loss rate is taken into account for RD-cost calculation. After the cost J is decided, the mode with minimal J is chosen as the current MB coding mode, as in step 404 . If J intra is greater than J inter , the intra-coding mode is chosen, as in step 405 ; otherwise, the inter-coding mode is used, as in step 406 . In step 407 , if this is the last MB, the process proceed to process the next P frame as in step 408 ; otherwise, return to step 402 and continue processing the next MB of the current P frame. For error prone environment, the distortion of D will suffer more serious quality loss. It comes from both the original quantization error and the errors introduced when concealing the lost MB from nearby MB. So the above formula needs to be modified as
[0000] J =( D q ·(1 −p )+ D c ·p )+π· R
[0000] where
[0035] D q : Distortion induced from residue quantization
[0036] D c : Distortion induced from no-so-perfect concealment algorithm
[0037] p: Channel packet loss rate
[0000] To achieve the R-D optimization under the proposed intra-refresh encoding, the parameter of λ needed to be updated every frame to control the bits used under the same distortion. The updating formula is as follows:
[0000] λ n+1 =λ n (1+α(Σ R i −n·R target )), α=1(20 ·R target )
[0000] The parameter of a comes from a variety of experimental trials for buffer control. The packet loss rate is used to model the internet protocol. Using network condition to model the situation at the decoder is expected to reconstruct better image quality. If the modeling is 100% accurate, the same quality as transmitted one in error prone environment can be obtained.
[0038] On the other hand, resynchronization markers (RM) are enabled to stop the collapse of decoder to handle the packet loss. If the addresses of MBs are discontinued, the decoder will skip to the next resynchronization marker and restart decoding. Since the remaining parts from the error starting point to next RM will be dropped due to the uncertainty of the content, the length between RMs may have great influence over the reconstruction quality. If the length is long enough to be able to contain several blocks of information, it will suffer serious quality information loss with packet loss. However, if the length is too short, the redundant information will be distributed in the bit-stream and make the encoding inefficient. The tradeoff is chosen according to the application domain. Considering the application of VOD application under the bit-rate of above 256k bits per second (bps), the 1000 bits as the length of each video packet is a suitable selection.
[0039] A robust streaming system needs to have an error resilient decoding process and a good error concealment method. Error resilient process is to prevent the decoding process from crash. Error concealment method helps to improve the image quality corrupted by the transmission error. As shown in FIG. 3 , decoding VOP header module 302 and decoding VOP module 304 , which are at the middle part of FIG. 3 , constitute an original decoder. The upper part of FIG. 3 , including error detection module 308 , error recovery module 310 and error localization module 312 , constitutes the error resilience functional units. Timing check and correction module 306 is also added to handle the VOP header loss. The bottom part of FIG. 3 , including frame buffer 314 , hybrid scheme module 316 , spatial concealment module 318 , temporal concealment module 320 , smooth filter 322 , and an output buffer 324 , constitutes the error concealment functional units. The inclusion of error resilience functional units and error concealment functional units can realize a robust decoding system.
[0040] Error concealment uses the localizations of lost MBs and neighboring relevant data of lost MBs to conceal the corrupted VOP. To achieve good concealment results requires a simple and high performance method and using relevant data as much as possible. Because error concealment is an additional process to the original decoding process, the extra computational complexity will slow down the decoding rate. The bi-linear interpolation is chosen for spatial concealment and temporal BMA for temporal concealment due to their middle computational complexity and high performance. Other interpolation methods can also be used for the same purpose. The hybrid scheme is used to decide when to use spatial or temporal concealment. Because error concealment use relevant data to conceal the lost MBs, using relevant data as much as possible can make concealment method works well. The bi-directional error concealment is used in the present invention, as shown in FIG. 5 .
[0041] There are three innovations in the error concealment algorithm used in the present invention. The first is using a less complexity hybrid scheme to choose when to use spatial concealment or temporal concealment. The second one is to implement block-based concealment to refine general MB-based method. Finally, a simple smoothing filter is used for improving visual quality.
[0042] Based on the previous observations, spatial concealment is suitable for fast motion or low detailed sequences since the correlation across successive frames is smaller than the correlation of pixels within the frame. In other words, temporal concealment is suitable for slow motion or highly detailed sequences. The temporal concealment can avoid visible blocking artifacts introduced by the spatial concealment. Thus, an adaptive temporal/spatial error concealment scheme is present to provide video contents of better picture quality.
[0043] Several considerations to select spatial error concealment or temporal error concealment and block-based concealment are included in the adaptive hybrid error concealment method of the present invention.
[0044] Reference hybrid concealment methods use certain statistics characteristics such as temporal activity, spatial activity, or boundary similarity to decide to use spatial concealment or temporal concealment. The methods take more extra computational complexity to get the information. For example, if the boundary difference from BMA result is larger than the threshold, spatial concealment is used to conceal the MB which may have less temporal correlation. If the boundary difference from BMA result is smaller than the threshold, the result of temporal concealment is used to conceal the MB.
[0045] By observing the motion vectors in the sequence, when the motion vector is large, the correlation between surrounding motion vectors are very low because of fast motion or motion in great confusion. Spatial error concealment is used when detecting large motion vectors. In the fast motion area or scene change, the temporal correlation may become very low and motion vectors will be in great confusion or intra blocks are added. When the intra blocks are more, the surrounding motion vectors are less and insufficient temporal correlation is available for recovering the MB. Spatial error concealment is used to conceal the MB.
[0046] Considering the strong correlation of pixels within a small area and fit the 4-MV coding mode used by MPEG-4 Simple Profile, the block-based error concealment adopts an 8×8 block as a processing unit. Based on validation of four surrounding MBs and the location of the current block, each of four 8×8 blocks can be concealed in different orders. For example, according to the validation of the four neighbors, there are 15 conditions of concealment order. FIG. 6 shows three different conditions. The numbers within the central MB indicate the concealment order of a MB. The block-based refinement can apply both spatial and temporal concealment in a single MB.
[0047] The error concealment flowchart, combining hybrid concealment scheme and block-based refinement, is shown in FIG. 7 . Starting with step 701 with i-th lost MB, the error concealment performs an intra surrounding check in step 702 and a fast motion check in step 703 . If the result of the checking is yes, the MB-based and Block-based spatial concealment is used, as shown in step 704 . Then, proceed with the next MB. Otherwise, perform a block order in step 705 . In step 706 , a boundary matching algorithm is computed. In step 707 , comparing with the threshold to determine if the threshold has been exceeded. If so, take step 708 to perform motion compensation. Otherwise, set the flag as in step 709 , and proceed to use the MB-based and Block-based spatial concealment is used, as shown in step 704 . Then start to process the next MB.
[0048] To reduce the blocking effect caused by mismatch of temporal concealment result, a smoothing filter is used on the block boundary of lost MB concealed by temporal concealment. For example, a filter used can be a 3×3 first order filter, as shown FIG. 8 . This filter have better performance than the de-blocking filter provided by reference software and another 3×3 second order filter. The smoothing filter can also be applied to spatial concealment results. Because the interpolation only uses the nearest four pixels, some unexpected edges are observed. The smoothing filter can make the interpolation smoother. The same filter can be used to make the results of temporal concealment and spatial concealment smoother.
[0049] Several simulation runs are carried out using the system of the present invention. For example, the Foreman and Akiyo sequences are used to simulate the performance of the concealment method in fast motion and slow motion. The coding parameters are as follows: encoding frame rate is 30 frames/sec, decoding frame rate is 10 frames/sec, packet size is 2000 bits, GOP structure is I-P-P . . . , bit-rate is 512k for normal test. To off-line simulate packet loss condition and see the effect of packet loss rate and concealment method, the random drop with uniform distribution is used to simulate different packet loss rate. Because different lost places will make different results, the average of ten simulation results are taken to obtain the average performance. Seven different type of video sequences such as Foreman, Akiyo, Mobile, Football, Mother&Daughter, Stefan, and Bus, are experimented for 256 bits/sec (low bit-rate), 768 bits/sec (high bitrate). Packet loss rate are 1%, 5%, 10%, 15%. The results show that the fast motion and low detailed sequences need lower threshold to have more spatial concealment to get better quality, while the slow motion or highly detailed sequences need higher threshold. The present invention achieves 0.3˜0.7 dB improvement on PSNR for visual quality. The results of the simulation indicate that the present invention can achieve better performance when compared to the conventional methods.
[0050] In summary, while compared to the prior arts, the present invention offers two innovations. The first is the use of macroblock-based spatial-temporal hybrid error concealment methods instead of frame-based method. This will help to decide whether a spatial concealment or temporal concealment should be used more accurately and more efficiently. The second is to apply fast decision on the switching between spatial and temporal error concealments. The boundary difference between current frame and previous frame is calculated and a threshold is set to decide whether the spatial mode is satisfactory to be applied. Otherwise, temporal mode will be used to replace spatial mode. The threshold is chosen by simulation on various different conditions of bit-rate, packet lost rate, and different sequences.
[0051] Although the present invention has been described with reference to the preferred embodiments, it will be understood that the invention is not limited to the details described thereof. Various substitutions and modifications have been suggested in the foregoing description, and others will occur to those of ordinary skill in the art. Therefore, all such substitutions and modifications are intended to be embraced within the scope of the invention as defined in the appended claims. | An MPEG-4 system with error concealment is provided for video service under the network with packet loss. The MPEG-4 system includes an encoder and a decoder. The encoder uses an intra-refreshment technique is used to make coded bitstream more robust against noise in order to stop error propagation. The rate-distortion optimization criterion is also introduced to adaptively update in synchronization with intra-coded blocks adaptively based on the true network condition with minimal overhead. The Lagrange multiplier is modified to achieve the best rate-distortion balance. In addition, a decoder loop is used in the encoder and is synchronized with the true decoder to achieve the best performance and avoid mismatch with the decoder used in the MPEG-4 system. The decoder is able to achieve resilient decoding from any kind of noise and enhance the reconstructed image quality with spatial and temporal hybrid concealment method. The result shows that a 3.65-9.71 dB further improvement on peak-signal-to-noise-ratio (PSNR) can be achieved in comparison with the existing methods that adopt spatial copy and zero motion concealment in decoding. | 7 |
FIELD OF THE INVENTION
This invention relates to a mooring system for floating vessel such as a drill ship, and more particularly, to a mooring system which allows the vessel to change heading while the vessel remains essentially stationary over its mooring.
BACKGROUND OF THE INVENTION
Various arrangements have heretofore been proposed for anchoring a drill ship during drilling operations at sea. One arrangement heretofore proposed utilizes a rotating turret from which a plurality of anchor cables extend to widely spaced anchor points on the ocean floor. The turret is rotatable with respect to the ship so that the turret can be held by the anchors over a drilling location while the heading of the ship can be changed by rotating the vessel relative to the turret. By carrying on drilling through the center of the turret, the heading of the ship can be changed without interrupting the drilling operations. The turret type mooring system is described, for example, in U.S. Pat. Nos. 3,191,201 and 3,279,404.
To provide adequate mooring, it is general practice to use as many as eight anchors spaced in a wide circle around the drill site on the ocean floor. Cables from each of the anchors are brought up into the turret and directed onto suitable winches having drums on which the respective cables are wound. The winches and associated drums must be mounted on the turret structure so as to remain in fixed relation to the turret while allowing the ship to rotate freely about the axis of the turret. To provide room for the winches and cable storing drums, the turret structure is extended to the main deck, the top of the turret being provided with a large platform at the level of the main deck which rotates with the turret and on which the winches and cables drums are mounted. This arrangement has the disadvantages that it occupies valuable space on the main deck, interferes with movement of equipment (BOP stacks, etc.) into the center well (moonpool), and requires that the drilling platform be raised to provide necessary clearance to the main deck. This latter in turn can adversely affect the transverse stability of the vessel by raising the center of gravity relative to center of buoyancy.
SUMMARY OF THE INVENTION
The present invention is directed to an improved mooring system which is self-contained within the hull below the deck of the drilling vessel. The anchor cables of the mooring system extend outwardly from the bottom of the vessel, the cables where they pass through the bottom of the vessel being spaced around a circle which can be disposed concentric with a central drilling well where the mooring system is located amidships on a drill ship. The vessel is rotatable through 360° relative to the mooring system. This is accomplished by providing an annular hollow cell which is rotatably mounted in the interior of the vessel with its axis of revolution extending vertically. A plurality of cable drums are rotatably mounted inside the cell, the axis of revolution of the drums being coaxial with the axis of revolution of the cell. Separate drive means drives the cell relative to the vessel and rotates each of the drums individually with respect to the cell. Sheaves within the cell guide the anchor cables from the respective coaxial drums out through the bottom of the cell, the cables exiting out through the bottom of the hull at equally spaced arcuate intervals around the bottom of the cell.
DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the invention reference should be made to the accompanying drawings, wherein:
FIG. 1 is a partial plan view partly in section showing the annular cell with the top wall removed;
FIG. 2 is a sectional view in elevation taken substantially on the line 2--2 of FIG. 1;
FIG. 3 is an enlarged partial view in section showing details of the cable drum drive;
FIG. 4 is a sectional view taken on the line 4--4 of FIG. 1; and
FIG. 5 is a sectional view in elevation of an alternative embodiment of the present invention.
DETAILED DESCRIPTION
Referring to the drawings in detail, and particularly the embodiment as shown in FIGS. 1-4, the numeral 10 indicates generally the hull of a drill ship of the type conventionally used for offshore drilling on the ocean floor. The hull includes a main deck 12 and a bottom 14. In the conventional drilling ship, the ship is provided with a central amidships well or "moon pool" which extends vertically through the center of the vessel, providing access for a drill string from a drilling rig (not shown) mounted on a platform above the main deck to the ocean floor. In the embodiment shown in FIGS. 1-4 and especially in FIG. 2, the moon pool includes a smaller diameter upper portion 16 providing an opening in the main deck 12, the upper portion of the moon pool having a fixed cylindrical wall 18. A lower portion 20 of the moon pool has a larger diameter and is formed by cylindrical wall 22 extending upwardly from the bottom 14. The walls 18 and 22 are joined by a sub deck 24 within the hulls. The cylindrical walls 18, 22 and sub deck 24 form a watertight well through the ship which is open to the sea through an opening in the bottom 14.
Positioned in the larger diameter portion of the well within the cylindrical wall 22 is a mooring member in the form of an annular cell or structure indicated generally at 26. The annular cell 26 includes an outer cylindrical wall 28 which is coaxial with and is slightly smaller in diameter than the wall 22 of the moon pool. The cell 26 has a concentric cylindrical inner wall 30 which is preferably of the same inner diameter as the wall 18 of the upper portion of the moon pool. The inner and outer sidewalls 28 and 30 are joined by a top wall 32, a bottom wall 34, and an inner bottom wall 36. The walls of the cell are supported by suitable internal bracing including a plurality of vertical beams 38 extending between the top wall 32 and inner bottom wall 36. Radial cross members 40 at the top and intermediate cross members 42 provide rigidity. The side walls 28, 30 and the top wall 32 form a watertight annular compartment within the cell in which air is trapped to control the buoyancy of the cell.
The cell 26 is rotatably supported in the hull by a plurality of closely spaced rollers 44 journaled for rotation about horizontal axes by suitable support member 46 secured to the upper margin of the outer side wall 28. The rollers 44 project radially outwardly between a pair of flat circular guide tracks 48 and 50 positioned in a channel or slot extending around the upper periphery of the sidewall 22 of the hull 10. Thus any upwardly or downwardly directed thrust of the cell relative to the vessel is transferred by the rollers 44 to the tracks 48 or 50. A plurality of outer cell rollers 52, journaled on supporting brackets 54 secured to the hull wall 22, engages the outer wall 28 of the cell 26 near the upper end thereof. Similar guide rollers 56 journaled on brackets 58 are mounted on the hull wall 22 and engage the outer wall 28 of the cell 26 adjacent the lower end thereof. Thus the rollers 52 and 56 maintain the center of the cell concentrically within the moon pool, allowing the annular cell 26 to rotate relative to the vessel about the central vertical axis of the moon pool. All of the rollers are made of an elastomer material to accommodate flexing of the hull. Powered rotation of the cell relative to the vessel is provided by a suitable drive motor 60 mounted above the subdeck 24. The motor drives a pinion 62 that engages a gear rack 64 extending around the inner perimeter of the top wall 32 of the cell 26.
A plurality of annular cable storage and tensioning drums 66, eight of which are shown by way of example, are positioned inside the cell 26. The drums 66 are spaced vertically relative to each other and rotate about a common axis which is the axis of rotation of the cell. As shown in detail in FIGS. 3 and 4, each of the drums 66 is supported on a plurality of horizontal rollers 68. Each of the rollers 68 is journaled on a shaft 70 projecting from a suitable supporting bracket 72 secured to the inner wall 30 of the cell. A plurality of vertical rollers 74 are each journaled on a vertical shaft 76. The shafts 76 are supported at either end by suitable brackets 78 extending outwardly from the inner side wall 30.
Each pair of adjacent drums 66 is driven from a common reversible hydraulic drive motor 80 mounted inside the cell. While four motors 80 are located in the cell, only two of these motors are shown in FIG. 1. Each motor 80, as shown in FIG. 3, drives a vertical drive shaft 82 through a suitable worm gear drive 84. The ends of the drive shaft 82 are coupled through clutches 86 and 88 to separate reduction gear drives indicated generally at 90 and 92. The gear drive 90 engages a bull gear 94 extending around the outer perimeter of the upper one of the pair of drums 66 while the gear drive 92 engages a similar bull gear 96 extending around the outer perimeter of the lower of the pair of drums. Four such hydraulic motor and gear drive units selectively rotate any one of the eight drums 66 in either direction about the roll axis.
Each of the drums stores a length of anchor cable, indicated generally at 98. The cable 98 from each drum passes from the drum tangentially outwardly and around and upper sheave 100, there being one such upper sheave 100 for each of the eight drums. Each sheave 100 is positioned such that the top of the sheave is roughly even with the middle of the associated drum; thus the eight sheaves 100 of the embodiment shown in FIGS. 1-4 are located at eight different levels vertically within cell 26. The upper sheaves 100 are supported by suitable brackets 102 secured to the outer wall 28 of the cell. For clarity only one such mounting bracket is shown in FIG. 1. After passing around the upper sheave 100, each cable 98 extends downwardly through the interior space of the cell, passing through a tubular guide 103 (FIG. 2) through the inner bottom wall 36 to a lower sheave 104. The lower sheaves 104 have a portion of their perimeter extending through slots in the bottom 34 of the cell. Thus the cable 98 is directed around the lower sheave 104 and extends radially outwardly from the bottom of the vessel to a suitable anchor (not shown) on the ocean floor.
Hydraulic power is provided to the cell 26 for operating the drive units 80. To this end a hydraulic power unit 110 (FIG. 2) mounted in the hull 10 of the vessel is coupled through a hydraulic and electric power and control hose bundle 112 wound on a hydraulic hose storage reel 114 and lead therefrom to the cell. The hose bundle 112 passes around a sheave 116 positioned above the cell from whence the hose bundle is directed into a trough 118 in the top of the cell 26. The hose bundle connects to controls (not shown) within the cell through which power is controlled and distributed to the various drive units 80. While this arrangement does not permit unlimited rotation between the cell and the vessel, it does not permit the cell to rotate relative to the vessel through substantially a full 360° or more; in practice, this is more than sufficient.
As shown in detail in FIG. 4, storage drums 66 are provided with drum braking units 120, each braking unit providing brake control for an associated pair of reels 66. The braking unit includes a pair of brakes of the caliper disc type, which provide braking action by clamping the opposing faces of one flange of the associated drum.
In order that the drums may be made large enough to store the necessary cable, for example, it may be desirable that the annular cell be substantially larger in diameter than the moon pool. Thus the cell may be arranged as shown in the alternative embodiment in FIG. 5. In this arrangement, the cylindrical wall of the moon pool, indicated at 130, is of substantially smaller diameter than the inner wall 30 of the cell. The wall 130 of the moon pool is a fixed part of the hull structure and extends from the opening 16 in the main deck down to the bottom 14, or may terminate at some intermediate level. Concentric with the wall 130 is a second fixed concentric cylindrical wall 132 which extends downwardly from the sub deck 24 to form an annular cavity with the wall 22 in which the annular cell rotates. Additional rollers 52' and 56' journal the annular structure for rotation around the cylindrical wall 132. The walls 130 and 132 are joined by suitable bulkheads and cross bracing forming a rigid structure to provide air space within the hull structure. Thus in the arrangement of FIG. 5, the annular cell provides a self-contained mooring system that is entirely separate from, although concentric with the moon pool through which drilling operations take place.
In both the arrangements of FIGS. 1-4 and FIG. 5 it will be noted that the main deck itself is completely free of any equipment or rotating platforms normally associated with turret type mooring systems. Thus the deck is left unobstructed for the mounting of equipment required for or used in drilling operations. Also, the elimination from the main deck in the vicinity of the moon pool greatly simplifies the movement of drilling equipment, such as wellhead landing bases or blowout preventor stacks, to or from the moon pool. A blowout preventer stack is a large and massive piece of equipment which is lowered by the drill string to the submerged drill site at an early stage of the drilling operations, and handling of this piece of equipment is a difficult and potentially hazardous procedure which is not encumbered by the present amidships mooring system. Further, the location of all mooring equipment below the main deck according to this invention lowers the vessel center of gravity thereby enhancing the transverse stability of the vessel, and making possible a lowering of the drilling rig and its center of gravity. | A mooring system for a drill ship has an annular cell mounted in the bottom of the hull concentrically around the moon pool. A plurality of annular cable drums are rotatable within the cell, the drums and the cell being rotatable about a common vertical axis. Anchor cables wound on the respective drums are directed by sheaves through the bottom of the cell through an opening in the bottom of the hull to anchors on the ocean floor for anchoring the vessel over a drill site. The drums are individually driven to adjust the associated cable, while the entire cell together with the drums is rotated within the hull to change the heading of the vessel relative to the anchors. | 1 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to an image recording apparatus for recording an image by selectively adhering a developer on a recording material using a recording electrode array including a plurality of recording electrodes arranged in a line.
(2) Description of the Related Art
As an image recording apparatus using a recording electrode array as mentioned above, the ones disclosed in Japanese Patent Publication Kokai Nos. 57-114156, 57-190964 and 58-33269 are well known. These apparatus are each equipped with a counter electrode opposed to a recording electrode array with a recording material therebetween. Voltages corresponding to image signals are selectively applied to the plurality of recording electrodes, whereby to adhere a magnetic toner onto the recording material. Since such an apparatus requires no photoconductive drum or exposure device, the construction can be simpler and more compact compared with different-type apparatus such as a laser printer. However, this type of image recording apparatus requires high voltages to be applied to the recording electrodes, meaning a high possibility of an electric leakage between the neighboring recording electrodes. Lowering the voltages applied to the electrodes for preventing leakage deteriorates image clearness.
One of the above prior art materials, Japanese Patent Publication Kokai No. 58-33269, discloses a counter electrode array including a plurality of electrode elements, which are respectively opposed to the recording electrodes of the recording electrode array. This construction causes a leakage between the electrode elements of the counter electrode array.
Each image recording apparatus disclosed in the above three publications has the recording electrode array on a fixed sleeve, and the sleeve has a magnet roller therein for transporting a magnetic toner. Such a construction generates toner cloud (floating toner diffused in a smoke which is not involved in recording). Due to the toner cloud, unnecessary floating toner is adhered on the recording material, which causes fogging (black points and other noises printed around letters and pictures) and so lowers the image quality.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of this invention to offer an image recording apparatus for preventing an electric leakage from occurring between neighboring recording electrodes of a recording electrode array.
It is another object of this invention to offer an image recording apparatus which is equipped with a counter electrode including a plurality of electrode elements which are respectively opposed to the recording electrodes of the recording electrode array and also prevents an electric leakage from occurring between neighboring electrode elements.
It is still another object of this invention to offer an image recording apparatus for alleviating adverse effects of toner cloud generated in the vicinity of the recording electrode array.
Realization of either one of the above three objects leads to generation of an optimum electric field for image forming whereby to obtain a high quality image on a recording material.
The above objects are fulfilled by image recording apparatus for forming an image on a recording material, the apparatus comprising a recording head including a plurality of recording electrodes arranged in a line and a supporting member for supporting the plurality of recording electrodes, a pointed end of each recording electrode sinking in the supporting member; a sleeve on which the recording head is disposed; a counter electrode opposed to the recording head; a rotatable magnet roller arranged in the sleeve for transporting a developer to the recording head; and means for selectively applying an electric voltage to each recording electrode to provide the developer onto a recording material between the recording head and the counter electrode.
The above objects are also fulfilled by an image recording apparatus for forming an image on a recording material, the apparatus comprising a recording head including a plurality of recording electrodes arranged in a line and a first supporting member for supporting the plurality of recording electrodes, a pointed end of each recording electrode sinking in the first supporting member; a counter electrode unit including a plurality of counter electrodes opposed to the plurality of recording electrodes, respectively, and a second supporting member for supporting the plurality of counter electrodes, a pointed end of each counter electrode sinking in the second supporting member; transporting means for transporting a developer to the recording head; first applying means for selectively applying a first electric voltage to each recording electrode to provide the developer onto a recording material between the recording head and the counter electrode unit; and second applying means for selectively applying a second electric voltage of the opposite polarity from that of the first electric voltage to each counter electrode.
The above objects are also fulfilled by an image recording apparatus including a plurality of electrode elements arranged in a line and a supporting member for supporting the plurality of electrode elements, the improvement comprising means for magnetically transporting a developer to the plurality of electrode elements, wherein a pointed end of each electrode element sinking in the supporting member so that a wall portion is defined between the neighboring electrode elements.
In the above construction, since the pointed end of each recording electrode is sinking in the supporting member, the practical distance between the neighboring recording electrodes is larger than the case where the end of the recording electrodes are on the same plane with a top surface of the supporting member. Therefore, the recording electrodes are better insulated from one another, which makes an electric leakage hard to occur between the neighboring recording electrodes even if high voltages are applied to the recording electrodes. As a result, an optimum electric field for high quality image forming can be easily generated.
In compliance with the high voltage application to the recording electrodes, the bias voltages applied to the counter electrode or the counter electrode unit can also be high. Accordingly, a portion of the recording material on which the toner is to be adhered and the remaining portion thereof can be largely different in electric potential, which also contributes to generation of a desirable electric field. As a result, unnecessary toner is restricted from adhering on the above remaining portion, whereby a clear, high quality image can be obtained.
The above objects are also fulfilled by an image recording apparatus for forming an image on a recording material, the apparatus comprising a recording head including a plurality of recording electrodes arranged in a line and a first supporting member for supporting the plurality of recording electrodes; a counter electrode unit including a plurality of counter electrodes opposed to the plurality of recording electrodes, respectively, and a second supporting member for supporting the plurality of counter electrodes, a pointed end of each counter electrode sinking in the second supporting member; transporting means for transporting a developer to the recording head; applying means for selectively applying an electric voltage to each recording electrode to provide the developer onto a recording material between the recording head and the counter electrode unit.
The above objects are also fulfilled by an image recording apparatus for forming an image on a recording material, the apparatus comprising a recording head including a plurality of recording electrodes arranged in a line and a first supporting member for supporting the plurality of recording electrodes; a counter electrode unit including a plurality of counter electrodes opposed to the plurality of recording electrodes, respectively, and a second supporting member for supporting the plurality of counter electrodes, a pointed end of each counter electrode sinking in the second supporting member; transporting means for transporting a developer to the recording head; first applying means for selectively applying a first electric voltage to each recording electrode to provide the developer onto a recording material between the recording head and the counter electrode unit; and second applying means for selectively applying a second electric voltage of the opposite polarity from that of the first electric voltage to each counter electrode.
In the above construction, since the pointed end of each counter electrode is sinking in the counter electrode unit, the practical distance between the neighboring counter electrodes is large, whereby the counter electrodes are well insulated from one another. This means an electric leakage hard to occur between the neighboring counter electrodes even if high bias voltages are applied to the counter electrode unit, which leads to excellence in image quality.
The above objects are also fulfilled by an image recording apparatus for forming an image on a recording material, the apparatus comprising a recording head including a plurality of recording electrodes arranged in a line and a supporting member for supporting the plurality of recording electrodes; a counter electrode opposed to the recording head; transporting means for transporting a developer to the recording head; an auxiliary electrode disposed in the vicinity of the counter electrode; first applying means for selectively applying a first electric voltage to each recording electrode to provide the developer onto a recording material between the recording head and the counter electrode; second applying means for applying a second electric voltage of the opposite polarity from that of the first electric voltage to the counter electrode; and third applying means for applying a third electric voltage of the opposite polarity from that of the second electric voltage to the auxiliary electrode.
The above objects are also fulfilled by an image recording apparatus for forming an image on a recording material, the apparatus comprising a recording head including a plurality of recording electrodes arranged in a line and a supporting member for supporting the plurality of recording electrodes, a pointed end of each recording electrode sinking in the supporting member; a counter electrode opposed to the recording head; transporting means for transporting a developer to the recording head; an auxiliary electrode disposed in the vicinity of the counter electrode; first applying means for selectively applying a first electric voltage to each recording electrode to provide the developer onto a recording material between the recording head and the counter electrode; second applying means for applying a second electric voltage of the opposite polarity from that of the first electric voltage to the counter electrode; and third applying means for applying a third electric voltage of the opposite polarity from that of the second electric voltage to the auxiliary electrode.
The above objects are also fulfilled by an image recording apparatus for forming an image on a recording material, the apparatus comprising a recording head including a plurality of recording electrodes arranged in a line and a first supporting member for supporting the plurality of recording electrodes; a counter electrode unit including a plurality of counter electrodes opposed to the plurality of recording electrodes, respectively, and a second supporting member for supporting the plurality of counter electrodes, a pointed end of each counter electrode sinking in the second supporting member; transporting means for transporting a developer to the recording head; an auxiliary electrode disposed in the vicinity of the counter electrode unit; first applying means for selectively applying a first electric voltage to each recording electrode to provide the developer onto a recording material between the recording head and the counter electrode unit; second applying means for selectively applying a second electric voltage of the opposite polarity from that of the first electric voltage to each counter electrode; and third applying means for applying a third electric voltage of the opposite polarity from that of the second electric voltage to the auxiliary electrode.
The above objects are also fulfilled by an image recording apparatus for forming an image on a recording material, the apparatus comprising a recording head including a plurality of recording electrodes arranged in a line and a first supporting member for supporting the plurality of recording electrodes, a pointed end of each recording electrode sinking in the first supporting member; a counter electrode unit including a plurality of counter electrodes opposed to the plurality of recording electrodes, respectively, and a second supporting member for supporting the plurality of counter electrodes, a pointed end of each counter electrode sinking in the second supporting member; transporting means for transporting a developer to the recording head; an auxiliary electrode disposed in the vicinity of the counter electrode unit; first applying means for selectively applying a first electric voltage to each recording electrode to provide the developer onto a recording material between the recording head and the counter electrode unit; second applying means for selectively applying a second electric voltage of the opposite polarity from that of the first electric voltage to each counter electrode; and third applying means for applying a third electric voltage of the opposite polarity from that of the second electric voltage to the auxiliary electrode.
In the above construction, the auxiliary electrode is given the same polarity with that of the recording electrodes. Since some components of electric lines of force which would, without the auxiliary electrode, divert from the desirable toner transporting path between the recording head and the counter electrode or the counter electrode unit converge in the vicinity of the auxiliary electrode, whereby an optimum electric field is generated. Accordingly, the toner transported by Coulomb's force also converges in the vicinity of the auxiliary electrode to improve resolution and to substantially eliminate toner cloud. The result is a clear, high quality image.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, advantages and features of the invention will become apparent from the following description thereof taken in conjunction with the accompanying drawings which illustrate specific embodiments of the invention. In the drawings.
FIG. 1 schematically shows a vertical cross section of an image recording apparatus according to a first embodiment of this invention,
FIG. 2 is a perspective view of a recording electrode array according to the first embodiment,
FIG. 3 is a cross sectional view of the same along lines III--III of FIG. 2,
Fig 4 is a longitudinal cross sectional view of the same along lines IV--IV of FIG. 3,
FIG. 5 is a bottom view of the same,
FIG. 6 is an enlarged view of the longitudinal cross section of the same,
FIG. 7 is an enlarged view of a longitudinal cross section of another recording electrode array as a comparative example,
FIG. 8 explains symbols of Table 1,
FIG. 9 schematically shows toner grains adhered on the pin recording electrodes of the first embodiment,
FIG. 10 schematically shows toner grains adhered on the pin recording electrodes of the comparative example,
FIG. 11 schematically shows a vertical cross section of an image recording apparatus according to a second embodiment of this invention,
FIG. 12 is a perspective view of a counter electrode array according to the second embodiment,
FIG. 13 is a cross sectional view of the same along lines XIII--XIII of FIG. 12,
FIG. 14 is a longitudinal cross sectional view of the same along lines XIV--XIV of FIG. 13,
FIG. 15 is an enlarged view of the longitudinal cross section of the same,
FIG. 16 is an enlarged view of a longitudinal cross section of another counter electrode array as a comparative example,
FIG. 17 is a perspective view of a counter electrode according to a third embodiment,
FIG. 18 explains an electric field generated between the recording electrode array and the counter electrode of the third embodiment, and
FIG. 19 is a perspective view of a variation of the third embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiment I
A first embodiment according to this invention will be explained referring to FIGS. 1 through 10.
In FIG. 1, an image recording apparatus has a sleeve 2 fixed at a specified position thereof, the sleeve 2 including therein a rotatable magnet roller 1. The sleeve 2 has an opening 20 on a left (FIG. 1) portion of a peripheral surface thereof, the opening 20 running in parallel with a rotating axis of the magnet roller 1. A recording head 3 including a recording electrode array 4 is supported in the opening 20 also in parallel with the above axis with a tip portion thereof projected outward. Opposed to the recording head 3 is a holder 6, which includes a counter electrode 7. An upper surface of the holder 6 is curved upward with a specified radius of curvature. A recording material 5 such as a paper is to be transported between the recording head 3 and the counter electrode 7.
Disposed to the opposite side of the sleeve 2 from the counter electrode 7 is a casing 16 for accommodating a toner 17. A doctor blade 18 is provided on an upper left outside wall (FIG. 1) of the casing 16 for adjusting the height of toner brush and the amount of the toner 17 to be carried on the sleeve 2.
The image recording apparatus comprising the above construction is operated in the following manner.
When the magnet roller 1 is rotated clockwise as in FIG. 1, the toner 17 which is charged positive or negative is taken out from the casing 16 in accompaniment with the rotation of the magnet roller 1. The toner 17 is then carried on the peripheral surface of the sleeve 2 while covering the surface in the form of a thin layer, until it reaches the recording head 3.
When voltages and bias voltages corresponding to recording signals are respectively applied to the recording electrode array 4 and the counter electrode 7 in order to make a specified difference in electric potential between 4 and 7, the charged toner 17 is repulsively splattered due to Coulomb's force toward the recording material 5 between the recording electrode array 4 and the counter electrode 7. An image is recorded on the recording material 5 in this way. Thereafter, the recording material 5 is transported to a fixing unit (not shown) to have the image thereon fixed.
The above voltage application is done by a recording power supply 12, and the bias voltage application by a bias power supply 8. It is for approaching the recording electrode array 4 to the counter electrode 7 and thus improving recording efficiency that the tip portion of the recording head 3 is projected outward.
The toner 17 is charged by friction at a position of the doctor blade 18.
For development, a single-component developer comprising an insulating magnetic toner is used in the above embodiment. However, another single-component developer comprising a conductive magnetic toner or a double-component developer comprising an insulating non-magnetic toner and a magnetic carrier can also be used.
In the case of a single-component developer comprising an insulating magnetic toner, the toner is charged by friction with a portion of a developing unit such as the sleeve 2. When an electrostatic force of an electric field between the recording electrode array 4 and the counter electrode 7 gets stronger than a magnetic force of the magnetic roller 1, the charged toner is splattered from the sleeve 2 to be adhered on the recording material 5.
If a single-component developer comprising a conductive magnetic toner is used, the toner is not charged because the toner is also conductive. Instead, a toner chain is formed on the sleeve 2 by a magnetic force. When the toner chain is given an electric potential by the recording electrode array 4, an electric field is formed between the recording electrode array 4 and the counter electrode 7. When an electrostatic force of the electric field gets stronger than a magnetic force of the magnetic roller 1, the toner chain is broken and the toner is splattered from the sleeve 2 to be adhered on the recording material 5. Since the electric potential is given to a tip of the toner chain, the recording efficiency is high and so the voltages applied to the recording electrode array 4 can be as low as several to a hundred volts.
If a double-component developer comprising an insulating non-magnetic toner and a conductive magnetic carrier is used, the toner is charged by friction with the carrier and is carried on the surface of the sleeve 2 while being adhered on peripheral surfaces of carrier grains. When voltages of the same polarity with those of the toner are applied to the recording electrode array 4, the toner is repulsively splattered from the sleeve 2 to be adhered on the recording material 5. Since the carrier is conductive and so accepts an electric potential, the recording efficiency is high.
If a double-component developer comprising an insulating non-magnetic toner and an insulating magnetic carrier is used, the toner is charged by friction with the carrier and is carried on the surface of the sleeve 2 while being electrostatically adhered on peripheral surfaces of carrier grains. When voltages of the same polarity with those of the toner applied to the recording electrode array 4, the toner is repulsively splattered from the sleeve 2 to be adhered on the recording material 5. Since the carrier is insulating, substantially no leakage occurs between the recording electrode array 4 and the counter electrode 7.
A construction of the recording head 3 will be described in more detail referring to FIGS. 2 through 5.
As shown in FIG. 2, the recording head 3, which has the shape of a trapezoidal pillar lying horizontally, comprises a supporting unit 10 formed of a pair of plates 10a opposed to each other with a specified size of space therebetween and a plurality of pin recording electrodes 9 as the recording electrode array 4. The pin recording electrodes 9 are linearly arranged in the space, and the remaining space is filled with a filler 10b. It should be noted that upper ends of the pin recording electrodes 9 are sunk in the supporting unit 10 so that a wall portion is projected between the neighboring pin recording electrodes 9. Each pin recording electrode 9 is formed of enamel wires, the supporting unit 10 of acrylic resin, and the filler 10b of epoxy resin.
As shown in FIG. 5, bottom ends of the pin recording electrodes 9 are extended with no contact with one another for a certain length and gathered on a bottom surface of the recording head 3 to form an electrode cord 11. The electrode cord 11 is connected to the recording power supply 12. The recording power supply 12 is to selectively apply the voltages to the pin recording electrodes 9.
The recording head 3 is produced by the following method. After loading the pin recording electrodes 9 in the above space, the filler 10b is injected into the space and solidified. Thus, the pin recording electrodes 9 are integrated with the supporting member 10. The upper ends of the pin recording electrodes 9 are sunk in the supporting unit 10 by immersing an upper portion of the unit 10 in an aqueous solution of iron chloride (with hydrochloric acid) and etching a specified length of the pin recording electrodes 9. The length to be etched is controlled by adjusting the density and temperature of the above solution, immersing time, and the like.
The producing method of the recording head 3, the materials of the pin recording electrodes 9, the supporting unit 10 and the filler 10b are not limited to those mentioned above. Any construction in which pin recording electrodes are insulated from one another and supported by a supporting unit also insulated from the electrodes is acceptable. Pin recording electrodes formed of such a permeable material as insulated nickel or ferrite improve magnetic induction, whereby the height of toner brush can be set high. As a result, fast and accurate recording is realized.
In order to prove sinking the upper ends of the pin recording electrodes 9 in the supporting unit 10 is effective, the following two experiments were conducted. The experiments will be described referring to FIGS. 6 through 10.
A recording head 30 as a comparative example comprises a supporting unit 100 and pin recording electrodes 90.
The specifications of each pin recording electrode 9 and each pin recording electrode 90 will be mentioned in Table 1.
TABLE 1______________________________________ Pin electrode 9 Pin electrode 90______________________________________Diameter a (μm) 200 200Distance between 20 20neighboringelectrodes l (μm)Sinking 20 0depth d (μm)______________________________________
[Experiment I]
Regarding each of the recording head 3 and 30, every other pin recording electrodes were connected to a power supply and the remaining pin recording electrodes were grounded. How leakages occurred was checked by gradually raising the voltages applied to the pin recording electrodes.
Results
While a leakage occurred when voltages were set -300 to -400 V in the head 30, no leakage occurred at -500 V in the head 3.
Reasoning
From the above results, a leakage is attributed to creeping discharge, which occurs with no existence of the toner 17. In the case of the head 3 where the pin recording electrodes 9 are sunk, the practical distance between the neighboring pin recording electrodes is l+2d=60 μm. This is larger than l=20 μm in the case of the the head 30. Therefore, the head 3 is more excellent in insulation, and so creeping discharge is hard to occur.
[Experiment II]
The heads 3 and 30 were used for actual recording using the toner 17. For easier explanation, the diameter of the toner grains are illustrated larger than the distance between the neighboring pin recording electrodes in FIGS. 9 and 10.
Results
Also in this experiment, the leakage was smaller in the head 3 than in the head 30.
Reasoning
Experiment II shows the restriction of the leakage in the head 3 is attributed to the following.
When the toner 17 has a large electric resistance, the electric leakage through the toner 17 is small even when there is a large difference in electric potential between one of the pin recording electrodes 9a (90a) provided with voltages and the neighboring pin recording electrode 9b (90b) provided with no voltage. Therefore, there is almost no difference in the amount of electric leakage through the toner 17 between in the head 3 and the head 30. However, when the toner 17 has a small electric resistance, the amount of leakage in the head 3 is much smaller than that in the head 30.
This is due to the following. In the case of the head 30, since the distance between the neighboring pin recording electrodes is short, one toner grain is enough to occur a leakage (FIG. 10). In the case of the head 3, since the practical distance between the neighboring pin recording electrodes is large, at least three toner grains are necessary to occur a leakage (FIG. 9). It means the possibility of a leakage is lower in the head 3 than in the head 30.
According to this invention, even if the toner 17 has a small electric resistance, namely, even if the toner 17 is conductive, a leakage is hard to occur. Since the conductive toner is more effective in improving the recording efficiency, this is a great advantage. A leakage through a conductive carrier can also be restricted for the same reasons.
Embodiment II
A second embodiment will be described referring to FIGS. 11 through 16. The second embodiment has the same construction as the first embodiment except that a counter electrode array 27 includes a plurality of pin counter electrodes 29 (FIG. 12) and that the recording power supply 12 and the bias power supply 8 are constructed differently.
Voltages are applied to the arrays 4 and 27 respectively by the recording power supply 12 and the bias power supply 8. The recording power supply 12 has power supplies 12a and 12b respectively for applying positive and negative voltages. A switch 12 is provided for selecting positive or negative voltages. The bias power supply 8 has power supplies 8a and 8b respectively for applying positive and negative voltages. A switch 8c is provided for selecting positive or negative voltages. The switches 12c and 8c are to be switched over by control means (not shown) so that the arrays 4 and 27 are always charged oppositely to generate an electric field.
As the recording or the bias power supplies 12 or 8, a pulse power supply is desirable. If a pulse power supply is employed, the applied voltages can easily be adjusted in compliance with the type of the toner 17 only by changing a duty ratio of an output pulse.
As shown in FIG. 11, the tip portion of the recording head 3 is projected by an appropriate amount toward the counter electrode array 27. As well as strengthening the electric field to improve the image quality, this structure has another advantage mentioned hereinafter. Since the toner which has been transported to this portion is separated from the remaining toner, toner cloud causing fogging is restricted. This second advantage also greatly contributes to excellence in image quality.
The pin recording electrodes 9 of the recording electrode array 4 have their upper ends either sunk in or on the same plane with a top surface of the supporting unit 10.
The counter electrode array 27 and the holder 6 will be described in detail referring to FIG. 12 through 14.
The holder 6 comprises a pair of plates 6a opposed to each other with a specified size of space therebetween. The plurality of pin counter electrodes 29 are linearly arranged in the space, and the holder 6 and the counter electrode array 27 are integrated through resin filling the remaining space.
An upper surface of the integrated holder and array is curved upward with a specified radius of curvature (R) for smoothly guiding the recording material 5.
The holder 6 is formed of acrylic, ABS or epoxy resin. The pin counter electrodes 29 are provided in the same number as the pin recording electrodes 9 so that the former and the latter are respectively opposed to each other. Each pin counter electrode 29 is formed of enamel wires.
It should be noted that upper ends of the pin counter electrodes 29 are sunk in the holder 6.
As shown in FIGS. 13 and 14, bottom ends of the pin counter electrodes 29 are extended substantially in parallel and gathered to form an electrode cord 61. The electrode cord 61 is connected to the bias power supply 8. The bias power supply 8 is to selectively apply bias voltages to the pin counter electrodes 29.
The holder 6 and the counter electrode 27 are integrated by the following method. After loading the pin counter electrodes 29 in the above space, epoxy or some other insulating resin is injected from an upper portion 6b of the holder 6 and solidified.
The upper ends of the pin counter electrodes 29 are sunk in the holder 6 by immersing an upper portion of the holder 6 in an aqueous solution of iron chloride (with hydrochloric acid) and etching a specified length of the pin counter electrodes 29. The length to be etched is controlled by adjusting the density and temperature of the above solution, immersing time, and the like.
The integrating method, the materials of the holder 6 and the pin counter electrodes 29 are not limited to those mentioned above. Any construction in which pin counter electrodes are insulated from one another and supported by a holder also insulated from the electrodes is acceptable.
In order to prove sinking the upper ends of the pin counter electrodes 29 in the holder 6 is effective, the following experiment was conducted. The experiment will be described referring to FIGS. 15 and 16.
The counter electrode array 27 according to this invention and another counter electrode array 270 as a comparative example comprising pin counter electrodes 290 and a holder 60 were each incorporated in the image recording apparatus and how leakages occurred was checked. Table 2 shows the specifications of each pin counter electrode 29 and each pin counter electrode 290. Other specifications were the same for both 27 and 270. Table 3 shows the experiment conditions. The pin recording electrodes 9 of the recording electrode array 4 were on the same plane with the top surface of the supporting unit 10.
TABLE 2______________________________________ Pin electrode 29 Pin electrode 290______________________________________Distance between 20 20neighboringelectrodes l (μm)Sinking 30 0depth d (μm)______________________________________
TABLE 3______________________________________Pin recording Pin counterelectrode electrode Sleeve______________________________________ON -300 V +300 V GNDOFF +100 V -100 V GND______________________________________
Used as a developer was a double-component one comprising a non-magnetic toner (charged negative) formed of stylene-acrylic resin and an insulating magnetic carrier formed of ferrite.
Results
In the case of the array 270, a leakage occurred between some of the pin counter electrodes 290 in the state of ON and the other pin counter electrodes 290 in the state of OFF. As a result, both image density and resolution were lowered to deteriorate the image quality.
In the case of the array 27 according to this invention, a leakage was restricted in the same conditions with the above.
Reasoning
In the case of the array 270, a leakage was especially conspicuous when the recording paper was damp. This is attributed to that the dampness changes the electric resistance of the recording paper. It was also confirmed that, even when the recording paper was dry, continuous recording on multiple papers caused a leakage. This is considered to occur because paper powders accumulated on the curved surface of the holder 6 in the course of continuous recording are charged, whereby to cause a leakage.
In the case of the array 27, since the pin counter electrodes 29 were sunk in the holder 6, the practical distance between the neighboring pin counter electrodes 29 (l+2d) is larger than that of the array 270. Therefore, the array 27 is more excellent in insulation, and so there is a low possibility of a leakage even if the recording paper is damp or continuous recording is conducted.
Since this allows high voltage application to the arrays 4 and 7, an excellent image with less fogging can be obtained.
Embodiment III
In order to improve image quality in the image recording apparatus equipped with a recording electrode array including a plurality of pin recording electrodes and a counter electrode, the following four are indispensable:
1) Appropriate image density
This is realized by controlling the thickness of the developer carried on the surface of the sleeve in the form of a thin layer.
2) Fogging prevention for better contrast
This is realized by controlling the distance between the developer and the recording material.
3) High resolution
This is realized by controlling the strength of the electric field between the recording electrode array and the counter electrode.
4) Use of an appropriate developer
1) through 4) will be explained in detail referring to FIG. 1 for convenience. The thickness of the developer in 1) is controlled by adjusting the distance D B between the sleeve 2 and a tip of the doctor blade 18. According to an experiment conducted by the inventor of this invention using a double-component developer comprising a non-magnetic toner formed of stylene-acryl resin and an insulating magnetic carrier formed of ferrite, D B ≧0.2 mm is necessary for obtaining the uniform thickness. If D B is infinitely increased, however, the magnetic force between the developer and the sleeve 2 is weakened, which generates toner cloud to cause fogging. Therefore, the upper limit of D B is naturally determined.
The distance between the developer and the recording material 5 mentioned in 2) is controlled by adjusting the distance between the recording electrode array 4 and the counter electrode 7, or more practically, the distance D S between the recording electrode array 4 and a top surface of the holder 6. If D S is infinitely decreased, the recording material 5 gets in contact with the developer to cause fogging, and also the developer is partially accumulated on the surface of the sleeve 12. If D S is infinitely increased, the electric lines of force generated between the recording electrode array 4 and the counter electrode 7 is diverted to prevent accurate recording of thin lines or the like. In consequence, the upper and the lower limits of D S are naturally determined. An experiment by the inventor found out D B ≦D S ≦D B +0.3 mm.
The strength of the electric field mentioned in 3) is controlled by setting the difference in electric potential between the recording electrode array 4 and the counter electrode 7 large when recording is operated and small when recording is not operated. The above setting is possible by setting the voltages V r applied to the recording electrode array 4 high. If the upper ends of the pin recording electrodes 9 are not sunk in the supporting unit 10, the range of V r is restricted for the reason mentioned in the next paragraph.
The lowest possible resolution for practical use is 5 to 20 dots/mm. In order to obtain the above range of resolution, even the pin recording electrodes having the smallest possible diameter requires the distance between the neighboring pin recording electrodes to be, for example, 50 μm maximum. If every other pin recording electrodes of such a recording electrode array are grounded and the remaining pin recording electrodes are provided with voltages of -400 to -500 V for recording one dot line of pixels, a leakage occurs between the pin recording electrodes. This means V r is practically limited to several hundred volts at the maximum. If a conductive developer is used, the upper limit of the voltages is still lower.
If both the pin recording electrodes 9 and the counter electrode 7 are grounded when recording is not operated, the developer is adhered on the recording material 5 to cause fogging. Bias voltages V b of approximately -100 V are required to avoid the fogging.
From the above consideration, it can be concluded that the following conditions are desirable for practical use of the apparatus.
D B ≧0.2 mm
D B ≦D S ≦D B +0.3 mm
|V r |≦400 V
|V r |≧100 V
However, practical recording with the above conditions generated fogging on almost all over the recording material 5 and drastically lowered image contrast. Further experiments have shown that toner cloud, which is generated on a contacting area between the recording material 5 and the recording head 3, causes the fogging. In order to substantially eliminate the toner cloud, the radius of curvature (R) of the holder 6 was reduced to the smallest possible value and thus the recording material 5 was contacted with the recording head 3 in a smallest possible area. However, it was not enough.
The above-mentioned electric leakage and toner cloud are solved by the devices of the first and the second embodiments. A third embodiment shown in FIG. 17 offers another device to solve them.
The third embodiment has the same construction as the first embodiment except that the counter electrode 37 has an auxiliary electrode 21 and that the upper ends of the pin recording electrodes 9 are not sunk in the supporting unit 10.
The counter electrode 37 is a plane plate integrated with a holder 6. A bottom end of the counter electrode 37 is drawn out from the holder 6 to form a cord 37a, which is connected to the bias power supply 8.
As shown in FIG. 17, the auxiliary electrode 21 is formed of a film-type material and is pasted on the holder 6 with an adhesive. More precisely, the auxiliary electrode 21 comprises a pair of bank portions 21a pasted on both banks of the counter electrode 37 on the top surface of the holder 6 and a pair of side portions 21b (only one of them is shown) perpendicularly extended from middle of the bank portions 21c on both sides of the holder 6.
The bank portions 21a are insulated from the counter electrode 37 by insulating areas 23. Bottom ends of the side portions 21b are drawn out and connected to form a cord 21c, which is connected to another bias power supply 28.
In the above construction, negative voltages are applied from the recording power supply 12 to the recording electrode array 4, positive voltages are from the bias power supply 8 to the counter electrode 37, and another negative voltages are from another bias power supply 28 to the auxiliary electrode 21. The toner 17 charged negative is repulsively splattered to be adhered on the recording material 5. This operation realizes excellence in the image quality for the reason mentioned below.
As shown in FIG. 18, some components of electric lines of force which would, without the auxiliary electrode 21, divert from the desirable path between the recording head 3 and the counter electrode 37 converge in the vicinity of the auxiliary electrode. Since this generates an optimum electric field, the toner transported by Coulomb's force also converges in the vicinity of the auxiliary electrode. Accordingly, resolution is improved and also toner cloud is substantially eliminated. The result is a clear, high quality image.
In other words, some components mentioned above are electrically pushed back to an opposing area between the recording electrode array 4 and the counter electrode 37, whereby the density of the electric lines of force, namely electric flux density is improved and the desirable path of the electric lines of force is formed.
Concerning the third embodiment, another construction is also possible in which the whole holder 6 is formed of a conductive material and partially insulated from the counter electrode 37 so that the holder 6 should be charged oppositely to the toner 17. In this construction, since the holder 6 itself acts as the auxiliary electrode 21, the counter electrode 37 can be simplified in construction.
The auxiliary electrode 21 may be insulated from the counter electrode 37 by steps instead of the insulating areas 23. The steps offers better insulation than the insulating areas 23, resulting in a higher image quality.
FIG. 19 shows a variation of the third embodiment, which employs a counter electrode array 47 which is the same as the counter electrode array 27 of the second embodiment. The counter electrode array 47 comprises a plurality of pin counter electrodes 49, and the auxiliary electrode 21 is also disposed in the same manner as in the third embodiment.
The counter electrode array 47 including many pin counter electrodes 49 with upper ends thereof sunk in the holder 6 and also having the auxiliary electrode 21 realizes still more excellent image quality.
Although the upper ends of the pin recording electrodes 9 of the recording electrode array 4 are on the same plane with the top surface of the supporting unit 10 in the above embodiment and the variation, they may also be sunk in the supporting unit 10.
Although an image is recorded in the recording material 5 in the above embodiments, the image may also be first recorded an intermediate material such as a transfer belt and then re-recorded on the material such as a plain paper.
Although the present invention has been fully described by way of embodiments with references to the accompanying drawings, it is to be noted that various changes and modifications will be apparent to those skilled in the art. Therefore, unless otherwise such changes and modifications depart from the scope of the present invention, they should be construed as being included therein. | An image recording apparatus including a plurality of electrode elements arranged in a line and a supporting member for supporting the plurality of electrode elements, the improvement comprising means for magnetically transporting a developer to the plurality of electrode elements, wherein a pointed end of each electrode element sinking in the supporting member so that a wall portion is defined between the neighboring electrode elements. | 6 |
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