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BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates generally to text input technology. More particularly, the invention relates to a method and system that allows users to input handwritten Chinese characters to a data processor by entering the first few strokes required to write a character, so that users can perform characters input tasks in a fast, predictive way.
2. Description of the Prior Art
Around the globe, over 1.2 billion people speak Chinese. This includes the People's Republic of China, Taiwan, Singapore, and a large community of overseas Chinese in Asia and North America. Chinese character strokes and symbols are so different and so complicated that they can be sorted and grouped in a wide variety of ways. One can analytically sort out as many as 35–40 strokes of 4–10 symbols or more per Chinese character, depending on how they are grouped. Because of this unique structure of Chinese language, computer users cannot input Chinese characters using alphabetic keyboards as easily as inputting Western language.
A number of methods and systems for inputting Chinese characters to screen, such as the Three Corners method, Goo Coding System, 5-Stroke method, Changjie's Input scheme, etc., have been developed. However, none of these input methods provides an easy to use, standardized input/output scheme to speed up the retrieval, typewriting process, by taking full advantage of computer technology.
Several other methods and system for inputting handwritten Chinese characters are also deknown. For example, Apple Computer and the Institute of System Science in Singapore (Apple-ISS) have developed a system which features an application for dictation and a handwriting input method for Chinese. This system incorporates a dictionary assistance service wherein when a first character is recognized, the device displays a list of phrases based on the first character and the user may select the proper phrase without inputting any stroke. This technique effectively increases the input speed.
Another example is Synaptics' QuickStroke system which incorporates a prediction function based on a highly sophisticated neural network engine. This is not a graphics capture application where the users have to write out the entire character before the software can recognize which character is intended. Instead, it can recognize a character after only three to six strokes of the character have been written. It can be used with a standard mouse, Synaptics TouchPad™, or a Synaptics pen input TouchPad.
Another example is Zi Corporation's text input solutions based on an intelligent indexing engine which intuitively predicts and displays desired candidates. The solutions also include powerful personalization and learning capabilities—providing prediction of user-created terms and frequently used vocabulary.
It would be advantageous to provide a handwritten Chinese character input method and system to allow users to enter Chinese characters to a data processor by drawing just the first few strokes and one selection movement such as mouse clicking or stylus or finger tapping.
SUMMARY OF INVENTION
A handwritten Chinese character input method and system is provided to allow users to enter Chinese characters to a data processor by drawing just the first few strokes and one selection movement such as mouse clicking or stylus or finger tapping. The system is interactive, predictive, and intuitive to use. By adding one or two strokes which are used to start writing a Chinese character, users can find a desired character from a list of characters. The list is context sensitive, so in some cases no strokes are needed. It varies depending on the prior character entered. The system puts the handwritten-stroke-to-category mapping on top of the stroke category matching technology, including an optional “Match any stroke category” key or gesture. Compared to other existing systems, this system can save users considerable time and efforts to entering handwritten characters.
In one preferred embodiment, the handwritten Chinese character input system includes: (1) recognition means for recognizing a category of handwriting stroke from a list of stroke categories; (2) collection means for organizing a list of characters that commonly start with one or more recognized categories of handwriting strokes, the list of characters being displayed in a predetermined sequence; and (3) selection means for selecting a desired character from the list of characters.
In a typical embodiment, the strokes are classified into five basic categories, each having one or more sub-categories. The collection means contains predefined stroke order information. It also contain a display means to display a list of most frequently used characters when no strokes are entered, while strokes are being entered, and/or after a character is selected. The list of most frequently used characters is context sensitive. It varies depending upon the last Chinese character entered. The predetermined sequence may be based on any of: (1) number of strokes necessary to write out a character; (2) use frequency of a character; and (3) contextual relation to the last character entered.
The selection means is associated with any of: (1) mouse clicking; (2) stylus tapping; (3) finger tapping; and (4) button/key pressing.
The system also contains “stroke entry means,” such as an LCD touchscreen, stylus or finger pad, trackball, data glove, or other touch-sensitive (possibly flexible) surface.
The system may further includes means for displaying a numeric or iconic representation of each stroke that is entered and a full numeric or iconic representation of strokes for a Chinese character that is selected.
According to the preferred embodiment, a method for inputting handwritten Chinese characters includes the following steps:
adding a stroke into the stroke recognition apparatus; categorizing the added stroke into one of a predetermined number of categories; finding characters based on frequency of character use; displaying a list of found characters; if a desired character is in the list, selecting the desired character from the list; if a desired character is not visible in the list, adding another stroke; finding most common characters that appear after a previously selected character based on a present stroke sequence; and displaying another list of found characters.
The method may further comprise the steps of:
displaying a numeric representation for a stroke that is added; and displaying full stroke numeric representation for a character that is selected.
As an alternative, the method may comprises the steps of:
displaying an iconic representation for a stroke that is added; and displaying full stroke iconic representation for a character that is selected.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram illustrating an apparatus for inputting handwritten Chinese characters according to one preferred embodiment of the invention;
FIG. 2 is a flow diagram illustrating a method for inputting handwritten Chinese characters in a predictive manner according to another preferred embodiment of the invention;
FIG. 3 is a diagram illustrating five basic strokes and their numeric representation;
FIG. 4A is a pictorial diagram illustrating an overview of the Stroke Recognition Interface prior to any input;
FIG. 4B is a pictorial diagram illustrating the Stroke Recognition Interface when a first single horizontal stroke is added;
FIG. 4C is a pictorial diagram illustrating the Stroke Recognition Interface when a second horizontal stroke is added;
FIG. 4D is a pictorial diagram illustrating the Stroke Recognition Interface when a third horizontal stroke is added;
FIG. 4E is a pictorial diagram illustrating the Stroke Recognition Interface when a desired character appears to be the first character in the Selection List;
FIG. 4F is a pictorial diagram illustrating the Stroke Recognition Interface when the first character in the selection list is selected;
FIG. 4G is a pictorial diagram illustrating the Stroke Recognition Interface when a desired character is not the first character in the selection list;
FIG. 4H is a pictorial diagram illustrating the Stroke Recognition Interface when the desired character rather than the first character in the selection list is selected;
FIG. 4I is a pictorial diagram illustrating the Stroke Recognition Interface when the first desired character is selected and a stroke is added for another character;
FIG. 4J is a pictorial diagram illustrating the Stroke Recognition Interface when two strokes are added;
FIG. 4K is a pictorial diagram illustrating the Stroke Recognition Interface when third stroke is added;
FIG. 4L is a pictorial diagram illustrating the Stroke Recognition Interface where the desired character is indicated;
FIG. 4M is a pictorial diagram illustrating the Stroke Recognition Interface when the second desired character is selected;
FIG. 4N is a pictorial diagram illustrating the Stroke Recognition Interface where a third desired character appears in the most frequently used characters;
FIG. 4O is a pictorial diagram illustrating the Stroke Recognition Interface when a third desired character is selected without adding any stroke; and
FIG. 5 is a schematic diagram illustrating the input interface for touchscreen PDA according to the most preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic diagram illustrating an apparatus for inputting handwritten Chinese characters according to one preferred embodiment of this invention. The apparatus includes three basic components: a Stroke Recognition Interface 20 for recognizing entered stroke patterns, an Input Device 24 for entering strokes, and a Processor 30 for performing data process tasks.
The Stroke Recognition Interface 20 has three basic areas: a Message Display Area 28 , a Selection List Area 26 , and a Stroke Input Area 22 .
Message Display Area 28 is the place where the selected characters are displayed. It represents an email or SMS message, or whatever application intends to use the generated text.
Selection List Area 26 is the place to display the most common character choices for the strokes currently entered on the stroke input window. This area may also list common characters that follow the last character in the Message Display Area 28 , that also begin with the strokes entered in the Stroke Input Area 22 .
Stroke Input Area 22 is the heart of the Stroke Recognition Interface 20 . The user begins drawing a character onscreen in this area, using an Input Device 24 such as a stylus, a finger, or a mouse, depending on input device and display device used. The display device echos and retains each stroke (an “ink trail”) until the character is selected.
Stroke Recognition Interface 20 may further includes a Stroke Number Display Area to display the interfaces interpretation, either numeric or iconic, of the strokes entered by the user. When a character is selected, the full stroke representation, either by numbers or by icons, is displayed here. This area is optional, but could be useful for helping users learn stroke orders and stroke categories.
The system may further include: the capabilities to match Latin letters and punctuation symbols and emoticons, with user-defined stroke sequences; user-defined gestures for predefined stroke categories, and unique gestures representing entire components/sequence/symbols; learning/adapting to user's handwriting style, skew, or cursive; optional training session with known characters; optional prompting user to clarify between ambiguous stroke interpretations, and/or a means to enter explicit strokes,e.g. via stroke category keys), and/or remedy a stroke misinterpretation; optional indication of level of confidence of stroke interpretations, e.g. color-coding each “ink trail” or a smiley-face that frowns when it is uncertain; means to display all strokes that make up a character, e.g. drag & drop from text editor to Stroke [Number] Display Area); as well as ability to delete the last stroke(s) in reverse order (and ink trail(s)) by some means.
FIG. 2 is a flow diagram illustrating a method for inputting handwritten Chinese characters in a predictive manner according to the preferred embodiment of the invention. The method includes the following steps:
Step 50 : Adding a stroke into the Stroke Input Area 22 ; Step 52 : Categorizing the added stroke into a stroke category. Step 54 : Finding characters based on frequency of character use; Step 56 : Displaying a list of found characters. The list of characters is displayed in a predetermined sequence. The predetermined sequence may be based on (1) number of strokes necessary to write out a Chinese character; (2) use frequency of a Chinese character entered; or (3) contextual relation to the prior character entered; Step 58 : Checking whether the desired character in the list; Step 60 : If the desired character is not in the list, adding next stroke in the Message Display Area 28 ; Step 70 : If a desired character is in the list, selecting it by clicking a mouse or tapping a stylus or finger, depending on the input and display devices used; Step 72 : Putting the selected character in the Message Display Area 28 ; Step 74 : Checking whether the message is complete; Step 76 : Adding next stroke if the message is not complete; Step 62 (continued from Step 60 or Step 76 ): Finding most common characters that appear after a previously selected character based on a present stroke sequence. This also happens before the first stroke, i.e. before Step 50 ] and Step 80 : Displaying a list of found characters and the process continues on Step 58 .
The apparatus may have a function to actively display the interfaces interpretation, either numeric or iconic, of the strokes entered by the user. Therefore, the method described above may further comprise the steps of:
Displaying a numeric representation for a stroke that is added; Displaying full stroke numeric representation for a character that is selected; Displaying an iconic representation for a stroke that is added; and Displaying full stroke iconic representation for a character that is selected.
As an alternative, Step 54 may be replaced by:
Finding characters that commonly start with one or more recognized stroke patterns.
FIG. 3 is a diagram showing five basic strokes and their numeric representation. There is a government standard of five stroke categories for simplified Chinese characters. There are other classification of the stroke categories. The method and system according to this invention apply to any kind of classification.
One of the major advantages of the recognition system according to this invention is the great reduction of ambiguities arising in the subtle distinction between certain subtypes of the stroke categories. To reduce ambiguities, there are further definitions on the subtypes. For example, a horizontal line with a slight hook upwards is stroke 1 ; a horizontal line with a slight hook down is stroke 5 ; a horizontal line angled upwards is stroke 1 ; and a curved line that starts right diagonally then evens out to horizontal or curved up is stroke 4 , and etc.
One technique for resolving, or at least limiting, ambiguities, is the use of limited wildcards. These are stroke keys that match with any stroke that fits one type of ambiguity. For example, if the stroke may fit into either stroke category 4 or stroke category 5 , the limited wildcard would match both 4 and 5 .
Often the difference between a stroke of one type and a similar stroke of another type are too subtle for a computer to differentiate. This gets even more confusing when the user is sloppy and curves his straight strokes, or straightens his curved strokes, or gets the angle slightly off.
To account for all of the variation of an individual user, the system may learn the specific idiosyncrasies of its one user, and adapt to fit that person's handwriting style.
The specifics of the exaggeration needed may be determined as appropriate. Key to this aspect of the invention is that the user has to make diagonal strokes very diagonal, straight strokes very straight, curved strokes very curved, and angled strokes very angled.
The result on paper is a character that would look somewhat artificial and a caricature of its intended character. However, this greatly simplifies the disambiguation process for finding the strokes, which then helps the disambiguation of characters.
In the following paragraphs in conjunction with a series of pictorial diagrams, the operation process is described.
FIG. 4A illustrates an overview of the Stroke Recognition Interface before any stroke is added. Note that the Character Selection List shows the first ten most frequently used characters. If a user's first desired character is in the list, he just selects the character by clicking the mouse or by tapping a stylus or his finger, without need to add a stroke. If the desired character is not in the list, the user adds a stroke using mouse, stylus, or finger.
FIG. 4B illustrates the Stroke Recognition Interface when a first single horizontal stroke is added. The stroke category is determined to be “1”, and is listed in the Stroke Number Area. The Selection List is re-ordered to predict the most likely character to be chosen based on the first stroke.
FIG. 4C illustrates the Stroke Recognition Interface when a second horizontal stroke is added. After a second horizontal line is entered, the selection list is re-ordered again, showing only the most likely characters that start with two horizontal lines (stroke category 1 ). Note that the position and relative lengths of the strokes do not affect the selection list, only the stroke categories.
FIG. 4D illustrates the Stroke Recognition Interface when a third horizontal stroke is added. After a third horizontal line is entered, the selection list is re-ordered again, showing only the most likely characters that start with three horizontal lines (stroke category 1 ).
FIG. 4E illustrates the Stroke Recognition Interface when a desired character appears to be the first character in the Selection List. Note that the character drawn so far is identical to the first character listed in the selection list. If this were the character desired, simply click that character from the list.
FIG. 4F illustrates the Stroke Recognition Interface when the first character in the selection list is selected. If the user chooses the first character, it is added to the message; at the same time, the stroke numbers are displayed at the bottom, and the input area is cleared, ready for the next character. Note that to select a character, the user has to take one additional mouse click (or stylus or finger press/tapping) than there are strokes. Novice users may find this annoying until they get used to the system, and lean to take advantage of its predictive features.
FIG. 4G illustrates the Stroke Recognition Interface when a desired character is not the first character in the selection list. The strength of this system is its predictive abilities. If the user desired the very complex, but somewhat common, character pointed to in the above illustration, he needs not complete the stroke for that character. As soon as it is displayed in the selection list, it can be selected by clicking a mouse (or stylus or finger tapping) on the character.
FIG. 4H illustrates the Stroke Recognition Interface when the desired character rather than the first character in the selection list is selected. Once the complex character is selected, we see that it is a 15-stroke character, added to the message with only three strokes and one additional click. The user gets a 15-stroke character using four movements. The saving of movement and hence time is about four to one. Additionally, the entire stroke order is displayed now, so if the user was used to an alternate stroke order for the character, he can learn the Government Standard stroke order used by this system.
FIG. 4I illustrates the Stroke Recognition Interface when the first desired character is selected and a stroke is added for another character. Once the character is entered, the program is ready to accept the strokes for another character. Here the initial stroke is a different category, to enter in a very different character. Notice that the selection list is very different than it was with the first stroke of the previous character.
FIG. 4J illustrates the Stroke Recognition Interface when two strokes are added. Note that the strokes entered already form a character that matches the most likely choice in the selection list. The character that we are aiming for in this example is already displayed (see the fifth character from the left) after the second stroke is added. But we want to continue to demonstrate the disambiguation feature of the system.
FIG. 4K illustrates the Stroke Recognition Interface when the third stroke is added. After a third stroke is entered, the selection list contains two characters that are only slightly different from each other. In fact, these two characters have exactly the same stroke order, and choosing from the selection list is the only way to disambiguate the two characters. Note that the second character being pointed to one is less commonly used than not only the first, but also of a slightly more complex character.
FIG. 4L illustrates the Stroke Recognition Interface where the desired character is indicated. Note that the desired character was first visible after the second stroke was entered, and is still a likely choice in the selection list (see the fourth character from the left). If a desired character is removed from the selection list for some reason, it is indication that the stroke order entered by the user does not match the Government Standard stroke order used in the system.
FIG. 4M illustrates the Stroke Recognition Interface when the second desired character is selected. The character is selected, and added to the message. It is a 9-stroke character. We selected it at three strokes, but could have selected it at two strokes.
FIG. 4N illustrates the Stroke Recognition Interface where a third desired character appears in the most frequently used characters. For very common characters, there is no need to enter any strokes. The ten most frequently used characters are displayed even when no strokes are entered. If the user wants to enter one of these common characters, simply selecting it will add it to the message. Note that the selection list of the most frequently used characters is context sensitive. The system displays the ten most frequent characters to follow the last character entered.
FIG. 4O illustrates the Stroke Recognition Interface when a third desired character is selected without adding any stroke. This is a saving of seven to one for the third character.
FIG. 5 illustrates a recommended layout of the input interface according to the most preferred embodiment, where the message area is omitted and the text goes directly into the active application, so there is no need for a message area.
In a typical embodiment, the stroke entry means is a handwriting input area displayed on a touchscreen on a PDA. Each entered stroke is recognized as one of a set of stroke categories. The graphical keys, each assigned to a stroke category, are optionally available to display and enter strokes, as an alternative input means. One of the graphical keys represents “match any stroke category”.
The method described above may be carried out by a computer usable medium containing instructions in computer readable form. In other words, the method may be incorporated in a computer program, a logic device, mobile device, or firmware and/or may be downloaded from a network, e.g. a Web site over the Internet. It may be applied in all sorts of text entry.
Although the invention is described herein with reference to some preferred embodiments, one skilled in the art will readily appreciate that other applications may be substituted for those set forth herein without departing from the spirit and scope of the present invention.
Accordingly, the invention should only be limited by the claims included below. | A handwritten Chinese character input method and system is provided to allow users to enter Chinese characters to a data processor by adding less than three strokes and one selection movement such as mouse clicking or stylus or finger tapping. The system is interactive, predictive, and intuitive to use. By adding one or two strokes which are used to start writing a Chinese character, or in some case even no strokes are needed, users can find a desired character from a list of characters. The list is context sensitive. It varies depending on the prior character entered. Compared to other existing systems, this system can save users considerable time and efforts to entering handwritten characters. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is related to an innovative process to produce fine (nano- or submicron-scale) ceramic powder by the glycine-nitrate combustion method through a chemical reactor with the powder collection device.
[0003] 2. Description of the Prior Art
[0004] Nanotechnology is considered as one of the most important industries in 21 st century. From consumer products to advanced high-tech areas, there are always applications of nanotechnology. However, due to the limitation of strict manufacturing conditions for nanomaterials, mass production with low cost has not been achieved. Thus, mass production of nanomaterials to reduce cost will be a critical factor to the success of commercialization.
[0005] For ceramic materials, in general, the industrial process uses solid-state reaction method. The oxide precursors are mixed first, and then subject to sintering and reaction to form the specific crystal structure required for the product. After that, physical processes like crushing, grinding and dispersing are used to treat the product to a submicron scale. Although such a process can be scaled up for mass production, it usually involves a time-consuming process of high-temperature sintering for crystalline phase formation and it tends to generate impurity phase. Besides, the grinding and dispersing processes to control particle size are very tedious, lengthy and costly. On the other hand, in academic research, sol-gel method is commonly used to synthesize powder. Although this method can obtain purer crystal phase structure, it is limited by the reaction processed in the solvent system and expensive precursors. So mass production based on this method is also difficult. Recently, glycine-nitrate combustion method (GNC) to produce submicron- or nano-scale ceramic powders has been accepted with a great attention. Its general reaction equation can be expressed as follows:
[0000] x M n+ +y NO3 −+z NH2CH2COOH→ a MiO j+b H2O+ c CO2 +d N2 +e O2
[0006] in which M represents metals with a charge number of n, and x, y, z, a, b, c, d, e are stoichiometric constants for reactants and products, i, j are the number of atoms in formula. Due to low ignition temperature (about 180° C.), fast reaction and uniform composition, the method is very suitable for producing composite ceramic material with multiple metal components. However, the method also has some drawbacks to hinder its use for mass production. For example, its flare temperature of the instant reaction can be as high as 1400° C. and it is very difficult to collect the powder from reaction due to explosive spillover. Therefore, to commercialize GNC powder manufacturing process, it is necessary to have a sophisticated design of an appropriate reactor to solve the issue of powder loss and improve the yield. The present invention includes an innovative reactor design that can be effectively applied to GNC process to produce fine (nano- and submicron-scale) ceramic powders in a mass-production scale and satisfy the requirements of safety, high yield, and low cost with simple operation.
SUMMARY OF THE INVENTION
[0007] The main objective for the present invention is to propose an innovative chemical reactor with powder collection system and its application to glycine-nitrate combustion process to produce fine ceramic powder, so it not only generates fine ceramic powder with specific chemical composition in a mass-production scale, and in particular the reactor system also has the essential functions in handling the instant high-temperature flare and pressure during powder formation reaction and effectively collecting the powder to assure reaction system safety and high yield.
[0008] The present invention mainly includes the application of CRPC reactor system to glycine-nitrate combustion process (GNC-P) to produce fine (nano- and submicron-scale) ceramic powder. The main equipments include heating, chemical reactor with powder collection and off-gas treatment systems for powder dust recovery. The chemical reactor with powder collection is a combination of a reactor body, a plural number of porous powder-blocking plates, a plural number of cylindrical tubular powder collection tower components and a porous flare-blocking plate. The porous powder-blocking plate assembly comprises a hollow top support plate, a plural number of metal mesh filters and a hollow bottom support plate. The porous flare-blocking plate assembly comprises a hollow top support plate, a plural number of metal mesh filters, a hollow bottom support plate and a porous flare-blocking plate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is an integrated reactor system diagram for the present invention.
[0010] FIG. 2 is a cross-sectional diagram for the reactor for the present invention.
[0011] FIG. 3 is an assembly diagram for the top and bottom support plates between the reactor body and the first powder collection tower, metal mesh filter and porous flare-blocking plate for the present invention.
[0012] FIG. 4A is an assembly diagram for the close-type porous bottom support plate (with the closed space in the first and the third quadrants) of the powder collection tower and the metal mesh filter.
[0013] FIG. 4B is an assembly diagram of the close-type porous bottom support plate (with the closed space in the second and the fourth quadrants) of the powder collection tower and the metal mesh filter.
[0014] FIG. 5 is a diagram of powder capture and collection for the present invention.
[0015] FIG. 6 is an XRD pattern diagram for LSGM powder for the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The preferred embodiment for the present invention includes designing and fabricating a CRPC reactor system and a process to apply CRPC reactor system to GNC-P to produce the fine (nano- and submicron-scale) ceramic powder with specific chemical composition. The procedures are described as follows.
[0017] 1. Fabricate and design a CRPC reactor system that at least comprises the following three sub-systems:
[0018] 1) Design and Fabricate Heating Equipment with Temperature Control and Support to Reactor.
[0019] a) The equipment is fabricated with metal (primarily stainless steel) material and includes a temperature-control heating furnace 3 with sensor, so it will shut off once reaction temperature exceeds the set temperature. This is to judge the GNC reaction completion. It also records the relationship between operation temperature and time.
[0020] b) The operating temperature range for the heating equipment is between 25° C. and 500° C. It provides heating as well as supporting the chemical reactor with powder collection 1 . Thus, the bottom of the chemical reactor with powder collection 1 can effectively contact the heating plate 31 of the temperature-control heating furnace 3 and achieve the objective of heating the reactor 1 .
[0021] 2) Design and Fabricate a Chemical Reactor with Powder Collection
[0022] a) In the embodiment, chemical reactor with powder collection 1 comprises reactor body 11 , the first powder collection tower 12 and the second powder collection tower 13 . The chemical reactor 1 is mainly made of Inconel alloy or other stainless steels like SS-316, SS-304, SS-316L and SS-304L.
[0023] b) The shape of the chemical reactor with powder collection 1 can be cylindrical, as shown in FIGS. 1 , 2 and 3 , square or others. One end of the reactor body 11 and both ends of the cylindrical tubes of the first and the second powder collection towers 12 , 13 have an outer ring 15 for the coupling and fixation with screw nut 14 . The material thickness of cylindrical tube is determined by the requirement, usually above 0.3 cm. Its inner diameter is 26.0 cm and its length is 45.9 cm, varying according to production scale. The bottom of reactor body 11 is a sealing plate, so the reactor like a container can hold liquid. Above the reactor body 11 , it is a coupling tube, which is hollow at both ends to be used as the powder collection unit.
[0024] c) Above the reactor body 11 , it is a powder collection tower that is a hollow coupling tube at both ends. They are the first powder collection tower 12 and the second powder collection tower 13 , as shown in FIG. 1 . The coupling components between the reactor body 11 and the first powder collection tower 12 include a screw nut 14 , a porous top support plate 21 , a porous bottom support plate 22 , a metal mesh filter 23 and a porous flare-blocking plate 24 . Please refer to FIG. 3 . These components allow complete and tight coupling of the reactor body 11 and the powder collection towers 12 , 13 and stepwise expansion of capacity to form a series of powder collection towers, which increases the capacity of the entire reactor system. The first powder collection tower 12 and the second powder collection tower 13 have the same inner diameter and they make up an integrated chemical reactor (including chemical reaction, product collection, emission buffering).
[0025] d) The number of expandable powder collection tower can increase according to the demand. The embodiment is a two-level powder collection tower with unit length about 16.46˜15.1 cm, inner diameter 26.0 cm and material of Inconel alloy.
[0026] e) In the chemical reactor with powder collection 1 , as shown in FIGS. 1 , 2 , 3 , 4 and 5 , the coupling components between the first powder collection tower 12 and the second powder collection tower 13 and at the top end of the second powder collection tower include a screw nut 14 for inserting a porous top support plate 21 , a porous bottom support plate 22 and two levels of 400 mesh (level and mesh number vary according to demand) metal filter 23 to effectively block reaction flare and catch the powder emission to the collection tower. The size of porous top and bottom support plates 21 , 22 and the metal mesh filter 23 is determined by the reactor body 11 and the first powder collection tower 12 and the second powder collection tower 13 to assure complete airtightness of the reactor body-powder collection tower. The first and third quadrants of the porous bottom support plate 221 at the coupling interface between the first collection tower and the second collection tower are close-type. The second and fourth quadrants of the porous bottom support plate 222 at the top of the second collection tower are close-type. Please refer to FIGS. 4A and 4B .
[0027] 3) Design and Fabricate Off-Gas and Powder Dust Treatment System
[0028] a) The system comprises the off-gas exhaust, water (or specific solution) scrubber, and powder collection units. The emission gas of the little amount of GNC reaction stream ejected from the top of the chemical reactor with powder collection 1 contains very little product powder, which is finally subject to treatment by exhaust and water scrubber system to assure emission quality. Besides, powder can be re-collected from the scrubber solution and heated and dried to return to the product stream, which can increase the yield, assure public safety and environmental safety and meet the environmental requirements.
[0029] 2. A process to produce the fine (nano and submicron-scale) ceramic powder of specific chemical composition by applying an innovative chemical reactor with powder collection system (CRPC reactor system) to glycine-nitrate combustion method (GNC-P) at least comprises the following steps:
[0030] 1) Prepare nitrate precursors. Weigh La(NO 3 ) 3 .6H 2 O, Sr(NO 3 ) 2 , Ga(NO 3 ) 3 .XH 2 O, Mg(NO 3 ) 2 .6H 2 O in cation molar ratio 0.9:0.1:0.8:0.2. Mix them into deionized water to form a mixture. Pour a pre-dissolved 3.16 mole Glycine into the mixture to form a solution. Heat and agitate the solution to start chelation. For nitrate precursors, besides LSGM-9182, other ceramic oxides with multiple metals can be used, including doped cerias, La 1-x Sr x MnO 3-δ , La 1-x Sr x CO 1-y Fe y O 3-δ , Ba 1-x Sr x CO 1-y Fe y O 3-δ , the materials of perovskite structure.
[0031] 2) Dissolve the above nitrate precursors in deionized water and add an appropriate amount of glycine. After mixing evenly, pour it into the reactor body 11 .
[0032] 3) Assemble the glycine-nitrate combustion reactor system. Cover it with the porous top plate 2 . Lock the reactor body 11 with the powder collection tower 12 , 13 . Leave it inside the temperature-control heating furnace 3 . This is to complete the assembly of the chemical reactor with powder collection 1 . The assembly diagram is shown in FIG. 1 . FIG. 2 is the cross-sectional diagram. Except for mesh filter, all material for the chemical reactor with powder collection 1 is Inconel alloy. The filter material can be SS or Inconel alloy.
[0033] 4) Turn on heater. Set temperature at 350° C. and start heating until the reaction product is formed. When the bottom heating plate senses the instant high reaction temperature, temperature-control heating furnace 3 will automatically shut off. This indicates completion of reaction.
[0034] 5) When reaction flare 5 ejection occurs, the porous flare-blocking plate 24 and the porous top support plate 21 can effectively block the flare to prevent direct flare burning of the metal filter 23 (mesh) of the first powder collection tower 12 and the second powder collection tower 13 and also allow the release of the high pressure caused by the high temperature and preliminarily filter the ejected powder. The filter on the collection tower will catch smaller powder particles. With increasing number of collection towers, the powder collection will be even more complete. The dust collector can collect the escaped powder.
[0035] 6) Open reactor body 11 , the first powder collection tower 12 and the second powder collection tower 13 . The reaction powder product 4 is mainly accumulated at the bottom of the reactor and each collection tower. Collect the powder from the reactor body 11 , the first powder collection tower 12 and the second powder collection tower 13 to complete powder production process. Measurement and characterization of thermal treatment characteristics of powder can be conducted. Powder characterization is mainly on crystal lattice to assure product quality and provide the basis for further sintering process.
[0036] FIG. 5 is the diagram of powder capture and collection for the reactor of the present invention. FIG. 6 is the XRD analysis diagram for the LSGM powder from the reactor of the present invention. They all prove that the excellence, necessity, innovation and technical importance of the reactor shall meet the patent application requirements. Thus, the application is submitted. | The present invention is related to producing fine nano or submicron-scale precision ceramic powder by applying an innovative chemical reactor with powder collection to the glycine-nitrate combustion process (GNC-P). The unique feature lies in the utilization of a simple-operating process to massively produce nano or submicron-scale ceramic oxide powder with multiple metal components. The present invention not only provides very high powder collection efficiency and production yield as well as safety but also satisfies requirements of industrial safety and environmental safety, and lowers production cost. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to vibration isolating systems, and more particularly to a suspension system for isolating vibrations of a moving system from the frame on which it is supported.
The problem of isolating vibrations of moving parts has long been recognized, and many solutions have been proposed therefor. While many of the systems which have been evolved have been satisfactory, it has been found most difficult to provide an arrangement which, together with the eliminatioin of undesirable vibrations in the supporting framework of the apparatus, is also economical while at the same time restricting the vibrational movement of the apparatus to a reasonable extent. In addition, it frequently occurs that the moving parts of such apparatus must often be allowed only a certain number of degrees of freedom, and there is thus the problem of absorbing the vibrations between the moving system and the frame while retaining the motion of the moving system within the predetermined limits established usually by the outer cabinet.
As an example of the problems encountered along this line, most automatic washing machines of this type presently commercially available for domestic use provide a clothes basket in which the clothes are washed and rinsed, and when it is desired to remove the liquid from the clothes the basket is rotated at a high speed so as to centrifuge the liquid out of the clothes. Very often, the system for effecting the washing and centrifuging operations does not have its weight symmetrically distributed about the axis of rotation so that there is inherently an unbalance in the system. In addition, the clothes which are being laundered most often will not distribute themselves perfectly about the inner surface of the cylindrical wall of the basket but will provide an additional degree of unbalance. There is the further consideratioin that vibration-caused motion of the moving system must be maintained within reasonable limits, usually on the basis that the supporting frame or cabinet of the machine must be small enough to be commercially attractive for home usage. Yet a further item for consideration is that vertical axis washing machines, that is, washing machines of the type with a basket, open at its top and reached through a lid in the top of the machine, generally should have a highly limited amount of vertical freedom, both from proper functioning of the apparatus itself and again because of the restrictions on size inherent in an appliance which is to be used in the space normally available in most homes.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide an improved system which will be simple in structure and economical to manufacture, yet which will effectively prevent the vibratioins of the moving system from reaching the stationary part of the apparatus in which the moving system is included.
A more specific object of the invention is to provide a vibration isolating system wherein all degrees of freedom of movement are provided including both vertical and horizontal while at the same time insuring that the node while allowed to move both vertically and horizontally will remain below movable mass.
In one aspect of the invention there is provided in a vertical axis washing machine a cabinet including a base, a movable mass, a rotatable basket and means for imparting oscillation and rotation to the movable mass, and a suspension system for suspending the movable mass within the cabinet and above a base.
The suspension system is formed to include a plurality of circumferentially spaced spring members. The springs are secured at their lower end to the base of the machine and at their upper end are joined to a support member. A plurality of circumferentially spaced links are provided which extend in the general direction of the vertical axis. Each of the links has one of its ends connected to the support member with its other ends connected to the movable mass. The dimension of the spring members and links are such that the movable mass is supported both for vertical and horizontal movement above the base so as to be self-correcting.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view in section of a washing machine incorporating the suspension system of the present invention;
FIG. 2 is an enlarged elevational view in cross section showing details of the suspension system;
FIG. 3 is a plan view of the suspension system taken along line 3--3 of FIG. 1;
FIG. 4 is an enlarged elevational view taken along line 4--4 of FIG. 3 showing a detail of construction;
FIG. 5 is a plan view of a portion of the suspension system secured to the movable mass of the machine; and
FIG. 6 is a plan view of a portion of the suspension system secured to the base of the machine for supporting the movable mass.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown a washing machine 10 of the vertical axis type which includes a cabinet 12. Within the cabinet 12 is disposed an imperforate tub 14. Within the imperforate tub 14 there is disposed a basket 16 for receiving fabric articles, such as clothing to be washed. The basket side wall 18 includes a plurality of apertures 20 for discharge of water during a centrifugal extraction portion of the operating cycle of the machine. The bottom wall 22 of basket 16 slopes upwardly from a low portion at the outer circumference of the side wall 18 toward the central vertical axis designated by the letter "A" in the drawings. The tub 14 is composed of an imperforate side wall 26 and a generally imperforate and substantially horizontally disposed bottom wall 28 having a single drain opening 30. The tub 14 is mounted on a stationary support flange 29 arranged on the vertical axis. At the center of the basket 16 there is positioned a vertical axis agitator 34 which includes a vertical center post 36 and a plurality of vanes 38 extending outwardly from the central post 36 thereof. The agitator vertical center portion 36 is concentrically mounted above a center post 42, and is driven by an oscillating agitator drive shaft 44, by means of a drive motor 46.
The basket 16 is mounted on a flange 47 of a rotatable spin hub 45. During operation of the washing machine in the washing cycle, the agitator 34 driven by shaft 44 is first oscillated back and forth within the basket 16 to wash the clothes therein. Then, after a predetermined period of this washing action, the basket 16 driven by spin hub 45 is rotated at high speed to extract centrifugally the washing liquid and discharge it through apertures 20 into the outer tub 14 for draining from the machine through drain opening 30. Liquid from the drain 30 is carried from the machine by a pump 31 which may be energized during the extraction operation or a selected portion thereof. The above described cycle may be repeated in carrying out a wash operation depending on the fabric to be washed. The basket 16 and agitator 34 may be driven by any suitable means as the drive means forms no part of the present invention. However, by way of example, they are shown as driven by an electrically commutated reversible motor 46.
The shaft 44 and the enclosing vertical sleeve 50 extend a substantial distance below the tub 14 to a driving mechanism including a pulley 51 driven by a belt 52 passing over the output shaft of the electrical motor 46. The machine so far described will hereinafter be designated as the movable mass which is carried on a chassis or suspension system generally designated at 54.
The suspension system 54 is formed to include a frame portion or structure fixedly secured to the operating components of the washing machine or movable mass, and a supporting portion secured to the base 55. The portion secured to the movable mass includes an upper frame 56 on which the tub 14 is supported, and a lower frame 58 on which the motor 46 and lower portion of the sleeve 50 is supported.
The upper frame 56 as shown in FIG. 3 and 5 is substantially rectangular in configuration, and consists of side frame members 60 interconnected at each corner to depending leg members 62. The lower frame 58 includes side frame members 64 connected as shown in FIG. 2 to the leg members 62 at a position below the frame members 60. The dimension of the frames 56 and 58 are such that the legs 62 converge axially downwardly and inwardly toward the central axis "A".
The motor 46 as shown in FIG. 1 is supported on a pair of elongated cross members 66 which as shown in FIG. 2 and 3 are secured to and supported on the lower frame members 64. The lower end portion of the sleeve 50 is formed to include a flange 68 which as shown in FIG. 1 is supported on and fixed to the members 66. As can readily be understood, the portion of the suspension system 54 (FIG. 5) fixedly secured to the tub 14 and accordingly movable therewith in fact becomes part of the singular movable mass which as will now be explained is supported on the base member 55.
The movable mass is supported on the base 55 through the supporting portion of the suspension system by means of a plate or load support member 74. The support member 74 is mounted on leaf spring legs or straps 76. In the present embodiment there are shown four spring legs each extending inwardly from a position adjacent a corner of the base 55 as shown in FIG. 3 and 6. However, it may be possible under certain parameters to employ any number of spring legs. The spring legs 76 extend upwardly and inwardly from an attachment 72 on the base 55 to an upper end 77 which is secured to the plate 74. An ample generally circular clearance opening 78 in the plate 74 permits the sleeve 50 to depend freely through the plate 74. As best seen in FIG. 4 the upper ends 77 of the springs 76 at the connection to the plate 74 curve toward a vertical orientation. This portion 77 of the spring extending toward vertical adds vertical stiffness to the springs at their upper ends. Further, the position of the springs 76 by extending inwardly from each corner of base 55 toward the central axis "A" offer greater resistance toward movement in the side-to-side direction of the cabinet while offering less resistance in a diagonal direction of the cabinet. Accordingly, a bigger excursion is allowed in the direction toward the corners of the cabinet where there is greater tolerance for movement. The movable mass is supported on the plate 74 above the base 55 as shown in FIG. 2 through a plurality of links 80. The upper ends 82 of the links 80 pass through and are secured to the plate 74, the lower ends 84 of the links 80 are secured to an inwardly bent flange 86 the lower ends of the legs 62 of the chassis 54. As best seen in FIG. 3 and 5, the lower ends of the legs 62 extend radially inwardly from their attachment to the upper frame members 60. This arrangement readily permits the links 80 to, in effect, converge radially inwardly as they extend downwardly from the plate 74 to their connection on legs 62. This selected angle of inclination relative to the axis "A" of the machine provides greater stability of the movable mass and further ensures that the node while movable both horizontally and vertically will always be below the basket. In the present instance four links 80 were employed in carrying out the suspension system. It was determined in carrying out the present invention that the selection of four links provides a parallelogram action between the plate 74 and the movable mass or hanging portion of the system. However, it may be possible under certain design parameters to employ any number of links. Due to the stiffness of the links 80, the parallelogram is maintained between the links and its connecting parts. While the portion of the suspension system connected to the movable mass (FIG. 5) is shown assembled and separate from the portion connected to the base (FIG. 6), it should be understood that because of the interwoven parts they are assembled as a single unit as shown in FIGS. 1-3.
As can be readily understood, horizontal motion of the movable mass is provided by the arrangement of the links 80 while vertical movement of the movable mass is provided through the action of the springs 76. Damping of the movable mass is provided wherein dampers 88 are anchored to the base 55. The dampers 88 as shown in FIG. 1 include a U-shaped spring clamp member 90 resiliently secured to the base member 55 and a pair of friction pads 92. The pair of friction pads 92 are held in engagement with the surface of a plate 94 secured to the legs 62 of the movable mass by the U-shaped spring clamps 90. The spring clamp 90 are relatively strong so that each plate 94 is gripped tightly by the friction pads 92. The damping devices 88 and their action relative to the movable mass as shown are independent of the load and accordingly have a constant clamping characteristic.
The imbalance forces operating on the moving system or mass supported by the load member 74 when the basket is spinning at a relatively high speed cause, basically, two types of vibration motion. Firstly, there is a generally swinging or pendulous motion of the movable mass within a vertical plane. Such pendulous motion causes the link members 80 to pivot at their end portions. By the present arrangement, the pendulous movement of the movable mass tends to become almost a substantially horizontal movement with, very little tilting because of the parallelogram configuration as explained above. The pendulous movement of the mass is thereby seen to be of a self-correcting or self-balancing nature and has a tendency to remain substantially horizontal and thereby enabling the system to support a load wherein the center of gravity will always remain within a vertical cylinder whose diameter is defined by a circle drawn from a radius generated from the central axis and whose circumference passes through the center of the link mounts 82 on the upper plate 74. The second type of motion which may occur is a rocking or oscillating motion about a point wherein the mass tends to rotate relative to the support base 55 in a manner similar to that explained in detail for the aforedescribed pendulous motion, the present system tends to self-correct or self-balance the tilting tendancy of the support member.
The third type of motion which may occur is vertical or axial movement of the mass. Such vertical motion causes the spring support members 76 to flex and thereby to cause the support plate 74 to tilt. The dimension of the spring support members 76 is such that such tilting when it does occur will be slight. This arrangement of spring support members has a self-correcting or self-balancing tendency of the vertical movement on the support member.
It will thus be seen that the present suspension system will accommodate both pendulous and rocking motion. However, almost invariably there is a combination of rocking and pendulous motion. Such a combination of motions, however, poses no additional problem for the present system as the components thereof coact in substantially the same manner to self-correct the effects of either motion or a combination thereof.
The spring support members 76 have desirable flexibility for allowing lateral mobility of the suspended mass as well as sufficient strength for supporting the weight of the mass. This allows the suspension system to provide a substantially solid support for the tub assembly 14 during the agitation cycle and some dampening of forces during a normal spin cycle. These characteristics are desirable because during the washing cycle large forces are created by the oscillatory motion of the agitator against the clothes and the water in the tub 14, and a relatively firm or stable tub support is needed to prevent significant movement or excursion of the tub 14 within the cabinet 12 which might cause damage to the cabinet. The relatively firm or stable base during the agitate cycle is provided in the instant invention by the dimension of the springs when water is added to the tub 14.
However, during the extraction cycle it is best to provide only a limited amount of dampening since, if an unbalance occurs in the basket 16 due to an off balance load, the forces created by the off balance load will be most effectively isolated from the cabinet base 55 by a suspension system with a low dampening co-efficient. Furthermore, a suspension system with a low spring rate generally has a lower natural frequency so that during acceleration of the basket at the start of the extraction cycle, the basket will more quickly pass through the critical speed. The term "critical speed" is the rotational speed of the basket which approximates a natural frequency of the suspended system and this speed may be, for example, about 100 revolutions per minute.
When the basket 16 is rotating at or near a critical speed, the tendency of excursion or orbital movement of the basket, especially a basket carrying an unbalanced load, is substantially increased. As a principal matter, when the spinning basket has passed through the critical speed, excursion of the tub 14 and basket assembly 16 within the cabinet 12 is reduced. Therefore, the continued application of dampening to prevent excursion after the basket has exceeded the critical speed may tend to unnecessarily transfer motion to the cabinet base.
Due to the dimension of the springs 76, as the springs 76 are compressed by the filled tub, the suspension system 54 provides a substantially solid support for the tub assembly during the agitation cycle. However, when the liquid is drained from the tub the system provides a low spring rate for the extraction cycle. Because of the low spring rates which are utilized and which allow relatively free movement of the tub, it is necessary to additionally limit the large excursions of the tub as the spinning basket approaches and passes through the critical speed in order to prevent excessive noise and even damage to the appliance.
The instant suspension system provides for limited excursion of the tub and basket assembly as the basket is accelerated through critical speed during the extraction cycle, and has the desirable feature of increased effectiveness proportionate to the increase of such excursion. During the spinning mode of operation, the suspension system 54 together with the damping devices 88 will have a snubbing effect on any horizontal movement which exceeds a given amount and will selectively dampen vertical excursion during such excessive horizontal movement of the tub and basket assembly.
It should be apparent to those skilled in the art that the embodiment described heretofore is considered to be the presently preferred form of this invention. In accordance with the Patent Statues, changes may be made in the disclosed apparatus and the manner in which it is used without actually departing from the true spirit and scope of this invention. | This invention relates to centrifuging machines, and more particularly to vertical axis washing machines, wherein improved vibration-isolating devices are provided to prevent unbalance-caused vibrations of the movable mass from being transmitted to the support structure of the machine to the extent that damage to or "walking" of the machine may occur.
A suspension system is provided for suspending the movable mass above the machine support structure. The suspension system is formed by a plurality of circumferentially spaced spring members supported at the lower ends to the support structure. The springs are connected at their upper ends to a support member. The suspension system for supporting the movable mass on the support member includes a plurality of circumferentially spaced links which extend in the general direction of the vertical axis. Each of the links has one of its ends connected to the support member and the other lower end connected to the movable mass so that the movable mass is supported above the base in a manner which absorb both vertical and horizontal vibrations, and is essentially self-correcting. | 3 |
FIELD OF THE INVENTION
The present invention is generally in the field of controllers for controlling the operation of different actuators. More specifically the present invention is concerned with controllers suited for use in conjunction with return-biased actuators and in particular the invention provides intensification of the return force of the actuator.
BACKGROUND OF THE INVENTION
Controllers for operating and governing the operation of actuators which in turn are coupled to a varsity of valves and other devices are known. Such controllers typically comprise one or more ports connectable to a pressurized fluid source, which by sequential control signals close and open pressure ports and venting ports thereof to thereby impart motion to various valves and the like, articulated thereto.
A number of differing designs have been formulated for actuator controllers, such as those utilizing dual electromagnetic actuators to move a valve spool in opposite directions. Another example is the use of a double wound actuator, able to energize in both directions.
An alternative approach is the so called spring return pneumatic actuators which typically comprise one or more cylinders slidingly accommodating therein a spring-biased piston, wherein the piston is spring biased in one direction and pneumatically urged in the opposed direction. Such actuators are at times referred to as single action pneumatic actuators. Accordingly, when compressed air is applied at one end of the piston, the piston is thrust to load the biasing spring so as to provide a useful output bias thrust. However, upon discharging the compressed air the piston is retuned and the spring member is relaxed, with a useful but reversed output linearly reducing thrust, as the spring relaxes. This arrangement offers strong spring-biasing effect at the initial displacement of the piston, whereby the final thrust available as the piston comes to rest is considerably less than the initial return thrust.
An example of such as design is discussed in GB Patent No. 1373070 to Tugwell disclosing a pneumatic actuator comprising a double-acting piston separating two first chambers, spring means to urge the piston in one direction, and valve means adapted to admit compressed air to one of the chambers and thus to load the spring means, then to transfer some of such air into the other chamber at a selected phase position of the piston, and then to open the said one chamber to atmosphere whereby the combined forces of the spring means and of the compressed air acting on the piston in the other chamber, complete the power stroke of the actuator.
Hereinafter in the specification and claims, reference will be made to a pressurized fluid useful for operating the controller, with particular reference to pneumatic devices operated by pressurized air. The skilled person will appreciate that such apparatuses are operable with either pressurized air or liquid, the former often being more readily available and suitable for industrial environments.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a fluid-assist actuator controller, for cooperation in conjunction with an actuator of the spring-loaded type, wherein return action of one or more working pistons of the actuator is facilitated by said spring member and with aid of pressurized fluid already gained in the system.
According to the present invention there is provided an actuator controller comprising a body formed with a pressurized fluid inlet port for coupling to a source of pressurised fluid, and being in flow communication with a primary spool bore and a secondary spool bore extending axially within said body; a primary spool supported and axially displaceable within said primary spool bore; a secondary spool supported and axially displaceable within said secondary spool bore; a first cross-flow port and second cross flow port providing fluid communication between said primary spool bore and said secondary spool bore, at least one compression outlet port and at least one expansion outlet port both extending from said primary spool bore, and a venting outlet port.
According to a particular design of the present invention, the primary spool bore is formed with a first chamber and an second chamber partitioned from one another by a neck portion sealable by a first seal fixed over the primary spool; said primary spool further comprises a first one-way seal membrane extending in the first chamber and a second one-way seal membrane extending in the second chamber, and admitting fluid flow only in direction from the first chamber towards the second chamber; and a second seal fitted at an end of the primary spool to selectively seal the venting outlet port.
Furthermore, the secondary spool comprises a small spool head being in flow communication with the pressurized fluid inlet and comprising a small seal; and a large spool head being in flow communication with the expansion outlet port and comprising a large seal.
The arrangement according to the present invention is such that the secondary spool is displaceable between a first position in which the small seal seals fluid flow between the pressurized fluid inlet and the first cross-flow port, and a second position admitting fluid flow between. Furthermore, the secondary spool comprises a secondary first chamber being in fluid communication with the pressurized fluid inlet and partitioned from an intermediate chamber by the small seal; said intermediate chamber being in flow communication with the first cross-flow port; and a major chamber partitioned from the intermediate chamber by the large seal and being in flow communication with the second cross flow port.
According to a particular design of the invention the large spool area has a large surface area extending in the major chamber, and a small surface area extending in said intermediate chamber.
According to a particular arrangement of the invention the second one-way seal membrane is axially displaceable about the primary spool.
By some further embodiments, the controller may comprise one or more of the following arrangements:
a manual override for axially displacing the primary spool within the primary spool bore so as to open the venting outlet port. Said manual override may be formed at a sealing plug coaxial with the primary spool bore; an adjusting member for adjusting axial positioning of the primary spool so as to govern seal engagement of the first seal of the primary spool within the neck portion of the primary spool bore. The adjusting member is screw fitted at a sealing plug coaxial with the primary spool bore. The at least one compression outlet port and at least one expansion outlet port are fitted with a Namur-type coupling arrangement. The venting outlet port may be fitted with an adjustable valve for controlling venting rate of the second chamber. The controller according to the invention may be applied to a variety of mechanisms such as, emergency braking systems, door systems, etc. utilizing a pneumatic lock/return system.
By a further particular design of the controller the first cross-flow port and second cross flow port extend coaxially with the compression outlet port and at least one expansion outlet port, respectively.
According to the invention, the primary spool is displaceable between a first extreme position where a fore spool head bears against a sealing plug of the primary spool bore, and a second extreme position wherein a shoulder of the primary spool extending intermediate the first seal and the first one-way valve seal bears against a shoulder of the neck portion of the primary spool bore.
the design of the controller is such that the pressurized fluid inlet port entails full displacement of the primary spool and the secondary spool, into a first position respectively, wherein the primary spool is displaced so as to admit pressurized fluid flow to the compression outlet port and the first chamber and an second chamber are sealingly disengaged from one another; and the secondary spool is displaced so as to seal fluid flow between the pressurized fluid inlet and the first cross-flow port.
Furthermore, the arrangement is such that terminating pressure through the pressurized fluid inlet port entails displacement of the primary spool so as to seal the venting outlet port and resume fluid flow between the first chamber and an second chamber; and further, the secondary spool displaces so as to resume fluid flow in direction from the first cross-flow port towards the pressurized fluid inlet, until the pressure camber and the second chamber are at pressure equilibrium.
And further wherein the venting outlet port opens only to exhaust fluid from the second chamber and is otherwise sealed by is a sealing ring mounted on the primary spool, to thereby prevent external fluid from entering the controller through the venting outlet port.
According to a further aspect of the present invention, there is provided an actuator system comprising an actuator and an actuator controller as described hereinabove, said actuator being formed with one or more pistons displaceable within a piston cylinder, each cylinder being sealingly divided into a first chamber being in flow communication with an compression outlet port of the said actuator controller, and an second chamber being in flow communication with an compression outlet port of said actuator controller; said piston being biased in direction to expand said second chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to understand the invention and to see how it may be carried out in practice, several embodiments will now be described, by way of non-limiting examples only, with reference to the accompanying drawings, in which:
FIG. 1 is a three-dimensional sectioned illustration of an actuator controller in accordance with the present invention;
FIG. 2 is an elevation of the primary spool used in the controller in accordance with the illustrated embodiment;
FIG. 3 is an elevation of the secondary spool used in the illustrated embodiment;
FIGS. 4A-4C illustrate consecutive steps of a sequence of operation of the controller in accordance with the present invention cooperating in conjunction with an actuator;
FIG. 5 is a modification of a controller in accordance with the present invention fitted with a manual override;
FIG. 6 is a modification of the invention illustrating a controller fitted with a primary spool adjusting member; and
FIG. 7 is a further embodiment of a controller in accordance with the present invention wherein the venting outlet port is fitted with an adjustable vent valve.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
Attention is first being directed to FIGS. 1 to 4 for understanding the general construction of the actuator controller in accordance with the present invention generally designated 10 . The controller comprises a body 12 fitted with a pressurized flowing inlet bore 14 adapted for coupling to a source of pressurized fluid, e.g. by a threaded coupling, or otherwise, as known per se.
Transversely extending within the body 12 there is a primary spool bore 16 sealed at one end by a sealing plug 18 screw coupled at 19 to the body 12 .
Extending from the pressurized fluid inlet port 14 and in parallel to the primary spool bore 16 , there is a secondary spool bore 20 sealed by a plug 24 screw threaded to the body at 28 .
The primary spool bore 16 is divided into a first chamber 30 and a second chamber 34 and the secondary spool bore 20 is divided into a secondary first chamber 38 being in flow communication with conduit 120 and the pressurized fluid inlet port 14 , and further there is an intermediate chamber 42 and a major chamber 44 .
A first cross-flow port 48 extends between the first chamber 30 of the primary spool bore 16 and the intermediate chamber 42 of the secondary spool bore 20 , and a second cross-flow port 52 extends between the second chamber 34 of the primary spool bore 16 and the major chamber 44 of the secondary spool bore 20 , providing controlled fluid flow between said chambers, as will become apparent hereinafter.
Extending from the first chamber 30 of the primary spool there is a compression outlet port 53 and an expansion outlet port 54 extends from the second chamber 34 .
Whilst in the present embodiment, and as illustrated in the annexed drawings, there is provided only a single compression outlet port and a single expansion outlet port, it is to be appreciated that there may be more such ports, depending on the desired application. Furthermore, in the particular embodiment, the body 12 is fitted with a Namur-type coupler 57 (i.e. Namur-type interface), configured and sized in accordance with that standard.
With further reference being made to FIGS. 3 and 4 , it is noticeable that the primary spool bore 16 accommodates an axially displaceable primary spool 60 and the secondary spool bore 20 accommodates an axially displaceable secondary spool generally designated 62 . The primary spool 60 comprises a substantially flat fore-end 66 fitted for stopping against a substantially flat end 68 of plug 18 ( FIG. 1 ) and further the primary spool 60 comprises a first one-way seal membrane 70 made of resilient material and fixedly retained in position within a groove 72 sized accordingly. A first seal 74 , in the form of an O-ring is fixedly positioned on the primary spool 60 which further comprises a second one-way seal 78 slidingly displaceable over a intermediate portion 80 of the primary spool 60 . Spool 60 is further fitted at its other end with a second seal 82 in the form of an O-ring, fitted for selective sealing of shoulder 84 formed at the venting outlet port 23 .
Turning back now to FIG. 1 , it is noticed that the first one-way seal membrane 70 slidingly bears against the substantially smooth wall portion 80 of intermediate portion of the primary spool bore 16 in a sealing engaging manner, allowing fluid to flow only in one direction namely from left to right as visualized in the figure. Similarly, the second one-way seal membrane 78 slidingly bears against a corresponding second substantially flat portion 86 of the primary spool bore 16 to thereby provide sealing engagement therebetween and allow fluid flow over the one-way seal membrane in the same direction, namely from left to right as visualized in FIG. 1 and as will be explained hereinafter and exemplified with reference to FIGS. 4A to 4D .
The first O-ring seal 74 is fitted for sealing fluid flow between the first chamber 30 and the second chamber 34 at an abutting sealing portion 88 of the primary spool bore 16 .
FIG. 3 illustrates the secondary spool 62 comprises a small spool head 90 formed with a substantially flat forehead 92 and being in flow communication with the pressurized fluid inlet 14 ( FIG. 1 ) and comprising a small O-ring seal 94 fitted for sealing against a corresponding neck portion 98 in the secondary spool bore 20 , partitioning the secondary first chamber 38 from the intermediate chamber 42 . At an opposite end of the secondary spool 62 there is a large spool head 100 formed with a flat head 102 and comprising a large O-ring seal 106 fitted for sealing abutting against smooth wall 108 ( FIG. 1 ) of the secondary spool bore 20 thereby forming a sealed partition between the intermediate chamber 42 and the major chamber 44 .
Further attention is now directed to FIGS. 4A-4D illustrating how the actuator controller 10 in accordance with the present invention cooperates in conjunction with an actuator, in accordance with one particular embodiment designated 110 . Whilst in the particular embodiment the actuator 110 is a double piston actuator, of the so-called spring return type, it is to be appreciated that the controller in accordance with the present invention may be used with a variety of different actuator types such as rack and pinion, skotch yoke, diaphragm and vane types, spring return pistons, etc. as known in the art.
In the particular example of FIGS. 4A-4D a pressure compartment 112 of the actuator 110 is coupled to the compression outlet port 53 of the controller, and two outlet ports 113 , each extending from a spring compartment 114 , are flow coupled to one another by a pressure line 116 which in turn is coupled to the expansion outlet port 54 of the controller 10 .
Hereinafter in the particular example, particular reference is made to a pneumatic system wherein the working fluid is compressed air. However, it is to be appreciated by a person skilled in the art that the working fluid may be any gas or liquid.
At an initial state ( FIG. 4A ) pressurized air is introduced into the pressurized fluid inlet port 14 expanding through conduit 119 into the primary spool bore 16 , deforms the first one-way seal membrane 70 resulting in axial displacement of the primary spool 60 until a shoulder 130 of the primary spool 60 (see FIG. 2 ) comes to rest against a corresponding shoulder 132 formed in the primary spool bore 16 .
During axial displacement of the primary spool 60 into the position seen in FIG. 4A , air initially captured within the second chamber 34 and at the major chamber 44 and the cross-flow port 52 , may now be discharged to the atmosphere through venting outlet port 23 since the second O-ring seal 82 disengages from the respective shoulder 84 , to allow a venting aperture therebetween. Pressurized air now flows through the first cross-flow port 48 into the intermediate chamber 42 of the secondary spool bore 20 resulting in pressure applied against the large spool head 100 resulting in further and complete displacement thereof against the stopper plug 24 .
Upon displacement of the primary spool 60 to the position seen in FIG. 4A , the first O-ring seal 74 adequately seals against surface 88 of the primary spool bore 16 , thus providing pressure seal between the first chamber 30 and the second chamber 34 of the primary spool bore 16 , resulting in pressure built-up in the first chamber 30 and within pressure compartment 112 respectively.
During displacement of the primary spool 60 , pressurized fluid (air in the discussed example) from the fluid inlet port 14 expands also through conduit 120 into the secondary first chamber 38 of the secondary spool bore 20 , resulting in axial displacement of the secondary spool 62 in the direction of arrow 124 , until its head surface 102 comes to rest against face 25 of seal plug 24 . At this situation the small seal 94 of the secondary spool 62 seals fluid flow between the pressurized fluid inlet 14 and the intermediate chamber 42 of the secondary spool bore 20 , also sealing fluid flow between duct 120 and first cross-flow port 48 . Displacement of the secondary spool 62 to the position of FIG. 4A entails exhaustion of residual air from major chamber 44 through the second cross-flow port 52 and out through the open venting outlet port 23
Air pressure build up in the actuator pressure chamber 112 of the actuator 110 , results in axial displacement of the double-rack pistons 111 in opposite directions as illustrated by corresponding arrows 131 , against the biasing affect of compression springs 115 in spring chambers 114 . Now the system is in a so-called steady state and standby position.
It is appreciated that in the standby position, in the event of pressure fluctuations of the pressurized fluid, the pressurized air trapped in the first chamber 30 retains the actuator at its recent position as all outlets from the first chamber 30 are now sealed, namely by the first one-way seal membrane 70 , the small O-ring seal 94 and the large O-ring seal 106 (of the secondary spool 62 ) and by the first seal 74 , respectively. Similarly, any pressure surge will remain trapped within in the actuator such that upon pressure cease, the trapped compressed air is readily available, offering the highest available value of stored energy.
Upon ceasing the pressurized fluid through the pressurized fluid inlet port 14 ( FIG. 4B ), pressure at the pressure chamber 112 of the actuator 110 and within the first chamber 30 now acts against the non return membrane 70 which results in displacement of the primary spool 60 , in direction of arrow 140 until the fore surface 66 comes to rest against surface 68 of plug 18 . At this state, the first O-ring seal 74 disengages from shoulder 88 and fluid flow is facilitated, from the first chamber 30 towards the second chamber 34 , whilst seal 82 engages with shoulder 84 so as to seal the venting outlet port 23 . Pressurized air from pressure chamber 112 of the actuator 110 now flows into the first chamber 30 and via the gaps formed between the first O-ring seal 74 and the corresponding sealing edge 88 of the primary spool bore 16 thus deforms the second one-way seal membrane 78 such that the compressed air now flows through the second chamber 34 , along arrows 37 ( FIG. 4B ) and via the compression outlet port 54 to the coupling duct 116 and into the spring chambers 114 .
The compressed air now flowing into pressure line 116 generates pressure in piston chambers 114 which together with the biasing effect of return springs 115 results in force applied on the pistons 111 to contract and thus rotate the pinion 121 .
Further, pressurized air now flows also through the second cross-flow port 52 resulting in pressure build-up within the major chamber 44 whereby the secondary spool 62 now begins displacement leftwards (arrow 79 in FIG. 4C ). This occurs as a result of pressure equilibrium between the first chamber 30 and the second chamber 34 and the associated intermediate chamber 42 and major chamber 44 , respectively. This situation is reached as a result of difference in surface area applied on opposite faces of the large spool head 100 namely at the major chamber 44 and the intermediate chamber 42 and the surface area of the small seal 94 .
Upon displacement of secondary spool 62 leftwards, i.e. into the position of FIG. 4C , seal 94 disengages from neck portion 98 to allow fluid flow therethrough, and through conduit 120 into pressurized fluid inlet 14 , thus venting the pressure compartment 112 of the actuator 110 , the first chamber 30 (via first cross-flow port 48 ) and the intermediate chamber 42 , along arrow 99 . At this situation, residual pressure remains trapped at second chamber 34 and the pressure line 116 , spring cambers 114 , second cross-flow port 52 and the major chamber 44 , respectively.
The residual pressure within the system provides additional thrust on the pistons 111 of the actuator 110 , in addition to the biasing effect of the springs 115 .
The next sequence of operation is similar to the situation disclosed at the initial situation of FIG. 4A .
It is noticed from the above disclosure that the above system utilizes compressed air already contained within the actuator and which has been used for activating the pistons in one direction, for operating it in an opposite direction, instead of merely discharging said utilized pressurized air to the atmosphere.
The controller acts as a built-in automatic sensor for torque increase that will utilize the added energy from residual air in the first chamber to give additional torque for operating the actuator when required. Any delay in the actuator movement that is a result of increasing torque (i.e. resistance applied by a valve or other device articulated thereto), will cause the air pressure to equalize between the first chamber and the second chamber sooner and provide the additional torque required for overcoming said resistance.
The sealed position of venting outlet port 23 prevents ingress or suction of ambient air and particles into the controller 10 and/or actuator 110 whereby such ambient, untreated air (not to mention dirty air) may cause corrosion and damage the system.
Another advantage of the a actuator controller in accordance with the present invention is, as mentioned hereinabove, that at the event of non continuous pressure supply (sudden or scattering irregulate pressurized air supply) the actuator retains the highest pressure because of the non return seal valve membranes, and maintains its position so as to retain its last acquired position with maximal stored compressed fluid.
It is further noticeable that the second one-way seal 78 is displaceable over the primary spool 60 between its first position noticeable in FIGS. 4A and 4D and the second position noticeable in FIGS. 4B and 4C . This enables further displacement of the primary spool 60 with respect to the second one-way seal membrane 78 , in case of residual air pressure within the second chamber 34 and upon applying pressure through the pressurized fluid inlet 14 .
FIG. 5 illustrates a modification of the invention wherein a manual override system generally designated 150 is provided for axially displacing the primary spool 60 within the primary spool bore 16 so as to open the venting outlet port 23 , thus discharging compressed air within the spring chambers 114 of the actuator (not shown in FIG. 5 ).
The manual override system 150 comprises an eccentric wheel 152 fixed to plug 18 and fitted with a manual lever 154 whereby rotating the lever in the direction of arrow 156 entails axial displacement of a pushing rod 158 bearing against fore surface 66 of the primary spool 60 displacing it in the direction of arrow 162 , whereby the second O-ring seal 82 disengages from the sealing shoulder 84 , thus opening the venting outlet port 23 .
FIG. 6 illustrates still a modification of the invention wherein the plug 18 sealing the primary spool bore 16 is fitted with an adjusting member generally designated 170 comprising a screw threaded boss 172 which may gently be axially displaced with respect to plug 18 by means of an adjusting screw 174 . Such adjustment provides manual readjusting the axial positioning of the primary spool 60 within the primary spool bore 16 , so as to govern the sealing engagement of the first O-ring seal 74 with respect to the sealing shoulder 88 of the primary spool bore 16 so as to delay or advance displacement of the primary spool 60 by changing the point of sealing contact namely, changing the time at which pressure equilibrium between the first chamber 30 and the second chamber 34 is obtained.
In the embodiment of FIG. 7 the venting outlet port 23 is fitted with an adjustable nozzle 180 for controlling the venting rate of the second chamber 34 so as to control the actuator operating speed within the system at which the controller is applied. The adjusting nozzle 180 in accordance with the example of FIG. 7 is screw coupled to the venting outlet port 23 and comprises a tapering outlet nozzle 182 , the outlet section of which is controllable by a screw coupled nozzle end 184 , rotation of which adjusts the size of the outlet orifice.
It is to be appreciated that a controller in accordance with the present invention may be integrated within a housing of a solenoid pressure supply line.
Whilst some embodiments have been described and illustrated with reference to some drawings, the artisan will appreciate that many variations are possible which do not depart from the general scope of the invention, mutatis, mutandis. | Actuator controller comprising a body ( 12 ) with an inlet port ( 14 ) coupled to a source of pressurized fluid and in flow communication with primary and secondary spool bores ( 16, 20 ); primary and secondary spools ( 60, 62 ); first and second cross flow ports ( 48, 52 ) communicating said primary and secondary spool bores, compression and expansion outlet ports ( 53, 54 ) for applying pressurized fluid to a return-biased actuator ( 110 ); and a venting outlet port ( 23 ); wherein return action of the working piston of the actuator is facilitated with aid of pressurized fluid already gained in the system. | 5 |
FIELD OF THE INVENTION
[0001] The present invention is concerned with once-daily compositions of tetracyclines, which can be used for the treatment of acute or chronic diseases, for instance those with inflammatory components. More specifically, the present invention is directed to a pharmaceutical composition of doxycycline for the treatment of diseases or conditions in which collagen destructive enzymes or molecules involved with such things as inflammation are contributing factors, and which is a once daily formulation. The compositions are especially useful for treating such common disease states as periodontal disease, rosacea, dry eye, acne and rheumatoid arthritis.
BACKGROUND OF THE INVENTION
[0002] Conventionally, doxycycline and related tetracyclines are used as broad spectrum antibiotics to treat various bacterial infections. Tetracyclines interfere with the protein synthesis of Gram positive and Gram-negative bacteria by preventing the binding of aminoacyl-tRNA to the ribosome. Their action is bacteriostatic (preventing growth of bacteria) rather than killing (bactericidal). The doses commonly used for doxycycline to achieve the antibiotic effect are 100 mg and 50 mg.
[0003] Doxycycline, as well as other tetracyclines, also has other therapeutic uses in addition to its antibiotic properties. For example, doxycycline is known to inhibit the activity of collagen destruction enzymes such as collagenase, gelatinase, and elastase. Its collagenase inhibition activity has been used to treat periodontal disease. For another example, doxycycline can inhibit lipase produced by the bacterium P. acnes and thus reduces the availability of free fatty acids that are involved in inflammation. Doxycycline may also reduce inflammation by reducing cytokine levels so that the integrity of the follicular wall is preserved. Thus, doxycycline also has the potential in treating skin diseases, such as acne.
[0004] Investigators have found that sub-antimicrobial doses of tetracyclines are useful in the treatment of various ailments, although the mechanisms responsible for the effects are not entirely clear. For instance, U.S. Pat. No. 6,455,583 discloses treating meibomian gland disease by oral administration of non-antimicrobial amounts of a tetracycline to the patient. U.S. Pat. No. 6,100,248 teaches a method of inhibiting cancer growth by administering tetracyclines which have been chemically modified to attenuate or delete their antibacterial activity. Methods to reduce collagenolytic enzymes by administration of amounts of a tetracycline that are generally lower than the normal amounts used for antimicrobial therapy are disclosed in U.S. Pat. No. 4,666,897. The patents cited in this paragraph are hereby incorporated herein by reference.
[0005] In the market, there are two implantable products for site-specific use in the treatment of periodontal disease. The PerioChip® is a small, orange-brown chip, which is inserted into periodontal pockets. Each PerioChip® contains 2.5 mg of chlorhexidine gluconate in a biodegradable, resorbable matrix. It is recommended that PerioChip® treatment be administered once every three months in pockets that remain at 5 mm or deeper. A second product, Atridox®, is an injectable, resorbable gel, which provides the subgingival controlled-release of 42.5 mg doxycycline for approximately one week. Additionally, there is now available a new oral medication called Periostat®, which delivers 20 mg doxycycline systemically as a collagenase inhibitor used in patients with adult periodontal disease. Most people would prefer to take a pill to the implant. However, Periostat® requires twice daily dosing and raises concerns about patient compliance. Thus, it would be highly beneficial to develop a once-a-day formulation for doxycycline.
[0006] While doxycycline is generally effective for treating infection, the use of doxycycline can lead to undesirable side effects. For example, the long-term administration of the antibiotic doxycycline can reduce or eliminate healthy biotic flora, such as intestinal flora, and can lead to the production of antibiotic resistance organisms or the overgrowth of yeast and fungi. Because of the undesirable side effects from its antibiotic properties, there is a need for a unique dose and an improved formulation to deliver doxycycline such that the anti-collagen destructive enzymes or other such beneficial effect of tetracyclines, especially doxycycline, is attained, but antibacterial effects are avoided.
SUMMARY OF THE INVENTION
[0007] The present invention is in its broadest sense directed to pharmaceutical compositions of tetracyclines designed to provide an extended release profile in vivo of levels of active ingredient that at steady state are high enough to be effective to have a beneficial effect in the treatment of a disease or condition, but not as high as to exert an antibacterial effect. Such pharmaceutical compositions are formulated into dosage forms that can be taken once a day.
[0008] One object of the present invention is to provide a pharmaceutical composition of doxycycline, which can be given once a day yet meet the steady state blood levels required for the treatment or prevention of diseases or conditions caused by overproduction of collagenase, such as periodontal disease, or other biochemicals associated with certain disease states which could be regulated with doxycycline, such as conditions involving inflammation, without the undesirable effects of long term antibiotic activity.
[0009] One object of the present invention is to provide a once-daily pharmaceutical composition containing doxycycline that will give steady state blood levels of doxycycline of a minimum of about 0.1 μg/ml and a maximum of about 1.0 μg/ml.
[0010] In one aspect of the invention is an immediate release formulation of doxycycline containing less than 50 mg but more than 25 mg, preferably about 40 mg. doxycycline base.
[0011] In another aspect, the invention is directed to a pharmaceutical composition of doxycycline that contains an immediate release (IR) component of the drug and a delayed release (DR) component of the drug, which are combined into one dosage unit for once-daily dosing. The components can be present in various ratios, although preferred are ratios of about 70:30 to about 80:20, and most preferred 75:25, IR:DR, with the total dosage of doxycycline being less than about 50 mg. and preferably about 40 mg. The ratio refers to the dose breakdown between IR and DR, e.g., 80:20 means 80% of 40 mg is from IR portion and 20% of 40 mg is from DR portion.
[0012] Yet another object of the invention is to provide a method for treating diseases or conditions in which collagenase is produced in excessive amounts causing pathological destruction of tissues, such as periodontal disease, rheumatoid arthritis, hyperparathyroidism, diabetes and acne, by administering the once-daily dosage of doxycycline. See, e.g., U.S. Pat. No. 4,666,897 of Golub.
[0013] Another object of the present invention is to provide a method for systemic treatment of rosacea, a dermatological condition of humans, by administering the once-daily dosage of doxycycline according to the present invention.
[0014] Another object of the invention is to provide processes for preparing the once-daily compositions of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 shows dissolution profiles for doxycycline monohydrate immediate-release beads within the scope of the present invention, which were determined by utilizing a computer algorithm that is based on a compartmental absorption and transit model to deconvolute in vivo release profiles from in vivo human plasma data. The in silico model was first validated and tested using human plasma data from immediate release dosage forms.
[0016] FIG. 2 shows in silico dissolution profiles for doxycycline monohydrate delayed-release beads.
[0017] FIG. 3 shows in silico dissolution profiles for the composite capsules with 75% of immediate-release beads and 25% of delayed-release beads.
[0018] FIG. 4 shows predicted blood levels vs. time profiles at steady state for various treatments (i.e., 40 mg once-a-day IR formula, 40 mg once-a-day IR and DR combinations at 70:30 and 80:20 ratios, and twice-a-day 20 mg doxycycline treatment).
[0019] FIG. 5 represents the pharmacokinetic profiles of 75:25 IR:DR (40 mg.) formulation at day 1 and day 7 (steady state) in humans.
[0020] FIG. 6 compares the pharmacokinetic curves of 75:25 IR:DR (40 mg.) formulation with the Periostat® 20 mg. twice daily dosage form.
DETAILED DESCRIPTION OF THE INVENTION
[0021] While the following description is directed primarily to doxycycline, it is contemplated that the present invention is applicable to other tetracyclines, particularly other tetracyclines that have similar in vivo absorption profiles as doxycycline, more specifically tetracyclines that have a similar region of absorption in the gastrointestinal tract as doxycycline. Different kinds of tetracyclines and the beneficial effects on various disease states are disclosed in, for example, WO 02/083106 and U.S. Pat. No. 6,638,922, each of which are incorporated in their entireties herein by reference.
[0022] The present invention can be accomplished by providing an orally administered composition of, as an example, doxycycline which is designed to provide certain steady state blood levels of the drug, while in a formulation that requires that the mammal, preferably human, to take only one dosage a day. The compositions of the present invention are intended to be useful in lieu of multiple daily dosing, such as twice-daily dosing, of compositions that achieve the same effects. The preferred blood level of doxycycline, or other tetracyclines of comparable physiological and absorption properties, is between about 0.1 and about 1.0 μg/ml at the steady state. Preferably, the blood levels stay within the preferred blood level, with daily dosing, for the entire course of treatment. More preferably, the blood levels are between about 0.3 μg/ml and about 0.8 μg/ml.
[0023] The above blood serum levels allow for the desired anti-collagenase and anti-inflammatory activity of doxycycline, without being accompanied by undesirable antibiotic activity. It was surprisingly found that these levels can be accomplished with a single daily dose of an immediate release formulation containing below 50 mg. but more than 25 mg., preferably about 40 mg. doxycycline base.
[0024] “About” means within the pharmaceutically acceptable limits found in the United States Pharmacopia (USP-NF 21), 2003 Annual Edition, or available at www.usp.org, for amount of active pharmaceutical ingredients. With respect to blood levels, “about” means within FDA acceptable guidelines.
[0025] By “immediate release” formulation is meant a dosage form that is intended to release substantially all of the active ingredient on administration with no enhanced, delayed or extended release effect. Such a composition of doxycycline can be in the form of a liquid suspension or solution, or as a solid such as a tablet, pellet (used interchangeably with bead or beadlet herein), particle, capsule or gel. Preferred in the present invention are tablets, or beadlets in a capsule.
[0026] As pharmaceutically active ingredients, any form of the tetracycline compound can be used provided it will comply with the required blood serum levels of the present invention. Doxycycline, for instance, is commonly used in pharmaceutical formulations under two chemical forms: the monohydrate form and the hyclate form. The monohydrate is the base molecule hydrated with one molecule of water and is used in the formulation of capsules and, in some markets, powder oral suspensions (to be reconstituted with water). The hyclate is a hydrochloric acid salt solvated with water and ethanol and is typically used in the formulation of capsules or tablets. The amount of doxycycline in the compositions of the present invention refers to doxycycline base. Also, in the compositions of the present invention there may be more than one active ingredient. That is, the doxycycline can be combined with another therapeutic or nutritional substance in the dosage forms.
Immediate Release Dosage Forms
[0027] There are many ways known in the art to formulate such immediate release dosage forms. For instance, an immediate release tablet can be prepared by mixing doxycycline with a bulking agent such as microcrystalline cellulose, for example, AVICEL® (FMC Corp.) or EMCOCEL® (Mendell Inc.); dicalcium phosphate. for example, EMCOMPRESS® (Mendell Inc.); calcium sulfate, for example, COMPACTROL® (Mendell Inc.); and starches, for example, STARCH 1500. Additionally, one can add a disintegrating agent, such as microcrystalline cellulose, starches, crospovidone, for example, POLYPLASDONE XL® (International Specialty Products); sodium starch glycolate, for example, EXPLOTAB® (Mendell Inc.); and croscarmellose sodium, for example, AC-DI-SOL® (FMC Corp.). Antiadherants and glidants employed herein can include talc, cornstarch, silicon dioxide, sodium lauryl sulfate, colloidal silica dioxide, and metallic stearates.
[0028] Lubricants may be employed, such as magnesium stearate, calcium stearate, sodium stearate, stearic acid, sodium stearyl fumarate, sterotex, talc, waxes and the like. Binding agents may be employed, such as polyvinyl pyrollidone, starch, methylcellulose, hydroxypropyl methylcellulose, carboxymethyl cellulose, and the like.
[0029] The present invention is preferably formulated into a tablet prepared using methods known in the art, including a wet granulation method and a direct compression method. The oral tablets are prepared using any suitable process known to the art. See, for example, Remington's Pharmaceutical Sciences, 18 th Edition, A. Gennaro, Ed., Mack Pub. Co. (Easton, Pa. 1990), Chapters 88-91, the entirety of which is hereby incorporated by reference. Typically, the active ingredient, doxycycline, is mixed with pharmaceutically acceptable excipients (e.g., the binders, lubricants, etc. listed above) and compressed into tablets. Preferably, the dosage form is prepared by a wet granulation technique or a direct compression method to form uniform granulates. Alternatively, the active ingredient(s) can be mixed with the granulate after the granulate is prepared. The moist granulated mass is then dried and sized using a suitable screening device to provide a powder, which can then be filled into capsules or compressed into matrix tablets or caplets, as desired.
[0030] In a preferred embodiment, the tablets are prepared using the direct compression method. The direct compression method offers a number of potential advantages over a wet granulation method, particularly with respect to the relative ease of manufacture. In the direct compression method, at least one pharmaceutically active agent and the excipients or other ingredients are sieved through a stainless steel screen, such as a 40 mesh steel screen. The sieved materials are then charged to a suitable blender and blended for 10 minutes with an intensifier bar for three minutes. The blend is then compressed into tablets on a rotary press using appropriate tooling.
[0031] As mentioned above, another preferred dosage form for the immediate release composition is a capsule containing immediate release beadlets or pellets. Methods for making such pellets are set forth in the section below (i.e., the IR pellets). The pellets are filled into capsules, for instance gelatin capsules, by conventional techniques.
[0032] Combination IR/DR Dosage Forms
[0033] In another embodiment of the present invention is a composition having a substantially immediate release dose of doxycycline, followed by at least one additional dose at a predetermined time, in a unit dosage. The first immediate release dose of the composition can be in the form of powder, granule, beadlet, or tablet; the second delayed-release portion can be coated granular, coated beadlet, coated tablet, or uncoated matrix tablet. The ratio between the immediate-release portion, or component, and the delayed-release portion, or component, can be used to adjust the in vitro drug release profile and in vivo blood concentration profile. By providing such a drug release profile, the compositions eliminate the need for a second dose for the day. Additionally, the total dose of doxycycline is below 50 mg. to avoid the undesirable side effects from its antibiotic properties, but more than 25 mg. to achieve the anti-collagenase and/or anti-inflammatory effect.
[0034] Several dosage form variations can be used to achieve a product with these attributes. For example, an immediate-release powder blend can be encapsulated with a delayed-release tablet or delayed-release pellets. A further example is an immediate-release tablet and a delayed-release tablet that are prepared separately and encapsulated into an appropriate sized capsule shell. Or, for example, a delayed-release tablet can be used as a core and the immediate-release portion can be compressed as an outer layer using a press coater or overcoated using a drug layering technique, both techniques of which can be found in Gunsel and Dusel, Chapter 5, “Compression-coated and layer tablets”, in Pharmaceutical Dosage Forms:Tablets, Second Edition, Volume 1, Edited by H. A. Lieberman, L. Lachman, and J. B. Schwartz, Marcel Dekker, Inc. New York and Basel (1990).
[0035] Multiparticulate Capsules
[0036] As a preferred embodiment, the IR/DR composition of doxycycline is in the form of a capsule containing beadlets. At present, it is preferred to have two different types of units in a single form multiple-unit dosage form.
[0037] The first unit is an immediate release dosage form, preferably in pellet form. This component can also be a powder if desired or necessary. In either case, the dosage form may have a surface-active agent such as sodium lauryl sulfate, sodium monoglycerate, sorbitan monooleate, polyoxyethylene sorbitan monooleate, glyceryl monostearate, glyceryl monooleate, glyceryl monobutyrate, any one of the Pluronic line of surface-active polymers, or any other suitable material with surface active properties or any combination of the above. Preferably, the surface-active agent would be a combination of sodium monoglycerate and sodium lauryl sulfate. The concentration of these materials in this component can range from about 0.05 to about 10.0% (W//W).
[0038] Other excipient materials that can be employed in making drug-containing pellets are any of those commonly used in pharmaceutics and should be selected on the basis of compatibility with the active drug and the physicochemical properties of the pellets. These include, for instance: binders such as cellulose derivatives such as methylcellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose, polyvinylpyrrolidone, polyvinylpyrrolidone/vinyl acetate copolymer and the like; disintegration agents such as cornstarch, pregelatinized starch, cross-linked carboxymethylcellulose (AC-DI-SOLA, sodium starch glycolate (EXPLOTAB®), cross-linked polyvinylpyrrolidone (PLASDONE® XL), and any disintegration agents used in tablet preparations, which are generally employed in immediate release dosages such as the one of the present invention; filling agents such as lactose, calcium carbonate, calcium phosphate, calcium sulfate, microcrystalline cellulose, dextran, starches, sucrose, xylitol, lactitol, mannitol, sorbitol, sodium chloride, polyethylene glycol, and the like; surfactants such as sodium lauryl sulfate, sorbitan monooleate, polyoxyethylene sorbitan monooleate, bile salts, glyceryl monostearate, the PLURONIC® line (BASF), and the like; solubilizers such as citric acid, succinic acid, fumaric acid, malic acid, tartaric acid, maleic acid, glutaric acid sodium bicarbonate and sodium carbonate and the like; and stabilizers such as any antioxidation agents, buffers, acids, and the like, can also be utilized.
[0039] The pellet can be made by, for example, simple granulation, followed by sieving; extrusion and marumerization; rotogranulation; or any agglomeration process that results in a pellet of reasonable size and robustness. For extrusion and marumerization, the drug and other additives are granulated by addition of a binder solution. The wet mass is passed through an extruder equipped with a certain size screen, and the extrudates are spheronized in a marumerizer. The resulting pellets are dried and sieved for further applications. One may also use high-shear granulation, wherein the drug and other additives are dry-mixed and then the mixture is wetted by addition of a binder solution in a high shear-granulator/mixer. The granules are kneaded after wetting by the combined actions of mixing and milling. The resulting granules or pellets are dried and sieved for further applications.
[0040] As stated earlier, it is also possible to have this immediate release component as a powder, although the preferred form is a pellet due to mixing and de-mixing considerations.
[0041] Alternatively, the immediate release beadlets or pellets of the composition can be prepared by solution or suspension layering, whereby a drug solution or dispersion, with or without a binder, is sprayed onto a core or starting seed (either prepared or a commercially available product) in a fluid bed processor or other suitable equipment. The cores or starting seeds can be, for example, sugar spheres or spheres made from microcrystalline cellulose. The drug thus is coated on the surface of the starting seeds. The drug-loaded pellets are dried for further applications.
[0042] The second unit should have a delayed release (DR) profile, and needs to be able to address the changing pH of the GI tract, and its effect on the absorption of doxycycline or other tetracycline. This pellet should have all of the ingredients as mentioned for the first unit pellet, as well as optionally some organic acid that will be useful to reduce the pH of the microenvironment of the pellet, and thus facilitate dissolution. These materials are, but not limited to, citric acid, lactic acid, tartaric acid, or other suitable organic acids. These materials should be present in concentrations of from about 0 to about 15.0% (w/w); preferably these materials would be present in concentrations of from about 5.0 to about 10.0 percent (w/w). The process for manufacturing these pellets is consistent with the process described above for the first unit pellet.
[0043] Unlike the first unit pellet, the second unit delayed-release component has a controlling coat applied to the surface of the pellet such that the release of the drug from the pellet is delayed. This is accomplished by applying a coating of enteric materials. “Enteric materials” are polymers that are substantially insoluble in the acidic environment of the stomach, but are predominantly soluble in intestinal fluids at specific pHs. The enteric materials are non-toxic, pharmaceutically acceptable polymers, and include, for example, cellulose acetate phthalate (CAP), hydroxypropyl methylcellulose phthalate (HPMCP), polyvinyl acetate phthalate (PVAP), hydroxypropyl methylcellulose acetate succinate (HPMCAS), cellulose acetate trimellitate, hydroxypropyl methylcellulose succinate, cellulose acetate succinate, cellulose acetate hexahydrophthalate, cellulose propionate phthalate, copolymer of methylmethacrylic acid and methyl methacrylate, copolymer of methyl acrylate, methylmethacrylate and methacrylic acid, copolymer of methylvinyl ether and maleic anhydride (Gantrez ES series), ethyl methyacrylate-methylmethacrylate-chlorotrimethylammonium ethyl acrylate copolymer, natural resins such as zein, shellac and copal collophorium, and several commercially available enteric dispersion systems (e.g., EUDRAGIT® L30D55, EUDRAGIT® FS30D, EUDRAGIT® L100, KOLLICOAT® EMM30D, ESTACRYL® 30D, COATERIC®, and AQUATERIC®). The foregoing is a list of possible materials, but one of skill in the art would recognize that it is not comprehensive and that there are other enteric materials that would meet the objectives of the present invention of providing for a delayed release profile. These coating materials can be employed in coating the surfaces in a range of from about 1.0% (w/w) to about 50% (w/w) of the pellet composition. Preferably these coating materials should be in a range of from about 20 to about 40 percent (w/w). The pellets may be coated in a fluidized bed apparatus or pan coating, for example.
[0044] With the enteric coated pellets, there is no substantial release of doxycycline in the acidic stomach environment of approximately below pH 4.5. The doxycycline becomes available when the pH-sensitive layer dissolves at the greater pH of the small intestine; after a certain delayed time; or after the unit passes through the stomach. The preferred delay time is in the range of two to six hours.
[0045] As a variation of this embodiment, the DR pellet contains layers of the doxycycline, separated by protective layers, and finally an enteric coating, resulting in a “repeat-action” dosage delivery. Such a dosage form may meet the blood level requirements of the release profile of the present invention if the release of the doxycycline, or other tetracycline, in all of the layers is within the absorption window for the drug.
[0046] An overcoating layer can further optionally be applied to the IR/DR pellets of the present invention. OPADRY®, OPADRY II® (Colorcon) and corresponding color and colorless grades from Colorcon can be used to protect the pellets from being tacky and provide colors to the product. The suggested levels of protective or color coating are from 1 to 6%, preferably 2-3% (w/w).
[0047] Many ingredients can be incorporated into the overcoating formula, for example to improve the coating process and product attributes, such as plasticizers: acetyltriethyl citrate, triethyl citrate, acetyltributyl citrate, dibutylsebacate, triacetin, polyethylene glycols, propylene glycol and others; lubricants: talc, colloidal silica dioxide, magnesium stearate, calcium stearate, titanium dioxide, magnesium silicate, and the like.
[0048] The delayed release and immediate release units are combined in the dosage form (in this instance, the different pellets are put into capsules) in a predetermined ratio, preferably about 70:30 to about 80:20, most preferably 75:25 (IR/DR), which will achieve the desired steady state blood serum levels with only once-daily dosing.
[0049] The composition, preferably in beadlet form, can be incorporated into hard gelatin capsules, either with additional excipients, or alone. Typical excipients to be added to a capsule formulation include, but are not limited to: fillers such as microcrystalline cellulose, soy polysaccharides, calcium phosphate dihydrate, calcium sulfate, lactose, sucrose, sorbitol, or any other inert filler. In addition, there can be flow aids such as fumed silicon dioxide, silica gel, magnesium stearate, calcium stearate or any other material imparting flow to powders. A lubricant can further be added if necessary by using polyethylene glycol, leucine, glyceryl behenate, magnesium stearate or calcium stearate.
[0050] The composition may also be incorporated into a tablet, in particular by incorporation into a tablet matrix, which rapidly disperses the particles after ingestion. In order to incorporate these particles into such a tablet, a filler/binder must be added to a table that can accept the particles, but will not allow their destruction during the tableting process. Materials that are suitable for this purpose include, but are not limited to, microcrystalline cellulose (AVICEL®), soy polysaccharide (EMCOSOY®), pre-gelatinized starches (STARCH® 1500, NATIONAL® 1551), and polyethylene glycols (CARBOWAX®). The materials should be present in the range of 5-75% (w/w), with a preferred range of 25-50% (w/w).
[0051] In addition, disintegrants are added in order to disperse the beads once the tablet is ingested. Suitable disintegrants include, but are not limited to: cross-linked sodium carboxymethyl cellulose (AC-DI-SOL®), sodium starch glycolate (EXPLOTAB®, PRIMOJEL®), and cross-linked polyvinylpolypyrrolidone (Plasone-XL). These materials should be present in the rate of 3-15% (w/w), with a preferred range of 5-10% (w/w).
[0052] Lubricants are also added to assure proper tableting, and these can include, but are not limited to: magnesium stearate, calcium stearate, stearic acid, polyethylene glycol, leucine, glyceryl behenate, and hydrogenated vegetable oil. These lubricants should be present in amounts from 0.1-10% (w/w), with a preferred range of 0.3-3.0% (w/w).
[0053] Tablets are formed, for example, as follows. The particles are introduced into a blender along with AVICEL®, disintegrants and lubricant, mixed for a set number of minutes to provide a homogeneous blend which is then put in the hopper of a tablet press with which tablets are compressed. The compression force used is adequate to form a tablet; however, not sufficient to fracture the beads or coatings.
[0054] It will be appreciated that the multiple dosage forms of the present invention can deliver dosages of pharmaceutically active doxycycline, or other tetracycline, to achieve the desired levels of the drug in a recipient over the course of about 24 hours at steady state with a single daily oral administration.
[0055] The present invention also provides a method for treating a mammal with doxycycline, or other tetracycline. The method involves administering a doxycycline, or other tetracycline, composition according to the present invention to a mammal, preferably a human, in need of the anti-collagenase or anti-inflammatory activity of doxycycline or other tetracycline substantially without accompanying antibiotic activity. Systemic administration is preferred, and oral administration is most preferred.
[0056] Using the compositions of the present invention, the steady state blood levels of doxycycline or other tetracycline of a minimum of about 0.1 μg/ml, preferably about 0.3 μg/ml and a maximum of about 1.0 μg/ml, more preferably about 0.8 μg/ml, can be achieved to treat diseases with increased collagenase production, such as periodontal, skin diseases and the like, as well as inflammatory states. Indeed, any disease state treatable with sub-antimicrobial blood levels of a tetracycline given in multiple daily dosages can also be treated using the corresponding once-daily formulations of the present invention.
[0057] The invention will now be illustrated by the following examples, which are not to be taken as limiting.
EXAMPLES
Example 1
Preparation of Layered IR Pellets Containing Doxycycline Monohydrate
[0058] A dispersion of doxycycline monohydrate was prepared as follows: To 5.725 kilograms of deionized water were added 0.113 kilogram hydroxypropyl methylcellulose and 1.5 kilograms of doxycycline monohydrate, followed by moderate mixing, using a stirring paddle for 30 minutes. The drug dispersion was sprayed onto sugar seeds (30/35 mesh) in a 9″ Wurster Column of a GPCG-15 fluid bed processor. Until the entire dispersion was applied, the pellets were dried in the column for 5 minutes. The drug-loaded pellets were discharged from the Wurster Column and passed through a 20 mesh screen. A protective coat (e.g., OPADRY® beige) also can be applied onto the IR beads to provide color or physical protection. FIG. 1 shows a typical dissolution profile for doxycycline monohydrate immediate-release beads.
Example 2
Preparation of Enteric Coated Pellets Containing Doxycycline Monohydrate
[0059] The EUDRAGIT® L30D55 coating dispersion was prepared by adding 0.127 kilogram of triethyl citrate into 3.538 kilograms of EUDRAGIT® L30D55 (solid content: 1.061 kilograms) and stirring for at least 30 minutes. Talc 0.315 kilogram was dispersed into 2.939 kilograms of deionized water. The plasticized EUDRAGIT® L30D55 was combined with the talc dispersion and screened through a 60 mesh screen. The resulting combined dispersion was sprayed onto drug-loaded pellets (3.5 kilograms) prepared according to Example 1 in a 9″ Wurster Column of a GPCG-15 fluid bed processor. A protective coat (e.g., OPADRY® beige) may be applied onto the DR beads to provide color or physical protection. FIG. 2 shows a typical dissolution profile for doxycycline monohydrate delayed-release beads.
Example 3
Encapsulation of Drug-Loaded Pellets and Enteric Coated Pellets
[0060] Capsules can be prepared by filling the drug-loaded pellets and enteric coated pellets individually into appropriate sized capsule shells. The ratio between the drug-loaded pellets and enteric-coated pellets can be 100:0 to 70:30. For example, at the ratio of 75:25, the fill weight of drug-loaded pellets can be calculated based on the actual potency of the drug-loaded pellets to deliver 30 mg doxycycline; the fill weight of enteric-coated pellets also can be calculated based on the actual potency of the enteric-coated pellets to deliver 10 mg doxycycline. Romoco CD5 or MG-2 pellet filling machine can be used to accurately fill the pellets into the desired capsule shells. FIG. 3 shows the typical dissolution profile for the composite capsules with 75% of immediate-release beads and 25% of delayed-release beads.
Example 4
Preparation of Delayed Tablet Containing Doxycycline Monohydrate
[0061] Doxycycline monohydrate 0.5625 kilogram was blended with 3.15 kilograms of microcrystalline cellulose in a V-shaped blender for 15 minutes and the powder blend was lubricated with magnesium stearate (0.0375 kilogram) for additional 5 minutes. Doxycycline monohydrate (0.2 kilogram) was granulated with EUDRAGIT® L100 powder. (1.280 kilograms) and microcrystalline cellulose powder (0.5 kilograms) using isopropyl alcohol as a granulating fluid. The wet granulation was dried in a fluid bed dryer and the dried granulations were blended with magnesium stearate (0.020 kilogram) in a V-shaped blender for 5 minutes. Doxycycline powder blend and granulation were put on a belayed tablet press to compress into a belayed tablet with target weights of 200 mg and 100 mg for the powder blend and granulation layers, respectively.
Example 5
Preparation of Immediate-Release Tablet Containing Doxycycline Monohydrate
[0062] Doxycycline monohydrate 1.0 kilogram was blended with 2.225 kilogram of microcrystalline cellulose (AVICEL® PH 102) in a V-shaped blender for 5 minutes. The remaining microcrystalline cellulose (1.75 kilogram of AVICEL® PH 202) is then added to the powder blend in the V-shaped blender and mixed for additional 30 minutes. The powder blend was then lubricated with magnesium stearate (0.025 kilogram) for 5 minutes. The lubricated powder blend was compressed into a tablet with the target weight of 200 mg. The tablets can be further coated with a polymeric protective layer.
Example 6
[0063] The simulated blood levels-time profiles at steady state for various treatments (e.g., 40 mg once-a-day IR formula, 40 mg once-a-day IR and DR combinations at 70:30 and 80:20 ratios, and twice-a-day 20 mg doxycycline treatment) were determined by in silico modeling, and are shown in FIG. 4 . Using the unique dose (i.e., <50 mg, preferably 40 mg) and composition (IR beads or IR/DR combinations), the steady state blood levels of doxycycline of a minimum of about 0.1 ug/ml, preferably about 0.3 ug/ml and a maximum of about 1.0 ug/ml, more preferably about 0.8 ug/ml, can be achieved to treat such conditions as periodontal and skin diseases.
Example 7
[0064] Size 0 capsules containing a ratio of 75:25 of drug-loaded IR pellets to enteric coated DR pellets were prepared as follows. The IR and DR pellets were prepared as set forth in Examples 1 and 2. From the assay value of the doxycycline used to make the pellets, it was determined that 41.26 mg potency of the capsules would correspond to an actual strength of 40 mg. doxycycline. The potency of the IR pellets was 194 mg doxycycline per gram of pellets (mg/g), and for the DR pellets was 133 mg/g. Accordingly, it was calculated that for each capsule the fill weight of IR beads would be 159.5 mg, and for DR beads 77.6 mg, corresponding to 75:25 of IR:DR of a 40 mg capsule.
Example 8
[0065] A pharmacokinetic (PK) study was conducted in human subjects to compare a first group taking the extended release doxycycline capsule (see Example 7) (75/25 IR/DR 40 mg) administrated orally once daily versus a second group taking Periostat® tablets (20 mg) administrated orally twice daily, twelve hours apart.
[0066] Pharmacokinetic blood draws were collected on Nominal Study Day 1 for first and second groups, and on Day 7 for the first group as follows: 0 (pre dose), 0.5, 1, 1.5, 2, 2.5, 3, 4, 6, 8, 12 (before the post-morning dose, if applicable), 12.5, 13, 13.5, 14, 14.5, 15, 16, 18, 20, and 24 hours after the morning dose.
[0067] The data from this study were shown in the following Table 1.
[0000]
TABLE 1
75/25 IR/DR
75/25 IR/DR
Periostat ®
Day 1
Day 7 steady state
Day 1
T max
2.2
2.3
1.9/11.9
C max
562
602
100/333
AUC 0-24 (Hr*ng/ml)
5388
7230
4280
[0068] Mean C max at Day 1 from the 75/25 IR/DR 40 mg capsules is comparable to that from the Periostat® tablets, and well below the potential antibiotic effect concentration (1000 ng/ml). The mean C min (177 ng/ml at 24-hour time point) is well above the minimum effective plasma concentration (100 ng/ml). Individual pharmacokinetic data from both 75/25 IR/DR 40 mg capsules and Periostat® 20 mg tablets show that 75/25 IR/DR 40 mg capsules provide more consistent in vivo performance in terms of less frequency of high peak plasma concentration (>1000 ng/ml) and low plasma concentration (<100 ng/ml) at the end of each dosing.
[0069] FIGS. 5 and 6 show two aspects of results obtained from the study. FIG. 5 compares the PK profiles of 75:25 IR:DR 40 mg doxycycline formulations over a 24 hour period on Day 1 and also on Day 7 (steady state). FIG. 6 compares the PK profiles of the 75:25 40 mg once daily dosage form and the Periostat® 20 mg (twice daily) dosage forms. | Disclosed are once-daily formulations containing tetracyclines, especially doxycycline. Such formulations are useful, for instance, for the treatment of collagenase destructive enzyme-dependent diseases, such as periodontal disease and acne, and acute and chronic inflammatory disease states, such as rosacea and arthritis. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of PCT International Patent Application No. PCT/AU2009/001467, filed Nov. 11, 2009, 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 alignment devices and particularly to those which can be used to align drilling rigs to ensure correct drilling azimuth.
[0004] 2. Description of the Related Art
[0005] In mining, whether underground or surface mining (e.g. diamond mining, goldmining etc), once the mine has been formed, exploratory drill holes are typically then formed to try to locate ore bodies. These drill holes can have a length of up to 1 km bur are usually much shorter.
[0006] Initially, geologists will determine the likely location of an ore body or seam. The mine geologist will design the mine and the location of the exploratory holes and the surveyors will place survey markers in appropriate locations marking the intended hole positions. The survey markers will comprise a first mark on one wall of the mine and a second mark on an opposed wall of the mine. The markers are usually small reflective squares pinned to the mine wall. A “string line” between the two markers will show exactly the direction that the drilling apparatus will need to drill. This is known technology. For surface mines, a pair of pegs or markers inserted into the ground are typically used.
[0007] The direction typically includes the two components “elevation” and the “azimuth”. The elevation is the angle to the horizontal at which the drill rod is oriented and the azimuth is the degree or direction about a vertical axis that the drill rod is oriented.
[0008] Ensuring the correct “elevation” is usually not a great problem as the drill rig can quite easily be angled upwardly or downwardly to the correct elevation. However, ensuring the correct “azimuth” has been a problem to date and even a small error in the azimuth can cause rejection of the bore hole.
[0009] Once the survey markers have been completed, a drill rig is positioned to drill the required core samples. The drill rig is usually a very large self-propelled apparatus. A typical apparatus comprises a wheeled or tractor vehicle which has a forwardly extending boom arm and attached to the boom arm is a drill rig. The drill rig is attached to the boom arm such that it can adopt any required angle (in FIGS. 1 and 2 the drill rig is pointing downwardly).
[0010] This type of apparatus is well-known and there are many different sizes and types of such apparatus, such as that illustrated in FIG. 3 for example which is an example of a skid-steered self propelled rig.
[0011] Once the drill rig is roughly in position (determined by the survey markers), it needs to be very accurately adjusted to the survey markers. Once the adjustment is complete, the drill rig is secured in position and this is usually done by bolting the drill rig to the mine floor using a known type of feed frame positioner. For larger rigs, the weight of the rig can be sufficient to maintain the position.
[0012] The drill rig is then turned on to drill the required hole.
[0000] The present invention is directed to a laser unit device that can be used to very accurately correctly adjust the azimuth of the rig prior to bolting (securing) the rig into position. Conventionally, string lines are used to align the rig prior to securement of the rig into position. That is, a string line is stretched between the survey markers on the opposed walls of the mine shaft. The apparatus is then positioned as close as possible to the string line and is aligned with the string line (that is the drill rig is aligned to be parallel with the string line to get the correct azimuth). Because of the size and shape of the apparatus, it is not possible to place the apparatus against the string line and usually the apparatus will be some distance away from the string line. For a “normal” sized apparatus, the apparatus will still be about 1 m away from the string line but a larger apparatus, this can be between 3 to 4 m from the string line. A measuring tape is then used to accurately measure the distance between the front and the rear of the apparatus and the string line to ensure that the apparatus is exactly parallel with the string line such that when a hole is drilled, the hole will be at the correct azimuth.
[0013] In practice, it is difficult to obtain the level of accuracy that is demanded by the geologists using this known technique of string lines and measuring tapes. Once a pilot hole is collared, and it reaches its first survey mark (normally at approximately 5 to 15 meters) a survey tool is then inserted into the drilled hole. This survey tool normally provides a reading of both the elevation and the azimuth of the pilot hole. The driller then checks this against the hole plans and if not exactly correct, the hole will need to be redone.
[0014] The cost of drilling each hole can be many thousands of dollars and it is not unknown for the cost to be about $100,000 per hole. A drilling contractor is not paid for a “rejected” hole. In the present specification, the term “drill rig” is not intended to be limiting and includes any type of drill or surface rig adapted to drill a hole in any type of mine including a surface or underground mine.
[0015] It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.
SUMMARY OF THE INVENTION
[0016] The present invention is directed to an adjustable hanging rack, which may at least partially overcome at least one of the abovementioned disadvantages or provide the consumer with a useful or commercial choice.
[0017] With the foregoing in view, the present invention in one broad form, resides broadly in a laser alignment device for use with a drill rig having an elongate drill rod, the laser alignment device including a head unit having at least one laser emitting devices, the laser devices movable in one plane only, an attachment means to attach the head unit to a drill rig and an adjustable assembly to adjust the positioning of the head unit relative to the drill rod, wherein the alignment device is used to align at least the azimuth of the drill rod relative to survey marks.
[0018] In an alternative, the invention resides in a laser alignment device for use with a drill rig having an elongate drill rod, the laser alignment device including a head unit having at least one laser emitting device, the laser device movable in one plane only, an attachment means to attach the head unit to a drill rig and an adjustable assembly to adjust the positioning of the head unit relative to the drill rod, wherein the alignment device is used to align at least the yaw of the drill rod relative to survey marks.
[0019] The least one laser emitting device may be a rotating or static laser capable of projecting a laser beam. Where provided in a rotating configuration, there will typically be only a single laser in each device.
[0020] However, multiple lasers may be provided with different purposes, for example, one rotating laser to align the drill rod azimuth and a second for the inclination or angle. In a preferred embodiment, the laser alignment device will align the pitch and the yaw of the drill rod, or put another way, the inclination and azimuth of the drill rod. Normally, a laser device will be used to align the azimuth or yaw of a drill rod relative to survey marks to ensure that the drill rod is on the correct heading. In addition or in the alternative, bearing devices may be used once a laser beam device has established the alignment.
[0000] An inclinometer or clinometer may be used to ensure that the drill rod has the correct inclination or tilt angle.
[0021] The device of the present invention can be used in underground situations or above ground, surface situations.
[0000] With the foregoing in view, the present invention in a second form, resides broadly in a laser alignment device for use with a drill rig having an elongate drill rod, the laser alignment device including a head unit having at least a pair of laser emitting devices mounted independently to one another thereon, each of the laser devices movable in one plane only and oriented in substantially opposite directions to one another, an attachment means to attach the head unit to a drill rig and a length adjustable assembly to adjust the separation distance between the head unit and the drill rod, wherein the alignment device is used to align at least the azimuth of the drill rod relative to survey marks.
[0022] Typically, the lasers will be used to align or adjust the drill rod to the correct elevation or angle as well as azimuth.
[0023] As discussed above, it is typically difficult to obtain the level of accuracy of alignment of the drill that is demanded by the geologists and surveyors using the known technique of string lines and measuring tapes. The present invention obviates the need for string lines and droppers and measuring tapes and increases the accuracy of the alignment of the drill rig and thereby the precision of the holes which is drilled.
[0024] Preferably the alignment of the drill rig takes place prior to securing the drilling rig in position to drill the hole.
[0025] The drill rig in relation to which the device of the present invention is used normally includes a pair of parallel steel feed rails. A carriage is provided which normally slides relative to the rails.
[0026] The device of the present invention will normally be attached to the feed rails although it may be attached to any portion of the drill rig. Any mechanism of attachment may be used but the preferred form of attachment is a secure attachment but one which is also easily removeable as the device will normally be removed prior to commencement of the drilling.
[0027] Preferred methods of attachment include pin and slot or clamping arrangements but most preferred is a magnetic attachment. A magnetic attachment increase utility of the device as the device can be attached to any metal portion of the drill rig according to the preference the user.
[0028] The device will typically be temporarily attached to the drill rig during the alignment phase of the operation of preparing the drill rig for use and will be removed prior to operation of the drill rig. The device will normally remain in place until after the drill rig has been secured in position to limit the chance that the drill rig moves accidentally during the fixing process and to check the alignment of the drill rig.
[0029] The device of the present invention includes a head unit. The head unit typically mounts the pair of opposed laser pointing devices in a removeable manner. Alternatively, the head unit may mount a single rotating laser device.
[0030] Any laser pointing devices may be used. Each of the laser pointing devices are typically held by a laser holding means. The laser holding means are typically attached relative to one another. Each laser pointing device can be moved relative to one another via a hinge or pivot or the like extending through both.
[0031] Each laser holding means will typically clamp or receive the laser pointing devices in a threaded engagement.
[0032] Each laser holding means is preferably provided with a finger tab extending at an angle to the holding means. These finger tabs typically allow each laser to be moved so to point to the survey marks during the alignment process.
[0000] The laser holding means may be “sandwiched” between a backing plate and a front plate. Each of the plates and typically the laser holding means itself will be provided with at least one magnetic strip. The respective magnetic strips will preferably function to magnetically clamp the laser holding means to hold the laser holding means in position once aligned with the survey marks or pegs. A pair of arcuate openings may be provided through the front plate through which the finger tabs extend.
[0033] Although the abovementioned magnetic means is preferred, any releasable attachment means can be used. Importantly, each of the laser devices move only in a plane which is substantially vertical, such that the laser pointing devices can move up and down only and not side to side. The head unit will therefore also be parallel to the foot portion.
[0000] The attachment means of the head unit is preferably associated with attachment means to attach the head unit relative to the drill rig.
[0034] Preferably an actuable electromagnet attachment will be used. The attachment means will also typically be length adjustable to adjust the distance between the drill rig in general and the drill rod in particular and the head unit.
[0035] The length adjustment means will typically include a rod or arm assembly which is length adjustable. Located at one end of the arm assembly will normally be the head unit and at the opposite end will be a foot to attach the arm assembly to the drill rig. The arm assembly may be length adjustable in any manner including telescopically or through the provision of a number of arm portions which are attachable relative to one another.
[0036] There is also typically an ability to move the head unit upwardly and downwardly relative to the rig.
[0037] There may also be a “remote control” variation. To explain, sometimes, the drilling rigs are operated by a single person. Larger rigs are medium- sized having a control cabin to operate the boom arm and various other components. As the laser unit is attached to the drill rig, it may become difficult for a sole operator to (a) operate the entire drill rig from the cabin while at the same time (b) needing to leave the cabin constantly keep check on the laser unit. Therefore, a remote-control laser unit where the lasers might be attached to some form of motor or other type of driving mechanism to adjust the lasers and where the telescopic arm can be extended and retracted by remote-control may be provided. The laser unit could then be operated from the cabin.
[0038] A further option is to have an alarm (which could be a light) which lights up when the lasers are correctly aligned. To do so, a reflective strip may be placed on the survey marker and if the laser beam is correctly aligned, the laser beam will bounce off the reflective strip and back to a sensor provided on the laser unit which would then activate the alarm when the laser is correctly aligned. An audio alarm may be provided although a mine is a very noisy environment and a visual alarm is probably of most benefit. A further option is to have a digital inclinometer attached to the laser unit (typically to the telescopic rod). This can then allow the correct elevation or inclination of the drill rig to be quickly determined, and together with the two lasers (to determine the azimuth), the drill rig can be correctly orientated. By having the inclinometer attached to the laser unit, it can also be removed prior to operation of the drill rig.
[0039] Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
[0041] FIG. 1 is a perspective photograph of a conventional boom operated drill rig in operation.
[0042] FIG. 2 is a perspective photograph of the drill rig illustrated in FIG. 1 from an alternative angle.
[0043] FIG. 3 is a side elevation view of a conventional skid-based drill rig in the installed configuration and anchored to the floor.
[0044] FIG. 4 is a schematic isometric view of a device of the present invention according to a preferred embodiment.
[0045] FIG. 5 is a perspective view of a drill rig with a laser alignment device according to a first embodiment temporarily attached to the drill rig.
[0046] FIG. 6 is a perspective view of a drill rig with a laser alignment device according to a second embodiment temporarily attached to the drill rig.
[0047] FIG. 7 is a group of views illustrating a device and components thereof according to a preferred embodiment.
[0048] FIG. 8 is an exploded perspective view of an alternative attachment mechanism for the device of the present invention.
[0049] FIG. 9 is a side view of the attachment mechanism illustrated in FIG. 8 in the assembled condition.
[0050] FIG. 10 is a schematic top view showing the alignment of a drilling rig using the present invention.
[0051] FIG. 11 is a schematic side view of the arrangement illustrated in FIG. 12 .
[0052] FIG. 12 is a schematic perspective view of a drilling rig with the device according to a preferred embodiment attached and aligned. FIG. 13 is a further schematic perspective view of a drilling rig with the device according to a preferred embodiment attached and aligned.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0053] Reference will now be made in detail to the present embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below in order to explain the present invention by referring to the figures.
[0054] According to a preferred embodiment, a laser device for use with a drilling rig and a drill rig with the device attached, are provided.
[0055] A conventional drill rig is illustrated in FIG. 3 . The drilling rig itself is of a commercial type and basically comprises a pair of parallel steel feed rails 10 which will typically have a length of between 1.5 m up to 6 m. A carriage 11 slides over the top of each feed rail, and can reciprocate between the retracted position illustrated above and an extended position where the carriage has been moved to the front of the feed rails 10 . A hydraulic ram 12 powers the carriage between its positions. On top of the carriage is a high speed hydraulic rotating apparatus 13 . The rotating apparatus will typically rotate at speeds of between 1000-10,000 rpm. A drill rod (not illustrated) passes into the front opening of the rotating apparatus and is rotated by the rotating apparatus. In a front part of the drill rig is a “centraliser” 14 through which the rods pass and the function of the centraliser is to keep the rods aligned and to minimise “wobble”. A hydraulic piston 15 is associated with the centraliser. The piston extends to lock the drill rod when the drill rod has stopped rotating.
[0056] In FIG. 5 and FIG. 6 , the drill rig is exactly the same but the laser unit is slightly different in how the laser unit is attached to the drill rig.
[0000] Turning now to the laser unit, the various parts are illustrated in FIG. 7 .
[0057] Basically, the laser unit is temporarily attached to the drill rig during the alignment process and is then removed prior to operation of the drill. Usually, the laser unit will also remain in place as the drill rig is secured in position just in case there is any inadvertent movement during the securing process. Once the rig is secured, the laser unit is removed and the drilling begins.
[0058] It is envisaged that the laser unit will be a separate device that can be attached to any commercial type of drilling rig. Therefore, the inventor believes that a magnetic attachment of the laser unit to the rig will be most versatile as this means that the laser unit can simply be magnetically clamped to any commercial rig. It also allows the laser unit to be clamped at any suitable position on the rig.
[0059] In practice, it is envisaged that in most circumstances, the laser unit will be attached to one of the feed frames of the drilling rig this being illustrated in FIG. 5 and FIG. 6 . The feed frames are made of steel.
[0060] FIG. 5 best illustrates the attachment of the laser unit. According to an embodiment illustrated generally by 20 A, the laser unit has a base member 20 in which is positioned a strong magnet. A switch is positioned on the base unit and turning the switch causes the strong magnet to turn inside the base member between a magnetic clamping position and a free position where the entire laser unit can be removed. The invention advises that this type of device is known.
[0061] FIG. 6 illustrates an alternative attachment 20 B of the laser unit which does not use the magnet. Instead, a more conventional fastener arrangement is used. A disadvantage with this alternative attachment is that it does require fasteners or something equivalent to be welded or otherwise attached to the feed frames which can result in projections that can form “snagging points” which is somewhat undesirable.
[0062] While a magnetic attachment is desirable, other forms of attachments may also be used such as temporary clamps, a pin and slot arrangement, fasteners, possibly the use of straps and the like. The inventor also does not see any reason to limit exactly where the laser unit is attached to the drill rig. In practice, the attachment will most probably be on the feed frame but this need not be so.
[0063] A rod 21 extends outwardly from the mounting plate or mounting block. The rod in the particular embodiment is length adjustable and this can be done by making the rod telescopic. The length of the rod should be sufficient to allow the lasers to align with the survey marks on the mine shaft wall.
[0064] As a typical drill rig can be placed no closer than about 1 m to the “string lines” which are presently in use, it is considered that the rod should at least the extendable to about 1 m. For the smaller drilling rigs, the rod should be extendable from at least 20 cm up to 1.5 m and for the larger drilling rigs the rod may need to be longer such as between 1.5 m up to 4 m.
[0065] Usually two rod designs will be used, one being telescopic for the smaller units and therefore being extendable between 20 cm up to 1.5 m and a second rod design which can extend between 1.5 m up to 4 m and which can be used for the larger units.
[0066] Attached to the end of the rod are two oppositely pointing lasers. An advantage of the present invention is that two lasers 22 , 23 (see FIG. 7 ) are used which point in the opposite direction. Each laser can be commercially available laser can be screwed into a laser holder. Therefore, there will be two laser holders as well.
[0067] The laser holders are attached to each other by a fastener 24 and importantly each holder (and therefore each laser) can hinge or pivot relative to each other.
[0068] Each laser holder is provided with a finger tab 25 , 26 . This enables each laser to be gripped and moved depending on the survey markers. Each laser holder is also provided with a magnetic strip.
[0069] The laser holders are “sandwiched” between a backing plate 27 (see for instance, FIG. 6 and which can be made of thin metal or plastic) and a front plate 28 . The backing plate also contains magnetic strips (see FIG. 7 ). These magnetic strips will magnetically clamp to the magnetic strip on each laser holder. In this manner, once a particular laser holder has been aligned with a survey mark, it will be held in place by the magnetic strip 30 on the backing plate attaching to the magnetic strip on the laser holder. The front plate 28 is provided with a pair of arcuate openings 29 through which the finger tabs 25 , 26 extend and allowing rotation of the lasers 22 , 23 .
[0070] The advantage of the “twin” lasers may be better illustrated with reference to FIGS. 10 and 11 which are rough schematic views. FIG. 10 is a top view looking down on the apparatus and what can be seen is the self-propelled wheeled or tractor vehicle 30 , the boom arm 31 and the drilling rig 32 . Also shown in FIG. 10 and in FIG. 11 are the two markers 33 and 34 . In the side view ( FIG. 11 ), it can be seen that one of the markers (e.g. 33 ) is in an upper part of the mine wall while the other marker ( 34 ) is at the bottom of the mine wall. This is not unusual, but if using string lines, it becomes very difficult to try to perfectly align the drill rig with the string line.
[0071] When using the twin lasers, (see particularly FIG. 11 ), the front laser can be pivoted upwardly to target the upper marker 33 while the rear laser can be pivoted downwardly to target the lower marker 34 . When looking at this in plan ( FIG. 10 ) it looks like a straight line but when looking at this in side view ( FIG. 11 ) it can be seen that the two lasers are at an angle relative to each other. Importantly however the lasers still project a “straight” line when viewed in plan ( FIG. 10 ) and this allows the drill rig 34 to be aligned with the lasers to be perfectly parallel thereto. That is, the front of the drill rig 35 and the rear of the drill rig 36 must be exactly the same distance away from the imaginary line formed by the lasers (see FIG. 10 ). Any deviation may result in the formed hole being rejected. This deviation can be seen as the “azimuth” and therefore the main function of the laser unit is to ensure that there is no deviation in the azimuth that is required.
[0072] The “elevation” can be seen as the angle of the drill rig from the horizontal (e.g. the mine floor) this can be easily adjusted by the apparatus. Thus, when looking at FIG. 6 , it can be seen that the drilling rig has not yet been correctly “elevated” such that the drilling rig will ultimately drill a hole next to the upper marker 33 . Once the all important “azimuth” of the drill rig has been aligned, the drill rig is secured (e.g. bolted to the floor) and then the elevation of the drill rig can be adjusted using the hydraulics of the apparatus.
[0073] For this reason, it is quite important that the lasers can only move up and down but cannot move from side to side. Any side to side movement can compromise the correct azimuth which is undesirable. It is also quite important that the lasers are exactly parallel to the drilling rig when the laser unit is attached thereto. The inventor advises that the drilling rigs are very precise and that the feed frames on the drilling rig are exactly parallel to the drilling rods. Thus, attachment of the laser unit to a feed frame will result in the lasers projecting a laser beam which is exactly parallel to the drilling rods. It also seems important in the manufacture of the laser units that the laser holders are exactly parallel to the magnetic mounting block wall mounting frame.
[0074] FIG. 4 is an isometric view of the head unit 50 of a laser device according to a further preferred embodiment including lights 37 which are activated once the correct azimuth is reached. Also illustrated is an alternative method of connecting the head unit to the rod for simple and easy attachment and removal.
[0075] The head unit 50 is provided with a bore therethrough. A collar 38 is located in the bore. The rod 21 of the device is provided with an internally threaded end portion into which a threaded fastener 39 is received. The threaded fastener 39 extends through the collar 38 located in the head unit 50 and attaches the head unit 50 to the rod 21 quickly and easily. An o-ring 40 or similar is provided to minimize unwanted rotation of the head unit 50 relative to the rod 21 .
[0076] A further embodiment of the present invention is illustrated in FIG. 13 showing a drilling rig 80 fitted with a cradle 82 at the rear of the boom 81 . The cradle 82 in turn holds a removable laser unit 83 comprising a rotating or static laser 85 capable of projecting a laser beam 84 to the extremities of the front and rear walls of the tunnel. The unit 83 will also contain a clinometer to take pitch readings and a device that will capture the yaw of the rig. The laser unit is set up so that the beam emitted runs parallel to the drill shaft. This means that when the drill rig 80 is moved to a position where the laser beam is aligned to the front marker tag 86 and rear marker tag 87 on the front and rear walls, as illustrated in FIG. 14 A, the drill rig is in the correct alignment for drilling, illustrated in FIG. 14B .
[0077] The cradle 82 is fitted with a removable extender section 88 , which can be stored safely when not in use. It also has a geared rack 89 incorporated to allow the head unit 83 to be moved in and out remotely. This function is to allow the fine-tuning which may be required to compensate for the movement of the rig 80 relative to the marker points.
[0000] If on the rare occasion the drill rig 80 isn't able to be positioned close enough to the marker points for the laser beams to reach the markers then alignment can be approximated by eye and the fine-tuning can be done by measuring the distances between the laser beam 84 and the tag at the front 86 and back 87 markers.
[0078] The clamp on cradle 82 has adjustable fixing points so it can be adapted to the majority of drill rigs used in this application.
[0079] The preferred embodiment illustrated in FIG. 15 is another variation of the present invention that allows the alignment of the drilling rig to the marker points without having to implicitly align the laser beams to the marker tags.
[0080] This embodiment has all of the functionality of the embodiment illustrated in FIG. 13 but adds a bearing device such as a compass or gyrocompass that allows the operator to align the rig 80 according to a bearing taken from the site plans or by repeating a bearing from a remote reading obtained by aligning the compass to the front 86 and back 87 markers. A laser/compass unit 90 including both a laser unit and a compass or bearing unit is provided.
[0081] This embodiment does not require an extended support system or the ability to move the laser/compass unit 90 relative to the rig 80 (as used in the previous embodiment) as there is no need to align the laser to the marker points when the unit is fixed to the rig.
[0082] In use a remote reading is translated to or taken from the compass from the alignment of the compass to the marker points on the front and back walls, using a laser beam 84 . This reading can be translated to the rig 80 by taking the laser/compass unit 90 with the reading on it and fixing it to the drilling rig 80 . The actual reading can be translated to the rig or a marker can be used to capture the zero point on the compass when aligned to the marker tags and then the rig can be aligned to the zero point defined by that marker.
[0083] For example, as illustrated in FIG. 16A , a laser/compass unit 90 is mounted on a tripod and using the laser being aligned with the front and rear markers, a true burying from the tripod mounted laser/compass unit 90 reads 45[deg]. And how to dial of the compass of the preferred embodiment can then be rotated to read 0[deg.].
[0084] As illustrated in FIG. 16B , the laser/compass unit 90 can then be transferred to the cradle 82 mounted on the drilling rig 80 entity drill rig is then rotated until the compass again shows the zero reading. The drill rig 80 will be parallel to the market points when the compass read zero as illustrated in FIG. 16E .
[0085] If the readings are to be taken from site plans then the compass should be calibrated to the site plans before any readings can be translated to the drilling rig. This would need to compensate for specific site grids that may be a fixed number of degrees off true north. In these situations the bearing may be a simple translation of the bearing dictated on the plans to the rig. Alternatively a true north reading can be translated directly to the rig with any site anomalies being accounted for in the bearing.
[0086] In order for the operator of the drilling rig to align the drilling shaft with the marker points he/she estimates the correct proximity to the front marker and then rotates the rig until the required bearing is met. The bearing devices used will need to be impervious to any external influences that may affect its accuracy, such as magnetic effects which are typically present in underground mines.
[0087] The compass, gyrocompass or any type of bearing reader/repeater and inclination reader (clinometer) can also be used to align any type of surface drill rig or any type of drilling equipment that needs aligning. Alternatively a true north bearing gyrocompass can be used to align the drill rig or equipment to the required azimuth and a clinometer can be used to determine the depth, or the gyrocompass can be set to a particular mine grid depending on the user's requirements that can be fixed to the mast of the rig or side or any part of the rig or equipment.
[0088] It is intended that the mobile units are stored safely and transported to the rig when required.
[0089] In the present specification and claims (if any), the word “comprising” and its derivatives including “comprises” and “comprise” include each of the stated integers but does not exclude the inclusion of one or more further integers.
[0090] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.
[0091] Although a few embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in this embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents. | A laser alignment device for a drill rig having an elongate drill rod, the laser alignment device including a head unit having at least a pair of laser emitting devices mounted independently to one another thereon, each of the laser devices movable in one plane only and oriented in substantially opposite directions to one another, an attachment means to attach the head unit to a drill rig and a length adjustable assembly to adjust the separation distance between the head unit and the drill rod, wherein the alignment device is used to align at least the azimuth of the drill rod relative to survey marks. | 4 |
TECHNICAL FIELD OF THE INVENTION
This invention relates to a method for fixedly depositing on cloth a semiconductor material capable of generating a contact-potential difference, and cloth having such a semiconductor material deposited thereon by the use of a color paste or resin liquid containing the semiconductor component in a specific concentration. The resulting cloth is useful for healthy clothes or other healthy goods.
BACKGROUND OF THE INVENTION
Heretofore, various healthy goods have been proposed. For example, there have been proposed adhesive plasters using magnetic material or granular semiconductor material (germanium, silicon or the like) of red bean size for giving magnetic stimulation or effects similar to finger-pressure therapy.
In consideration of the contact-potential difference which is exhibited by germanium and silicon upon contact with the human body, the present invention contemplates to facilitate the deposition of pulverized particles of these materials on cloth and the setting of the concentration of the semiconductor material when combining the same with a printing color paste or an organic polymer resin liquid, while diversifying the pole of potential difference, thereby to provide effective healthy clothes or healthy goods.
Although proposals of this sort have been made before, they all remain in the sphere of mere conception, without clarifying a particular form of the semiconductor material, a particular form of other material for fixedly depositing the same on an object article, or a particular method for fixedly depositing the same on an object article. Therefore, there have been a number of problems to be solved before reducing the concepts to practice.
SUMMARY OF THE INVENTION
The present invention is proposed in an attempt to solve the above-mentioned problems, and has as its object the provision of a method for fixedly depositing on cloth finely pulverized particles of a semiconductor material with a contact-potential difference by adding the same to a printing color paste or an organic polymer resin liquid, for providing healthy clothes and goods.
The gist of the invention resides in pulverizing a substance capable of producing a contact-potential difference into a particle size smaller than 200-250μ, and printing or coating the same on cloth by the use of a nonconducting organic polymer resin liquid or a printing color paste.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a to 1c are illustrations on an enlarged scale of the conditions of the semiconductor material and skin before and after contact with each other, showing at FIG. 1a the condition before contact, at FIG. 1b the condition at the time of contact, and at FIG. 1c the condition after contact; and
FIG. 2 is an enlarged partly sectioned view of the cloth on which the semiconductor material is deposited.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Useful for the cloth are various woven and knit fabrics of natural and synthetic fibers such as cotton, polyester/cotton and polyester.
Examples of the organic polymer resin liquid or printing color paste useful in the present invention include resin liquids for permanent treatment, polishing resin liquids, and pigmented color pastes and the like. Taking into consideration the contact-potential difference and the field strength as a semiconductor material, the printing color paste or the organic polymer resin liquid to be used in the present invention is preferred to be an insulator or to have values similar to an insulator. In this regard, an acrylic or epoxy resin is preferred.
The contact-potential difference producing material to be added, for instance, germanium, silicon or the like, is preferred to be refined material of high purity, and mixed with water before adding the same to the printing color paste or organic polymer resin liquid. Examples of applicable semiconductor material include, in addition to the above-mentioned germanium and silicon, silicon carbide, germanium-silicon alloys and the like, which may be used singly or in combination. Indium antimonide is unsuitable for application to the human body in view of its toxicity. The finely pulverized particles of the semiconductor material are preferred to have a shape with an acute angle rather than a spherical or elliptic shape in consideration that they are pressed on for finger pressure effect when used to improve stiff shoulders and recovery of muscular strength. In this connection, it has been revealed that grain sizes in the range of 200-150μ are more effective and better in productivity.
It is possible to add the semiconductor material to the printing color paste or the organic polymer resin liquid in a ratio of 4-100 g to 1 kg. Particularly, the semiconductor material is preferred to be added in an amount of 5-50 g g because the effects on health, recovery of muscular strength and stiff shoulders will become insufficient if its content is less than 49 g and the mass production will be disadvantageously hindered by variations of fluidity of the printing color paste or the organic polymer resin liquid if its content is larger than 100 g.
Turning now to an example of the method for fixedly depositing the semiconductor material on cloth, a printing color paste or an organic polymer resin liquid, which contains germanium, silicon or the like, is applied on or impregnated into cellulose base fabric, for instance, cotton broad, mercerized cloth or the like, followed by drying at 100° C. and, if necessary, a curing treatment for 3 minutes at 150° C. After depositing the semiconductor material in this manner, the cloth is cut into a suitable shape depending upon the purpose of use to obtain a final product of a desired shape.
This method of deposition of a semiconductor material on cloth is effective since it can be carried out by an ordinary textile treating method.
EXAMPLE 1
30 g of refined and finely pulverized germanium (99.999% purity) and 30 g of silicon (99.999% purity) were mixed with 100 cc of water, and admixed with a pigment resin (an acrylate copolymer) to make a total amount of 1 kg. The resulting mixture was stirred well to disperse germanium and silicon uniformly.
These semiconductor materials were printed on cotton broad by the use of a 120 mesh screen, and, after drying and curing, the cloth was cut into a suitable size and an adhesive tape was bonded on the non-printed side to obtain a final product which resembled an adhesive plaster.
EXAMPLE 2
10 g of New Laqutimine Yellow FL2R, 5 g of New Laqutimine Blue FLTR, 25 g of germanium and 60 g of silicon were mixed in 100 cc of water, and lactimine binder was added to make a total amount of 1 kg.
These semiconductor materials were printed on cotton knit elastic fabric by the use of a 120 mesh screen, and, after drying and curing, it was cut into a suitable size and the non-printed side was attached to a band using elastic substrate cloth (Spuntex, knit fabric etc.) through a hook and loop fastener to obtain a final product.
EXAMPLE 3
50 g of a cellulose-reacting type resin, 10 g of complex metal salt-base catalyst, 10 g of polyolefinic derivative, 20 g of germanium and 60 g of silicon were mixed adding water to make a total amount of 1 kg.
These semiconductor materials were impregnated into cotton sheeting dyed in solid color, by the use of a mangle of ordinary dye adjustment equipment (wet pick up 80%), followed by drying in a drier and curing in a baking machine.
EXAMPLE 4
30 g of germanium, 30 g of silicon and 100 cc of water were mixed with an acrylate copolymer and a foaming agent to make a total amount of 1 kg.
These semiconductor substances were printed in spots (with a diameter of about 5-10 mm) with a total printed area of about 50%, and, after drying, subjected to a curing treatment to foam the spots into a raised state.
The semiconductor material which is deposited on cloth acts on the human body in the manner explained below.
When the human body and germanium are brought into contact with each other, a potential difference of about 0.1 V is produced therebetween. If the mean distance d between the human body and germanium is 1 μm, the field strength is E 1 =0.1 V/1 μm=0.1/10 -4 =10 3 V/cm. On the other hand, it is dangerous if one approaches a cable of 10,000 V up to a distance of 1 m where the field strength is E 2 =10 4 V/10 2 cm=100 V/cm.
Comparing E 1 and E 2 , one will see that E 1 /E 2 =10-100 when d is 0.1-1 μm. Thus, the contact electric field is very strong and considered to have effects of improving stiff shoulders and recovering muscular strength.
Besides, the small current which flows at the time of contact is considered to have an effect of stimulating the skin. FIGS. 1a to 1c show the conditions of germanium and skin before and after the contact. In the Figures, element 1 is a semiconductor material, element 2 is an organic polymer resin liquid, element 3 is a substrate cloth and element 4 is skin. As the two contacting parts are separated, an electric field is produced with a strength of E 1 =10 3 -10 4 V/cm.
These effects are also produced by the semiconductor bearing cloth when it is provided with an adhesive tape on one side in the fashion of adhesive plaster and bonded on a shoulder or hip, improving a stiffened shoulder or recovering muscular strength. When elastic substrate cloth is used and the semiconductor plaster is applied pressingly around an elbow or knee, it has an effect of recovering the applied portion from fatigue. If the semiconductor material is applied to suitable portions of under wear or a bathrobe for contact with neck, wrist or shoulder portions, the effect of recovering the contacting portions from fatigue is also produced. If the semiconductor material is printed in a pattern of spots or staggered check and in a raised form by the use of a foaming agent, effects similar to finger pressure therapy are also produced.
FIG. 2 shows on an enlarged scale the condition of the semiconductor material which is deposited on cloth by the method of the present invention. The fore ends of the semiconductor particles which are in contact with the skin are pointed at acute angles which obviously impose a stronger stimulative pressure as compared with particles of flat or spherical shapes.
The organic polymer resin liquid 2 which fixes the semiconductor material 1 on cloth is desired to have an insulating property to produce a greater contact-potential difference.
The results of experiments proved extremely high durability including high washing durability of grade 4-5.
It has also been found that the pointed ends of the semiconductor material which contact the skin are exposed gradually as the insulating material over and around pointed ends are removed by repeated washing, thereby maintaining or rather improving the effects of the semiconductor bearing cloth.
As compared with a case using germanium grains which contact the skin 4 point-wise, the cloth according to the present invention maintains surface-wise contact which is effective for making contact near an effective point on the human body even when the effective point is unknown.
A contact-potential difference is produced when the semiconductor material 1 is brought into contact with the skin 4.
Namely, current flows upon contact, positively charging one of the contacting parts while negatively charging the other part as shown particularly in FIGS. 1b and 1c.
The same conditions apply even when the two parts are separated to a slight degree.
As clear from the foregoing description, the present invention provides a method for fixedly depositing on cloth a contact-potential difference producing substance in an appropriate manner, and a semiconductor deposited cloth which can be easily processed into a form suitable for end use, greatly contributing to the recovery and promotion of health. | A cloth having a semiconductor material deposited thereon is capable of producing a contact-potential difference when contacted with the skin for removing stiffness and recovering muscles from fatigue. The cloth is produced by pulverizing a contact-potential difference-generating substance such as germanium or silicon into a particle size of smaller than 200-250 μ, adding 4-100 g of the pulverized substance to 1 kg of a non-conducting organic polymer resin liquid or printing color paste, and printing or coating the mixture onto a woven or knit fabric. | 3 |
FIELD OF THE INVENTION
The invention relates to a device for the treatment of fractures of bones and/or for fixing surgical implants, surgical threads, or tissues in or on the bone.
BACKGROUND OF THE INVENTION
For the surgical treatment of fractures of bones or for fixing surgical implants, threads, or tissues in or on the bone, even rivets, in particular blind rivets, can be used. Particularly suitable are rivets with closing heads formed of separate anchoring tongues spread relatively wide. Such blind rivets are disclosed in the non-medical area, e.g. in UK Patent Application No. GB 2,054,082 to Tucker Fasteners. The anchoring tongues are formed by axial tearing of the wall of the rivet shaft at the front end of the blind rivet by means of a pyramid-shaped, sharp-edged closing head which is drawn into the hollow cylindrical rivet shaft from the front end. At least one disadvantage of these types of blind rivets is their limited application to soft materials and the necessity of high closing forces for forming the closing head on the blind rivet.
A need exists for an improved medically applicable fixation means, in particular a surgically applicable blind rivet which provides materials with high strength, e.g. titanium, and can be fixed by means of closing forces acceptable in surgery. A need also exists that the device be suitable for the treatment of fractures of bones and/or for fixing surgical implants, surgical threads, or tissues in or on the bone.
SUMMARY OF THE INVENTION
The present invention generally relates to a device comprising a closing element with a shaft and at the end position a head which is fixedly connected to the shaft or, for example, can be connected by means of a thread connection, to the shaft, and a rivet which comprises, coaxial to a central axis, a rivet shaft and a through-hole coaxially penetrating the rivet.
The shaft of the closing element can be displaced coaxially in the through-hole so that the head can be brought axially to lie at the front shaft end. The head and shaft of the closing element can be structured in two parts or as one part. Furthermore, the rivet shaft includes two grooves which extend from the front shaft end parallel to the central axis over a length L in the direction of the rear end of the rivet. The grooves serve as theoretical break points so that on further displacement of the closing element in the direction of the rivet head the rivet shaft is divided by the head of the closing element into anchoring tongues on a part of its overall length. In one preferred embodiment, the ratio of the length L to the overall length of the rivet shaft is between 20% and 90%.
In another preferred embodiment of the device according to the invention, the rivet shaft includes at least one slot, each slot having a first end intersecting the front shaft end and extending into the through-hole and a second end extending parallel to the central axis into a groove. In another embodiment, the rivet includes at its rear end a rivet head which can be fixedly connected to the rivet or, for example, can be connected to the shaft by means of a thread connection.
In another embodiment of the device according to the invention, the characteristic values of the rivet material lie within a range of the ratio of tensile strength to elongation at break of 10:1 to 50:1, preferably 10:1 to 30:1.
In still another embodiment of the device according to the invention, the geometric dimensions of the rivets are chosen so that the ratio of the outer diameter da of the rivet shaft to the diameter d of the through-hole lies in a range from 1.1:1 to 2.5: 1, preferably from 1.5:1 to 2:1. The ratio of the radial depth t of the grooves to the wall thickness of the rivet shaft lies suitably in a range from 1:1.2 to 1:2.5, preferably from 1:1.7 to 1:2.3. The wall thickness can be determined from the difference of the outer diameter da and the diameter d.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred features of the present invention are disclosed in the accompanying drawings, wherein similar reference characters denote similar elements throughout the several views, and wherein:
FIG. 1 is a top view of the device according to the invention,
FIG. 2 is a longitudinal cross-sectional view through the embodiment of the device according to the invention represented in FIG. 1 ,
FIG. 3 is a cross-sectional view taken along line I-I of FIG. 2 ,
FIG. 4 is a perspective view of the device of FIGS. 1 to 3 .
FIG. 5 is a perspective view of the device of FIGS. 1-4 in the closed state.
FIGS. 6A and 6B are left and right side longitudinal cross-sectional views, respectively, of another embodiment of the device according to the invention.
FIG. 7 is a perspective view of the device of FIGS. 6A and 6B .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 , a rivet 2 and a closing element 1 according to one embodiment of the device according to the invention are represented. The rivet 2 has a central axis 6 and comprises a cylindrical rivet shaft 3 running parallel to the central axis 6 . In a preferred embodiment, the cylindrical rivet shaft is not necessarily required to be circularly cylindrical. A rivet head 4 is fixedly connected to the rivet shaft 3 , and a cylindrical through-hole 5 penetrates the rivet 2 coaxially along the central axis 6 . The rivet shaft 3 has an outer diameter da and includes grooves 9 which run parallel to the central axis 6 , and extend from the front shaft end 7 over a length L, and have a depth t from the outer circumferential surface 14 . The depth t is determined so that the wall thickness, defined by the diameter da and d and the depth t, on closing of the rivet 2 with the closing element 1 allows a separation of the rivet 2 into separate anchoring tongues 13 ( FIG. 5 ) on the part to be closed. In a preferred embodiment, the number of anchoring tongues 13 corresponds to the number of grooves 9 introduced on the outer circumferential surface 14 of the rivet 2 .
The grooves serve as theoretical break points so that on further displacement of the closing element in the direction of the rivet head the rivet shaft is divided by the head of the closing element into anchoring tongues on a part of its overall length. In this embodiment, the ratio of the length L to the overall length of the rivet shaft may be between 20% and 90% so that the anchoring tongues can expand radially to a surface F which can be 3 to 20 times the cross-sectional surface of the rivet shaft. The number of the grooves distributed uniformly on the circumference of the rivet shaft may be in a range of 3 to 8, preferably 3 to 5. From the number of grooves the number of anchoring tongues in the fixed rivet also follows. In the embodiment of the rivet 2 represented here, the wall thickness of the rivet shaft 3 corresponds to 14% of the outer diameter da. From the front apical face 15 of the rivet shaft 3 , slots 12 penetrate into the rivet shaft 3 parallel to the central axis 6 . The slots run, on one side, at the front shaft end 7 into the through-hole 5 and, on the other side, parallel to the central axis 6 into the grooves 9 .
The closing element 1 comprises a shaft 10 parallel to the central axis 6 and at the end position a head 11 is disposed which runs in the form of a wedge into the shaft 10 . The closing of the rivet 2 is accomplished after the introduction of the rivet 2 , e.g. into a bone plate and a bone (not represented) by means of the closing element 1 . The head 11 of the closing element 1 has a diameter D which is greater than the diameter d of the through-hole 5 so that the head 11 of the closing element 1 is pressed into the inner cone 8 ( FIG. 2 ) of the through-hole 5 by means of a tractive force exerted on the shaft 10 . On pressing the widening wedge-like head 11 of the closing element 1 into the inner cone 8 ( FIG. 2 ) in the through-hole 5 , the wall 20 ( FIG. 2 ) of the rivet shaft 3 is expanded and on further pressing of the head 11 of the closing element 1 separated into the anchoring tongues 13 ( FIG. 5 ) at the theoretical break points formed by the grooves 9 .
Referring to FIG. 2 , a cross-section of the rivet is represented which corresponds to the above-described embodiment of the device according to the invention. The rivet 2 comprises a central axis 6 , a circularly cylindrical rivet shaft 3 with a front shaft end 7 intersecting the central axis 6 , and at its rear end 18 intersecting the central axis 6 at the end position a rivet head 4 , also circularly cylindrical. At the front shaft end 7 there is a front apical face 15 perpendicular to the central axis 6 . The rivet head 4 runs against the front shaft end 7 directed convexly or tapering in the form of a wedge into the rivet shaft 3 and also convexly or tapering in the form of a wedge into the rear apical face 19 of the rivet 2 . The rear apical face lies at the end position at its rear end 18 . A through-hole 5 penetrates coaxially to the central axis 6 and the rivet 2 from the front shaft end 7 up to the rear end 18 . The through-hole 5 runs at the front shaft end 7 with the inner cone 8 expanding into the front apical face 15 . Parallel to the central axis 6 , grooves 9 are introduced which penetrate from the front shaft end 7 up to a length L ( FIG. 1 ) into the rivet shaft 3 and have a V-shaped cross-section ( FIG. 3 ) perpendicular to the central axis 6 . Moreover, slots 12 penetrate into the rivet shaft 3 from the front apical face 15 also parallel to the central axis 6 . These slots 12 have a rectangular cross-section ( FIG. 1 ) perpendicular to the central axis 6 and have a wedge-like structure parallel to the central axis 6 . The slots 12 run parallel to the central axis 6 and run into the front apical face 15 , into the outer circumferential surface 14 , and into the grooves 9 . The tearing of the rivet shaft is promoted by these slots. At least one of the slots extends from a first end intersecting with the corresponding groove and extending toward the front end of the shaft tapering through a thickness of the shaft toward the central axis to open into the through-hole.
FIG. 5 shows the rivet 2 with central axis 6 , rivet head 4 , expanded rivet shaft 3 , and closing element 1 in the closed state of the rivet 2 . The rivet shaft 3 is expanded to the length L ( FIG. 1 ) and comprises three anchoring tongues 13 .
In one preferred embodiment, the rivet may have the following geometric dimensions: the outer diameter da of the rivet shaft may be 2 to 12 mm, preferably 3 to 8 mm; diameter d of the through-hole may be 1 to 8 mm, preferably 1.5 to 5 mm; wall thickness of the rivet shaft may be 0.2 to 4 mm, preferably 0.5 to 2 mm; and radial depth t of the grooves may be 0.1 to 3 mm, preferably 0.2 to 1 mm. In another embodiment of the device, the geometric dimensions of the rivets are selected so that the ratio of the outer diameter da of the rivet shaft to the diameter d of the through-hole is in a range from 1.1:1 to 2.5:1, preferably from 1.5:1 to 2:1.
The ratio of the radial depth t of the grooves to the wall thickness of the rivet shaft may be in a range from 1:1.2 to 1:2.5, preferably from 1:1.7 to 1:2.3. The wall thickness can be determined from the difference of the outer diameter da and the diameter d. In an additional embodiment, the grooves may have a triangular cross-section perpendicular to the central axis where the apical angle of the triangle in the base of the groove lies within a range of 30° to 80°, preferably of 40° to 70°.
The rivet material is preferably metallic and may include the following materials or alloys: a) materials based on iron, preferably steel, b) materials based on titanium, preferably Ti CP and titanium alloys, c) materials based on cobalt, preferably cobalt alloys, d) materials based on tantalum, preferably tantalum alloys, and e) materials based on zirconium, preferably zirconium alloys. In another embodiment, the rivet may be made from a material having the following physical properties or characteristics: the ratio of tensile strength (Rm in N/mm2) to elongation at break (A5 in %) is between 10:1 to 50:1, preferably between 10:1 to 30:1.
Referring to FIGS. 6A , 6 B, and 7 , another embodiment of the rivet 2 is represented which is distinguished from the forms of embodiment represented in FIGS. 1 and 2 in that the rivet 2 ′ includes no rivet head 4 ( FIGS. 1 and 2 ) at its rear end 18 ′. Furthermore, the closing element 1 ′ penetrates the rivet 2 ′ only on a part of its overall length and is structured with a hole 21 penetrating the closing element 1 ′ coaxially. The hole is provided at its end 22 lying axially opposite the head 11 ′ with a coaxial inner thread 23 . A Kirschner wire 24 can be screwed into this inner thread and can be screwed out of the inner thread 23 once again after the closing of the rivet 2 ′.
It will be appreciated that a more homogeneous introduction of force into the bones is possible as compared to the use of screws, and generally a more stable anchoring can be produced compared to bone screws, even with poor bone quality.
While various descriptions of the present invention are described above, it should be understood that the various features can be used singly or in any combination thereof. Therefore, this invention is not to be limited to only the specifically preferred embodiments depicted herein. Further, it should be understood that variations and modifications within the spirit and scope of the invention may occur to those skilled in the art to which the invention pertains. Accordingly, all expedient modifications readily attainable by one versed in the art from the disclosure set forth herein that are within the scope and spirit of the present invention are to be included as further embodiments of the present invention. The scope of the present invention is accordingly defined as set forth in the appended claims. | A device for treating bone fractures and/or for fixing surgical implants, surgical threads or tissues in or on the bone comprising a closing element and a rivet. The rivet includes a shaft extending from a rear end to a front end coaxial to a central axis and having a through-hole extending coaxially therethrough. The shaft of the closing element is coaxially displaceable in the through-hole and the head of the closing element can be axially brought to rest on the front shaft end. The rivet also comprises at least two grooves on the outside, these grooves extending from the front shaft in the direction of the rear end, parallel to the central axis. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to a composite material with an improved structure having dispersed therein an active organic compound, as well as to an effluent treatment process, especially a photographic effluent treatment process.
BACKGROUND OF THE INVENTION
[0002] Many manufacturing and processing steps are carried out in an aqueous phase, thereby generating aqueous effluents. One example of this is the photographic industry, in which exposed silver halide photographic films and papers pass through several aqueous processing baths. A photographic treatment generally comprises several processing baths and one or more wash and (or) stabilization baths.
[0003] These processes entail a high consumption of water. Owing to new stricter environmental legislation, new standards forbid the discarding of wastewater directly into the sewers without prior treatment, and in particular require a reduction in the consumption of water for photographic processing. The problem is that reducing the volume of water allowed favors bacterial pollution. The growth of microorganisms in aqueous solutions and in particular in prebaths, stabilization baths and wash baths is well known, and worsens as soon as the quantity of water consumed is reduced. The growth of microorganisms, if not controlled, causes the formation of sludge that clog equipment, adversely affect the process bath and so impair the quality of the resulting photographic image. In the field of traditional medical imaging, for example, it is desirable to reduce bacterial proliferation as much as possible because the bacteria cause defects on developed films. Such defects can lead to errors of diagnosis. In addition, bacterial proliferation causes the formation of a biofilm on the walls of the processing tanks and on the rollers and film drive sprockets, so that machinery has to be shut down for cleaning.
[0004] Bacterial growth control agents are commonly used to prevent or limit biological growth in processing solutions. For greater security, quantities in excess of those theoretically required are used. The result is that the wastewater discharged into the environment contains large quantities of bacterial growth control agents, which cause problems in sewage treatment centers that use the action of microorganisms to treat waste water.
[0005] Publication EP-A-937 393 describes a composite material and a method for preparing it, which comprises hydrolysing in a basic medium an alkylalkoxysilane of the formula RSiR 1 x (OR 2 ) 3−x wherein R is an alkyl group comprising a SH or —S(—CH 2 ) n —S— function wherein n is from 0 to 4, R 1 and R 2 are independently a methyl or ethyl group, x is 0 or 1, in the presence of an active organic compound and an aqueous solution of an inorganic imogolite gel in fiber form comprising active hydroxyl groups on the fiber surface.
[0006] The composite material obtained by this method comprises an organic-inorganic polymer matrix that is an imogolite gel in fiber form on which are grafted sulfur-containing molecules to capture the silver present in the wash water. In the matrix is dispersed an active organic compound such as a bacterial growth control agent. The composite material takes the form of a gel in which the active organic compound is trapped. When it is placed in contact with an aqueous effluent, the trapped active organic compound is slowly released into the effluent. In this material the imogolite fibers are interconnected by chemical hydrogen bonds, giving a physical gel. However, this physical gel is not dense enough to retain in its matrix the hydrophilic active organic compounds, which thus tend to diffuse too rapidly into the effluent. It is then no longer possible to control the quantity of active organic compound diffusing into the effluent. In addition, because the physical gel is thixotropic, it is relatively mobile when it is being handled, and so is difficult to package for subsequent commercialization.
[0007] The present invention provides a new material that allows a set quantity of active organic compound to be gradually released into an effluent, in particular when this active organic compound is hydrophilic.
[0008] The present invention provides also a material that is easy to package.
SUMMARY OF THE INVENTION
[0009] The present invention relates to a composite material that takes the form of a structured gel, comprising an aluminosilicate polymer matrix in the form of an imogolite gel made up of fibers, in which at least two distinct fibers are interconnected by at least two covalent bonds to form an irreversible chemical gel, and having dispersed therein an active organic compound. Owing to said covalent bonds, the material of the invention takes the form of a structured gel, and so retains the active organic compounds more effectively, especially hydrophilic compounds trapped in the matrix, thereby better controlling their diffusion out of the matrix. It is also more compact and can be packaged more easily for marketing.
[0010] The present invention further concerns a method of obtaining such a composite material. This process comprises the hydrolysis in basic medium of at least one structuring agent in the presence of an active organic compound and an aqueous solution of an inorganic imogolite gel made up of fibers comprising active hydroxyl groups on the surface, said structuring agent containing at least two leaving groups reacting with said active hydroxyl groups to form at least two covalent bonds between at least two distinct imogolite fibers to yield an irreversible chemical gel.
[0011] The term “active hydroxyl groups” here means groups able to react with the structuring agent in an aqueous medium.
[0012] The invention also relates to a method of treating a medium with said active organic compound, as well as a device for carrying out said method. This treatment method comprises contacting the composite material of the invention with said medium. The method of the invention is especially efficient for the treatment of photographic baths, in particular for releasing a set quantity of bacterial growth control agent into said baths, and especially when said control agent is hydrophilic
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a schematic representation of an embodiment of the treatment process of the present invention applied to the treatment of a photographic processing bath, and
[0014] FIGS. 2 to 5 illustrate the examples of implementation of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The composite material of the invention can be obtained from any aqueous solution of aluminosilicate polymer in fiber form comprising active hydroxyl groups on the surface of the fibers.
[0016] According to a preferred embodiment, the composite material of the invention is obtained from imogolite. Imogolite is an aluminosilicate polymer that occurs in the form of fibers comprising active hydroxyl groups on their outer surface. Imogolite occurs naturally. It was first described by Wada in J. Soil Sci. 1979, 30(2), 347-355. Imogolite can be synthesized using different methods. A method of obtaining a highly pure imogolite gel is described in U.S. Pat. No. 5,888,711.
[0017] The structuring agents that are useful for the invention include at least two leaving groups hydrolyzable in basic medium, and are selected from among compounds A or A′, wherein:
[0018] A has the formula (CH 3 ) n M(R) 4−nm wherein M is a quadrivalent atom selected from the transition metals and elements of groups III and IV of the periodic table of the elements, and R is hydrogen, halogen, a methoxy group, an ethoxy group, an isopropoxy group, a carboxyl or acetoxy group, and n is 0, 1 or 2, and wherein the different groups R can be either identical or different.
[0019] A′ has the formula (CH 3 ) n M′(R) 3−n wherein M′ is a trivalent atom selected from among the transition metals and elements of groups III and IV of the periodic table of the elements, R being as defined above, and n is 0 or 1, and wherein the different groups R can be either identical or different.
[0020] Preferably, M is silicon, titanium or zirconium, and M′ is aluminum or boron. The structuring agents as defined above and used in the scope of the invention are for example:
[0021] Tetramethoxysilane,
[0022] Tetraethoxysilane,
[0023] Silicon tetra-acetate,
[0024] Silicon tetrachloride,
[0025] Aluminum chloride,
[0026] Boron trichloride.
[0027] Alkoxides or chloroalkoxides of boron or aluminum can also be used.
[0028] Compounds that are sparingly soluble in water, such as tetraethoxysilane, can be mixed beforehand with ethanol.
[0029] According to the method of the invention, the structuring agent is hydrolyzed in the presence of an active organic compound and an aqueous solution of an inorganic aluminosilicate polymer in fiber form comprising hydroxyl groups on the surface of the fibers, said groups being active in aqueous solution. This hydrolysis is carried out at a pH greater than 7. Such a pH is achieved by adding a base to the reaction medium, for example NH 4 OH, NaOH, KOH. The addition of the base to the reaction medium allows the aluminosilicate to gel.
[0030] The material obtainable by this method takes the form of a structured gel. An infrared spectrum of this gel shows that covalent O—M or O—M′ bonds have been formed, wherein M and M′ are as defined above.
[0031] Furthermore, the gel obtained is an irreversible chemical gel. When hydrochloric acid is added to the material obtained in order to lower the pH to below the gelling threshold of the imogolite, the composite material according to the invention retains its gel state and does not recover the initial viscosity of the imogolite, which is close to that of water.
[0032] It may be assumed that this structured gel is obtained as a result of the cross-linking of imogolite fibers by the covalent bonds irreversibly formed between them. For example, when structuring agent A is tetramethoxysilane the —OCH 3 leaving groups react with the hydroxyl groups of the aluminosilicate to form stable O—Si covalent bonds, yielding a multitude of bridges composed of —O—Si—O— chains between at least two distinct imogolite fibers, thereby forming a dense structured network. Structuring agents that possess three or four hydrolyzable leaving groups have the highest potential structuring power because covalent bonds can be formed in three dimensions. The same reasoning can be applied to a structuring agent A′, which yields, for example, —O—Al—O— or —O—B—O— bridges. This hydrolysis reaction is accompanied by the gelling of the aluminosilicate, during which the active organic compound is trapped in the matrix of the structured network. An irreversible chemical gel is thereby obtained, which constitutes the composite material of the present invention. When the composite material of the invention is placed in contact with an aqueous effluent, the trapped active organic compound will be released at a rate that will depend on how strongly it is retained by the matrix or structured network.
[0033] To obtain a particularly dense structured composite material, tetramethoxysilane will be preferably selected, because its four methoxy leaving groups hydrolyze to form four covalent O—Si bonds from a single Si atom, to yield —O—Si—O— bridges between at least two imogolite fibers.
[0034] The density of the network can be adapted according to the functions of the structuring agent selected, but depends also on the amount of structuring agent used. The concentration of structuring agent, as defined above, is preferably less than 10% by weight of the [Al+Si] content of the imogolite. This percentage affords a gel that is sufficiently compact, while still allowing the active organic compound to diffuse.
[0035] The active organic compound used in the present invention is an organic compound that is soluble in the effluent to be treated, and which does not form covalent bonds with the matrix, otherwise it would stay trapped in the material.
[0036] According to one embodiment, the active organic compound is a hydrophilic bacterial growth control agent. In this case the composite material of the present invention reduces or halts the growth of micro-organisms in an effluent while avoiding the discharge into the environment of large amounts of bacterial growth control agent. Clearly, the hydrophilic bacterial growth control agent can be used with a hydrophobic control agent, which is less sensitive to the problem of too rapid diffusion in an aqueous effluent.
[0037] This bacterial growth control agent can be a pesticide, an algicide, a fungicide or a bactericide. In the scope of the invention, a hydrophilic bacterial growth control agent is defined as any control agent with a water solubility of more than 1,000 ppm. Conversely, a hydrophobic control agent has a water solubility less than or equal to 1,000 ppm.
[0038] A large number of hydrophilic or hydrophobic bacterial growth control agents are known to prior art. From general knowledge, those skilled in the art can easily select a hydrophilic bacterial growth control agent and a hydrophobic bacterial growth agent to obtain the composite material of the invention.
[0039] The hydrophilic, and when appropriate the hydrophobic bacterial growth control agents that are useful for the invention can be selected for example from among thiazole derivatives such as isothiazolones, azole derivatives such as benzotriazoles and benzimidazoles, sulfamide-type agents such as sulfanilamide, organoarsenides such as 10-10′-oxybis-phenoxyarsine, benzoic acid, sorbic acid, benzalkonium quaternary ammonium salts, nitro-alcohols, quaternary ammonium salts of formula R 5 (R 6 )N 1 (R 7 )R 8 X − in which R 5 , R 6 , R 7 , and R 8 are independently aliphatic, heterocyclic or carboxylic radicals and X − is a monovalent anion, and alkyl-amphoacetates. These derivatives can comprise substituents to make the derivative either hydrophilic or hydrophobic.
[0040] The substituents that afford hydrophilic bacterial growth control agents are for example lower alkyl groups preferably containing 1 to 3 atoms of carbon, halogens, or a hydroxyl group.
[0041] The substituents that afford hydrophobic bacterial growth control agents are for example alkyl groups with more than 3 carbon atoms, branched alkyl groups with more than 4 carbon atoms, straight or branched-chain fluoroalkyl groups with an alkyl radical containing more than 3 atoms of carbon, and perfluoroalkyl groups with a straight or branched-chain alkyl group containing more than 3 carbon atoms.
[0042] According to a preferred embodiment, the mixture of bacterial growth control agents includes at least one control agent of the hydrophilic isothiazolone type and at least one control agent of the hydrophobic isothiazolone type.
[0043] The isothiazolones can be represented by the formula:
[0044] wherein Y is a hydrogen atom, a substituted or unsubstituted alkyl or cycloalkyl group, a substituted or unsubstituted alkenyl group or a substituted or unsubstituted alkynyl group, R 1 and R 2 are independently a hydrogen atom, a halogen atom or an alkyl group, or R 1 and R 2 together form a benzene moiety.
[0045] Preferably, when the bacterial growth control agent is a hydrophilic control agent, Y is either methyl or ethyl, and R 1 and R 2 are chloride, methyl or ethyl. When the bacterial growth control agent is a hydrophobic control agent, Y is for example an octyl group, and R 1 and R 2 are alkyl groups with more than 3 carbon atoms.
[0046] For example the hydrophilic isothiazolones can be 1,2-benzisothiazolin-3-one, 2-methyl-4-isothiazolin-3-one, and 5-chloro-2-methyl-4-isothiazolin-3-one.
[0047] For example the hydrophobic isothiazolones can be 2-octyl-4-isothiazolin-3-one, 4,5-dichloro-2-N-octyl-4-isothiazolin-3-one.
[0048] The quantity of bacterial growth control agents that can be dispersed in the matrix varies widely according to the mixture of control agents, the solution to be treated, the possible extent of contamination by micro-organisms, and for how long the growth of micro-organisms is to be limited. The molar ratio of the inorganic matrix to the mixture of bacterial growth control agents can be between 10:1 and 1:200. The hydrophobic bacterial growth control agents can represent at least 50% by weight calculated relative to the total quantity of bacterial growth control agents.
[0049] According to one embodiment, the active organic compound dispersed in the matrix is a complexing agent that is released to form a complex salt with silver contained in a medium to be treated. The medium can be a photographic bath, and the complexing agent complexes the silver present when it is released into the photographic bath, in order to avoid the accumulation of metallic silver in the form of silver-laden slurries in the bath. Suitable complexing agents include thiols and in particular heterocyclic thiols, for example mercaptobenzimidazoles, mercaptobenzothiazoles, triazole-thiols, mercaptotetrazoles, imidazoline-thiones, mercaptocarboxylic acids, and mercaptobenzoxazoles. For example, it is possible to incorporate between 10 g and 300 g of thiol per kg of aluminosilicate polymer gel containing 3 g Al+Si per liter. The quantity of thiol that can be incorporated in the polymer gel depends on its texture and so on the quantity of Al+Si per liter.
[0050] As seen above, the composite material according to the invention forms a network of ranging density according to the choice and quantity of the structuring agent used. Thus when the active organic compound used is a bacterial growth control agent that is highly water-soluble, tetramethoxysilane will be preferably chosen; this affords a highly structured inorganic matrix that prevents rapid diffusion of said bacterial growth control agent in the effluent. The efficient quantity of structuring agent, as defined above, that yields a sufficiently compact gel that still allows the diffusion of bacterial growth control agents depends also on the control agent itself. Thus when the control agent is hydrophobic and so tends to remain in the inorganic matrix, an amount equal to 1% by weight of structuring agent, as defined above, relative to the [Al+Si] content of the imogolite is sufficient to obtain a compact gel. When the control agent is hydrophilic and so has a greater tendency to diffuse out of the matrix, an amount equal to 5% by weight of structuring agent, as defined above, relative to the [Al+Si] content of the imogolite, can be used to achieve a good compromise between the gel structure of the composite material and the kinetics of diffusion of the bacterial growth control agent. When it is desired only to reduce the thixotropic character of the gel to improve its packagability, a very small amount of structuring agent (less than 1% by weight relative to the [Al+Si] content of the imogolite) can be used without modifying the diffusion characteristics of the bacterial growth control agents.
[0051] The formulation of the composite material according to the invention thus affords perfect control over the diffusion of species that are highly soluble in the effluent. Consequently, it is possible to use bacterial growth control agents that are highly water-soluble, which could not be used hitherto because they diffused too rapidly. The range of bacterial growth control agents that can be used in the composite material of the invention is thus broadened, making it easier to adapt the composite material to comply with different environmental regulations.
[0052] In order to carry out the effluent treatment process of the invention it is necessary to optimize the contact between the composite material of the invention and the effluent to be treated.
[0053] The composite material of the present invention takes the form of a structured gel, is compact and can be easily packaged for commercialization. The compact gel can be easily placed in a container that is permeable to the effluent, e.g., a dialysis bag, a non-woven material, etc. The device that allows to carry out of the treatment process can be adapted according to the needs of the user. For example, when a curative effect is especially sought (in cases of poor water quality and (or) heavily soiled treatment apparatus), highly water-soluble bacterial growth control agents have to be used. In this situation a very compact composite material according to the invention will be placed in the treatment device, so as to deliver a perfectly controlled amount of hydrophilic bacterial growth control agent.
[0054] This process can be advantageously used in a photographic processing method that comprises passing a photographic material through a series of processing baths between which are intercalated washing and (or) stabilization baths, these baths being treated with the treatment process of the invention.
[0055] When the active organic compound is a bacterial growth control agent the composite material can be used in any application in which the bacteriological quality of water has to be controlled. In the photographic sector, for example, the composite material of the invention can be preferably used for the treatment of a washing bath.
[0056] [0056]FIG. 1 shows an embodiment of the treatment process of the present invention applied to the treatment of a photographic bath.
[0057] In this Figure a tank 10 , which can be a processing tank of a photographic processing machine, is supplied with water through the piping 12 . This tank 10 is fitted with an overflow 14 that allows the volume of solution held in the tank 10 to be kept constant. The tank is also fitted with an outlet 16 connected by piping 18 to a treatment device 20 containing the composite material of the invention, in which the active organic material is a mixture of hydrophilic and hydrophobic bacterial growth control agents. The treatment device 20 is connected to a pump 24 that sends the treated solution back to the tank 10 . The treatment device 20 can comprise several treatment units 26 . In the specific embodiment of FIG. 1 the treatment device 20 comprises three treatment units 26 .
[0058] According to a specific embodiment at least two units contain the composite material according to the invention. The third unit can contain a material of a different nature, for example a material designed to trap compounds to be eliminated from the solution. For example the third unit can contain a material that can trap silver contained in the solution to be treated.
[0059] According to a specific embodiment each unit can be replaced independently of the others.
[0060] The solution to be treated that is liable to harbor bacteria flows through the treatment device 20 that contains at least one treatment unit containing the composite material of the invention. By flowing through this material the solution takes up bacterial growth control agents. This solution containing bacterial growth control agents is then sent to the treatment tank 10 . Bacterial growth in the solution can thereby be limited. The composite material is formulated according to the hydrophilicity of the bacterial growth control agents in such a way as to achieve full control over the diffusion of these hydrophilic bacterial growth control agents.
[0061] The following examples illustrate the present invention in detail.
EXAMPLE 1
[0062] Preparation of an aqueous solution of imogolite.
[0063] The aluminosilicate of this example was prepared using teachings from Patent Application WO 96/13459.
[0064] To 1,000 ml of de-ionized water were added 16.7 mmoles of tetraethylorthosilicate Si(OC 2 H 5 ) 4 . The reaction mixture was stirred at ambient temperature for one hour and the solution was then added to 31.2 mmoles of AlCl 3 .6H 2 O dissolved in 1,000 ml of pure water. The mixture was stirred for 20 minutes and the pH was adjusted to 4.5 with 1 M NaOH. The solution became cloudy. When the solution became transparent again, 1 M NaOH was added until the pH reached 6.8. A white gel was obtained, which was centrifuged for 20 minutes at 2,000 rpm. This gel was collected and redissolved in 5 ml of a mixture of 1 M HCl and 2 M acetic acid. The volume was made up to 2 l with water. The solution contained 30 mmoles of Al, 16.6 mmoles of Si, 5 mmoles of HCl and 10 mmoles of acetic acid. This solution was stored at 5° C.
[0065] This solution was then diluted in de-ionized water to obtain a concentration of Al of 10 mmoles/l. The diluted solution was heated for 5 days at 96° C. and then filtered through an ultrafiltration membrane with a separating power of 10,000 Daltons (membrane manufactured by AMICON). A clear solution was obtained containing Al and Si in the Al:Si ratio of 1.8 with an [Al+Si] content of 2 g/l.
EXAMPLE 2 (invention)
[0066] Preparation of the composite material with tetramethoxylsilane as structuring agent, the active organic compound being a bacteriological growth control agent.
[0067] a) A gel containing Kathon 287T®, a hydrophobic bacterial growth control agent supplied by Rohm & Haas was prepared according to the following operating procedure.
[0068] 40 g of pure Kathon 287T® was dissolved with strong stirring in 80 ml of methanol at 50° C. After complete dissolution, 20 ml of tetramethoxysilane was added with stirring, i.e., 10% by weight relative to the [Al+Si] content of the imogolite. To this mixture was added 100 ml of a 2 g/l solution of imogolite prepared using the operating procedure of Example 1. The addition was made rapidly using an ‘Ultraturax’ emulsifier-homogenizer to obtain a homogeneous dispersion. 100 ml of imogolite was then added with mechanical stirring. The mixture was then cooled with stirring. When the temperature reached 25° C. ammonia NH 4 0H (8.4 ml) was added to obtain a compact cross-linked gel containing the imogolite in the form of an aqueous gel in which the hydrophobic Kathon 287T® is dispersed.
[0069] b) A gel containing Kathon LX®, a mixture of hydrophilic bacterial growth control agents that are completely soluble in water, supplied by Rohm & Haas, was prepared according to the following operating procedure. Kathon LX®: aqueous solution containing 13.7% by weight of isothiazolones of formula:
[0070] in which the chloroisothiazolone:isothiazolone ratio is 3:1.
[0071] 2 ml of Kathon LX® was mixed with 1 ml of methanol with magnetic stirring, and 10 ml of tetramethoxysilane was then added (i.e., 10% be weight relative to the [Al+Si] content of the imogolite). This mixture was added to 100 ml of a 2 g/l solution of imogolite. Addition of the mixture of Kathon LX® and tetramethoxysilane to the imogolite was carried out with slow mechanical stirring at ambient temperature. Ammonia was then added (0.4 ml). As soon as a gel mass appeared the stirring was stopped. After a few minutes a compact cross-linked gel was obtained.
[0072] (c) The composite material of the invention was obtained by mixing, with very slow mechanical stirring, the gel a) prepared above in which was dispersed Kathon 287T® (water solubility 5 mg/l) and gel b) prepared above in which was dispersed Kathon LX®. The proportion was ⅓ of gel containing Kathon LX® to ⅔ of gel containing Kathon 287T®.
[0073] To show that the imogolite was cross-linked and that the composite material of the invention was composed of an irreversible chemical gel, the following experiment was conducted : to a physical imogolite gel obtained according to Example 1 was added 3 ml of HCl (37%) to lower its pH to 3, below the gelling threshold. The imogolite reverted to its initial homogeneous liquid state with a viscosity close to that of water. When this experiment was carried out with the composite material of the invention, the latter retained its gel state owing to the irreversible formation of covalent bonds between the imogolite fibers.
EXAMPLE 3 (comparative)
[0074] A gel containing Kathon 287® was prepared as in step a) of Example 2, but without adding tetramethoxysilane.
[0075] A gel containing Kathon LX® was prepared as in step b) of Example 2 but without adding tetramethoxysilane.
[0076] A mixture of ⅓ of the gel obtained containing Kathon LX® and ⅔ of the gel obtained containing Kathon 287T® was made up. A non-compact, relatively mobile gel was obtained that lost water.
EXAMPLE 4
[0077] In two dialysis bags (Nadir, cellulose tube with pore size 2.5-3.0 nanometers, supplied by ROTH) were placed two 10 g samples of the composite material prepared according to Example 2 (tests A and B). In another dialysis bag was placed 10 g of a mixture of gels prepared according to Example 3, i.e., without tetramethoxysilane (test C).
[0078] Each bag was immersed in 400 ml of osmosed water. At regular intervals (every 30 minutes) the osmosed water was replenished. The recovered water was analyzed by UV-visible spectrophotometry. The optical density measured is characteristic of the quantity of bacterial growth control agent present in the osmosed water. A wavelength of 274 nm is characteristic of Kathon LX®, a wavelength of 280 nm is characteristic of Kathon 287T®, and an intermediate wavelength is characteristic of a mixture of Kathon LX® and Kathon 287T®. The diffusion of Kathon LX® alone was followed, because the absorption peak of Kathon 287T® was too close and too weak to be measured, being partly obscured by the absorption peak of Kathon LX®. Calibration using solutions of known concentrations of Kathon LX® allowed the relation between optical density and concentration to be determined, so that the concentration of Kathon LX® diffused in the osmosed water could be obtained from the optical density of the latter.
[0079] The results are reported in Table 1 below and represented diagrammatically in FIG. 2.
TABLE I Concentration of Kathon LX ® (mg/l) Change of water Test A (inv.) Test B (inv.) Test C (control) 1 2.35 1.93 5.34 2 1.33 1 3.34 3 0.93 0.62 2.02
[0080] Table 1 and FIG. 2 show that the concentration of Kathon LX® that diffused into the osmosed water was much lower when the Kathon LX® was dispersed in the cross-linked imogolite matrix. The composite material of the invention, composed of a cross-linked gel, allows a much slower diffusion of the hydrophilic bacterial growth control agent than a non-cross-linked imogolite gel. The composite material is sufficiently compact for packaging and to ensure a delayed diffusion of the hydrophilic bacterial growth control agent, but without excessively slowing the diffusion of the hydrophilic bacterial growth control agent.
[0081] As a result, the diffuser containing the composite material will remain efficacious for longer and will allow control over the rate of diffusion of bacterial growth control agents, in particular of the hydrophilic control agent, so that it can be adapted to particular cases when necessary by appropriate formulation of the composite material.
EXAMPLE 5
[0082] The synthesis of various composite materials was carried out according to Example 2 but with a modified tetramethoxysilane content, so as to have 5% and 10% of tetramethoxysilane relative to the [Al+Si] content of the imogolite. The diffusion of the bacterial growth control agents from these cross-linked composite materials was compared with that from the physical gel without tetramethoxysilane obtained according to Example 3.
[0083] For each composition 10 g of gel was placed in a dialysis bag, which was placed in 400 ml of osmosed water. The time course of the continuous diffusion of the active Kathon LX® was followed by UV-visible spectrophotometry. The results are reported in Table 1 below and represented diagrammatically in FIG. 3.
TABLE II Concentrations of Kathon LX ® (mg/l) for an imogolite gel with Time 10% 5% 0% (hours) tetramethoxysilane tetramethoxysilane tetramethoxysilane 0 0 0 0 0.5 1.88 11.63 10.79 1 2.97 16.83 14.21 1.5 3.83 20.82 16.98 2 4.68 23 19.27 2.5 5.20 21.32 3 5.97 26.19 22.62 24 9.85 29.48 32.11 48 11.49 31.30 33.99 78 12.28 34.5 96 13.48 35.19 144 31.56 168 31.10 192 30.96 198 13.54 36.21 216 13.96 31.99 36.66 240 14.10 37.41 264 13.40 37.50 312 32.98 360 13.28 38.58 384 12.28 37.63 408 12.67 38.42 432 14.22 38.01
[0084] Table II and FIG. 3 show that the concentration of Kathon LX® that diffused into the osmosed water in time was lower when an imogolite gel cross-linked with tetramethoxysilane (TMOS) was used, in particular when the TMOS content was equal to 10% relative to the [Al+Si] content of the imogolite. The more tetramethoxysilane there was in the composite material the more slowly did the hydrophilic bacterial growth control agent Kathon LX® diffuse into the osmosed water. This is because the more cross-linked and denser the composite material is, the more strongly the hydrophilic control agent trapped in the inorganic matrix is retained.
EXAMPLE 6
[0085] The synthesis of two cross-linked gels was carried out according to steps a) and b) of Example 2 respectively, but varying the tetramethoxysilane content to obtain 1%, 2%, 5% and 10% by weight of tetramethoxysilane relative to the [Al+Si] content of the imogolite.
[0086] For each composition 10 g of gel was placed in a dialysis bag, which was immersed in 400 ml of osmosed water The continuous diffusion from the gels containing only Kathon LX®, and that from the gels containing only Kathon 287T® was monitored by UV-visible spectrophotometry.
[0087] The results are reported in Tables III and IV below and represented diagrammatically in FIGS. 4 and 5.
TABLE III Concentration of Kathon LX ® (mg/l) for an imogolite gel with Time (hours) 5% tetramethoxysilane 10% tetramethoxysilane 0 0 0 0.5 11.63 9.06 1 16.83 11.49 1.5 20.82 2 23 16.98 3 26.19 18.29 24 29.48 25.71 48 31.30 27.57 144 31.56 28.78 168 31.10 29.26 192 30.96 28.62 198 216 31.99 240 264 312 32.98
[0088] [0088] TABLE IV Time Concentration of Kathon 287T ® (mg/l) for an imogolite gel with in 1% 2% 5% 10% hours tetramethoxysilane tetramethoxysilane tetramethoxysilane tetramethoxysilane 0.5 2.87 2.51 2.21 1.02 1 3.06 2.81 2.4 1.14 1.5 3.23 2.98 2.59 1.27 2 3.31 2.99 2.62 1.38 3 3.64 3.16 2.73 1.68 24 4.37 4.06 3.51 2.26 48 4.76 4.33 4.26 144 5.66 5.3 4.62 4.38 168 6.87 6.36 5.65 5.55 192 7.42 7.1 6.36 6.18 216 7.87 7.64 6.82 6.41 312 7.97 7.69 6.97 6.79
[0089] Table III and FIG. 4 show that to obtain a good compromise between gel structure and diffusion kinetics the gel containing Kathon LX® alone is not sufficiently structured when the tetramethoxysilane content is below 5% by weight relative to the [Al+Si] content of the imogolite. However, Table IV and FIG. 5 show that the gel containing Kathon 287T® alone and 1% by weight of tetramethoxysilane relative to the [Al+Si] content of the imogolite is sufficiently cross-linked to achieve a good compromise between gel structure and diffusion kinetics. The composite material of the invention can therefore be formulated by varying the tetramethoxysilane content to adapt it best to the bacterial growth control agents used.
PART LIST 10 Tank 12 Piping 14 Overflow 16 Outlet 18 Piping 20 Treatment device 24 Pump 26 Treatment units | The present invention relates to a composite material with an improved structure in which is dispersed an active organic compound, and a method for treating effluents, in particular a method for treating photographic effluents.
The present invention relates to a composite material that takes the form of a structured gel comprising an aluminosilicate polymer matrix in the form of fibers in which at least two distinct fibers are interconnected by at least two covalent bonds to form an irreversible chemical gel and, dispersed in the matrix, an active organic compound. The choice of the degree of cross-linking of the matrix makes it possible to control the diffusion of a hydrophilic active organic compound. The invention further concerns a method for preparing such a composite material. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a multi-colored synthetic resin sheet having an upper surface and a back surface wherein the boundary between adjacent colors is gradated on the surface and throughout a transversal cross-section of the sheet. This invention further relates to a multi-colored synthetic resin sheet which is formed by pouring, at least two differently colored polymerizable liquid materials into a polymerizing apparatus, such as an opposed belts-type-continuous sheet making apparatus, to effect polymerization and hardening.
2. Description of the Prior Art
Heretofore, multi-colored sheets having gradated boundary portions have been produced by first forming a sheet and then applying coating materials of different colors to the surface of the sheet. Coating can be effected by spraying, printing, coating, etc. or by applying a colored film to the surface of a sheet; wherein the film had previously been prepared by spraying, printing, coating, dyeing, etc.
However, these sheets prepared by overlaying a film onto a substrate are characterized by low permanence in that separation due to external forces or with lapse of time can be a problem. Moreover, when such sheets are subject to heat or stretching such as during molding, creases can occur between the colored film and the core sheet due to the differences in expansion coefficients; or the color of the stretched portion can be deteriorated resulting in a noticeable difference in color density between the stretched and unstretched portions, which can spoil the apperance of the products. A need therefore, continues to exist for a multi-colored synthetic sheet having at least two colors which can be molded or heated without the aforementioned disadvantages.
SUMMARY OF THE INVENTION
Accordingly, one object of the invention is to provide a multi-colored synthetic resin sheet having at least two colors which will be high in permanence.
Another object of the invention is to provide a multi-colored synthetic sheet wherein the boundary portion between adjacent different colors is gradated.
Still another object of the invention is to provide a method for the preparation of multi-colored synthetic resin sheets.
Briefly, these objects and other objects of the invention, as hereinafter will become more readily apparent, can be obtained by providing a multi-colored synthetic resin sheet having an upper surface, a lower surface, and a uniformly colored longitudinal cross-section which has at least two longitudinally adjacent different colors, with the boundary portion between said colors being in a gradated state on the upper surface and on the lower surface and throughout a transversal cross-section of said sheet. More particularly, this invention also concerns a method of producing a multi-colored synthetic resin sheet which comprises: adjacently feeding onto a moving belt at least two differently-colored polymerizable liquid materials, polymerizing and hardening said liquids; thereby obtaining a multi-colored synthetic resin sheet which has an upper surface, a lower surface, and a uniformly colored longitudinal cross-section, which has at least two longitudinally adjacent colors with the boundary portion between said colors being in a gradated state on the upper surface, on the lower surface and throughout a transversal cross-section of said sheet.
The multi-colored synthetic resin sheets of the present invention are suitable as blinds for windows and vehicles, displays of articles, various partionings, fences of porches, windscreens, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention 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:
FIG. 1 and FIG. 2 are oblique views of the multi-colored synthetic resin sheet of the present invention.
FIG. 3 is a front view of an apparatus for making the sheet of the present invention.
FIG. 4 and FIG. 5 are a front view and top view which show some of the main features of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The polymerizable liquid materials which may be used in the present invention include polymerizable monoethylenically unsaturated compounds or polyfunctional compounds, which are liquid under normal pressure. Suitable monoethylenically unsaturated compounds include methacrylates, ethylene and their halogen or alkyl substituted derivatives, vinyl acetate, or the like or mixtures of a major amount of said compounds with acrylates, acrylonitrile or derivatives thereof. Suitable polyfunctional compounds are glycol dimethacrylate, diallyl methacrylate, diallyl phthalate, diethylene glycol bisallyl carbonate, or the like. Mixtures of copolymers of methyl methacrylate and monomers copolymerizable therewith are especially preferred.
Polymerization initiators may be used with the polymerizable compounds. Suitable initiators include free-radical initiators such as azobisisobutyronitrile, azobisdimethylvaleronitrile, benzoyl peroxide, lauroyl peroxide, acetyl peroxide, caproyl peroxide, 2,4-dichlorobenzoyl peroxide, isopropyl peroxydicarbonate, isobutyl peroxide, acetylcyclohexylsulfonyl peroxide, or the like; which may be used alone or in combination.
Mixtures of monomers and polymers, namely mixtures of a monomer as above described in which a suitable amount of polymer is dissolved or suspended, or mixtures of partially polymerized monomers and polymers may be used, so long as the fluidity is not lost. Furthermore, as long as the polymerization is not seriously inhibited, various additives such as stbilizers, plasticizers, polymerization regulators, fillers, releasing agents, viscosity modifiers, and the like, may be admixed with the polymerizable compounds.
In the present invention, by the phrase "different colors", is intended to mean color tones ranging from colorless transparency, transparency, translucency and opaque and hue and chroma which can also be optically distinguished. Generally known dyes, pigments, and coloring additives may be used for coloring sheets. If a transparent multi-colored synthetic resin sheet is desired, preparations of one or more of the dyes or pigments which are previously dispersed in a carrier medium may be included in the polymerizable mix. Various carbonates or metal compounds may be used as the pigments. When translucent and opaque colored synthetic resin sheets are intended, it is possible to use particulate processed pigments. These are obtained by dispersing powdery or pasty pigments in polymerizable liquid raw materials, such as methyl methacrylate or styrene monomers in a high concentration, then polymerizing the dispersion with addition of polymerization initiators and finally grinding the polymers. This is especially preferred in the present invention. It is also possible to directly add powdery or pasty pigments to the liquid polymerizable compounds. In this case, however, color spots due to aggregation or sedimentation of the pigments or polymerization unevenness sometimes occurs due to the activity of the pigments, whereby the quality and appearance of the products is reduced. In order to control translucency, it is preferred to add a suitable amount of a previously prepared methyl methacrylate and styrene copolymer as a coloring assistant to the polymerizable liquid and then to carry out the polymerization.
In order that the longitudinally adjacent different colors be gradated at their boundary, each colored liquid material should have a viscosity of 3-50 poises at 20° C., preferably 5-40 poises at 20° C. when dye is used as coloring agent. Depending on the desired degree of gradation the difference in viscosity of two adjacent liquids should be less than 10 poises. When pigments are used as coloring agents the viscosities are determined depending on the desired degree of the gradation. For example, when the preferred copolymers of methyl methacrylate and styrene in a ratio of 2:8-8:2 are dissolved in an amount of 0.5-4.0%, each liquid has a viscosity of 3-30 poises at 20° C. and the difference in viscosity of two adjacent liquids should be 2-10 poises.
Good results have been obtained in the preparation of synthetic resin sheets of thicknesses of 1.5 mm-15 mm.
FIG. 1 shows a synthetic resin sheet in which two different colors (a,b) are arranged in width direction and the colors in the boundary section between said colors are in a gradated state.
FIG. 2 shows a synthetic resin sheet in which two or three different colors (a,b, or a,b,c) are arranged in width direction and the adjacent colors are in a gradated state in their boundary portions.
FIG. 3 shows one example of an opposed belts-type-continuous sheet making apparatus which may be used in practicing the present invention. In FIG. 3, endless belts 1 and 1' are usually metallic belts such as steel or stainless steel. If metallic belts 1 and 1' are used they should be polished in order to obtain sheets excellent in surface appearance. The thickness of the metallic belt is 0.1-3 mm, preferably 0.5-2 mm. These belts are stretched by main pulleys 2 and 3 and 2' and 3' and are provided with a predetermined tension. A hydraulic cylinder is provided in main pulleys 2 and 2' and the tension of the belts can be changed by changing the oil pressure. The tension of the belts can be adjusted by various means, such as for example using a spring or the like. The tension of the belts is preferably high to improve the shape of the belts to increase the accuracy of thickness of the sheets and generally they are driven at 3-15 kg/mm 2 .
The belts are moved by driving main pulley 3' and the weaving movements of the belts are controlled by adjusting the angles between main pulleys 2 and 3 and 2' and 3'. The angles of the main pulleys are adjusted by changing the oil pressure, or by other means. The weaving movement of the belts can also be controlled by changing the angle of rolls 12 and 12' which contact the back surface of the belts.
The liquid polymerizable mixture is blended or dissolved and fed at a constant flow rate, generally using a gear pump and fed to the space between the opposed belts through conduit 21 and inclined plate 22 which form feeding devices. As the raw material feeding devices, such feeding devices as plural inclined plates 22, 22', 22" are used in the present invention to feed at least two liquid polymerizable materials. A gasket, 13 which follows the movement of the belts so as to be positioned between both ends of the opposed belts in the width direction prevents leakage of the liquid materials from the belts. Gasket 13 is made of soft polyvinyl chloride, polyethylene, ethylenevinyl acetate copolymer, polyurethane and other materials. Rolls 4, 4' and 6 and 6' support the opposed belts at their back surface. Rolls 6 should be arranged in such a manner that liquid polymerizable materials do not leak from the space formed between the opposed belts and the gaskets in polymerization zones 5 and 5'. The belts deflect between adjacent rolls due to the liquid pressure of the liquid raw materials, repulsion power of the gaskets, etc. When this deflection amount is too great, the accuracy of thickness of the sheets will be deteriorated and the gradation state of colors in the boundary portions in the sheets will unacceptably vary or the sheets will be bent causing a reduction in quality and appearance.
One method to overcome said difficulties is to make the deflection of the belts small. For this purpose, it is preferred that the interval between the arranged rolls be small and the tension of the belts be increased. Thus, the interval between rolls (distance between centers of adjacent rolls) is about 20-100 cm. The rolls are set in such a manner that even when the liquid raw materials are polymerized and shrunk they will follow the belts and will not be separated from the surface of the belts. Spraying devices 7 and 7' are provided in the polymerization zone to apply hot water to the belts as a heat source. The temperature of hot water may be lower than 100° C., but it is preferred to effect polymerization as rapidly as possible to avoid use of a large continuous sheet-making apparatus and to increase productivity. Thus, a temperature of about 65°-90° C. is generally used. Far infrared heaters 8 and 8' may be provided in the second polymerization zone and to heat the polymerized and hardened sheet to higher than 100° C. for removal of any remaining monomers. It is also possible to use a hot-air oven. Zones 9 and 10 are provided for cooling the sheet leaving the second polymerization zone. A roll 11 is provided to support the belts in said zone 9 and 10. This roll is preferably cooled by a cooling liquid. The produced sheet 14 is recovered.
FIG. 4 and FIG. 5 show one example of devices for feeding the polymerizable liquid materials. Conduits 21, 21' and 21" for the liquid polymerizable materials are provided to constantly feed a multiplicity of different colored raw materials by optional feeding devices by a gear pump. Inclined plates 22, 22' and 22" are set in such a manner that the top ends of the plates are positioned at a given distance from the face of the lower belt 1', preferably 5-20 mm. These feeding devices can be freely moved in the width direction of the belts by a guide rail 23 and are provided on truck 26 which is connected to upper pulley 2 to prevent contact with the upper belt 1.
Having generally described this invention, a further understanding can be obtained by reference to certain specific examples which are provided herein for purposes of illustration only and are not intended to be limiting unless otherwise specified.
EXAMPLE 1
Into a methyl methacrylate syrup having a viscosity of 15 poises at 20° C. and a polymerization rate of 22%, namely, a monomer.polymer mixture, were blended and dissolved 500 ppm of azobisdimethylvaleronitrile as a polymerization initiator, 100 ppm of an ultraviolet absorbing agent and 20 ppm of dioctyl sulfosuccinate to obtain liquid raw material A. Separately, to the same methyl methacrylate syrup as above, 5% of methyl methacrylate monomer was added and the viscosity at 20° C. was 9 poises. Then was added 500 ppm of azobisdimethylvaleronitrile, 100 ppm of an ultraviolet absorbing agent, 20 ppm of dioctyl sulfosuccinate and 0.1% of a coloring agent obtained by dispersing ultramarine blue in a dispersion medium. Liquid raw material B was thus obtained. These liquid raw materials A and B were deaerated under reduced pressure and then were fed to the continuous sheet making apparatus by continuously feeding them between belts 1 and 1' through inclined plates 22, 22' and 22" which are a part of each feeding device shown in FIG. 4 and FIG. 5 through a gear pump. Belts 1 and 1' are endless belts of polished stainless steel having a thickness of 1.5 mm and a width of 1500 mm. Stretch was given to them by main pulleys 2 and 2' of 1500 mm in diameter, tension of the belts was set at 10 kg/mm 2 by oil pressure and the belts were moved at a speed of 2.4 m/min. The space between upper and lower belts 1 and 1' was maintained by roller groups 6 and 6' arranged at the interval of 400 mm so that the sheet like polymer had a uniform thickness of 3 mm. Gasket 13 used was a hollow pipe having an outer diameter of 8 mm and a thickness of 0.6 mm and made of polyvinyl chloride containing 60% (based on the polymer) of dibutyl phthalate as a plasticizer.
The first polymerization zones 5 and 5' had a length of 66 m and were heated by scattering hot water of 80° C. in shower form on the back surface of the belts from spraying devices 7 and 7'. Length of the second polymerization zones was 10 m and the sheets were heated to 135° C. by far infrared heaters 8 and 8'. Length of the heat retaining zone 9 was 10 m and the belts travelled through a duct which surrounded the belts. The length of cooling zone 10 was 2 m and the polymerized and hardened sheet which had a temperature of higher than 100° C. at the inlet of the cooling zone 10 was cooled to 100°-80° C. and taken out from the belts.
The thus obtained sheet was a methyl methacrylate multi-colored synthetic resin sheet excellent in appearance and having a thickness of 3 mm and a width of 400 mm in which the central portion of about 500 mm was colorless and transparent and both external portions were transparent blue and the two colors which were adjacent to each other in the portion of about 200 mm in width were gradated from colorless transparence to transparent blue.
EXAMPLE 2
Example 1 was repeated except as follows. 50 ppm of an oil soluble blue dye was dissolved in liquid raw material A. 40 ppm of an oil soluble blue dye and 0.9% of a copolymer of methyl methacrylate and styrene (3:7) were dissolved in liquid raw material B and this had a viscosity of 12 poises. As a result, there was obtained a multi-colored synthetic resin sheet mainly composed of methyl methacrylate, excellent in appearance and having a thickness of 3 mm in which the central portion of about 450 mm was transparent blue and both external portions were translucent and the two colors which were adjacent to each other were gradated in a width of about 200 mm from the transparent blue to the translucent blue from the upper surface to the back surface of the sheet.
EXAMPLE 3
Example 1 was repeated as follows. 0.2% of a coloring agent prepared by dispersing carbon in a dispersion medium was added to liquid raw material A and 0.25% of such coloring agent used in liquid raw material A and 1.0% of a copolymer of methyl methacylate and styrene (4.:6) were dissolved in liquid raw material B. Furthermore, liquid raw material C was prepared by adding 8% of methyl methacrylate monomer to the methyl methacrylate syrup of Example 1, adjusting the viscosity at 20° C. to 7 poises and then adding thereto 2% of a powder mixture of carbon, methyl methacrylate monomer and a copolymer of methyl methacrylate and styrene as a coloring agent. These liquid raw materials A, B and C were fed in this order in the width direction in the continuous sheet making apparatus shown in FIG. 3 through a gear pump and pouring devices. They were then polymerized therein to obtain a multi-colored synthetic resin sheet having a width of 1400 mm, a thickness of 4 mm and excellent in appearance which had a smoky transparent portion, a light black translucent portion and a black translucent portion, in width direction, wherein the adjacent two colors were gradated in their boundary portion in a width of about 200 mm from the upper surface to the back surface of the sheet.
Having now fully described this invention, it will be apparent to one of ordinary skills in the art that many changes and modifications can be made thereto without departing from the spirit or scope of the invention set forth herein. | A multi-colored synthetic resin sheet having an upper surface, a lower surface and a uniformly colored longitudinal cross-section which has at least two longitudinally adjacent different colors, with the boundary portion between the colors being in a gradated state on the upper surface and throughout a transversal section of sheet, is formed by adjacently feeding at least two differently colored polymerizable liquids into a polymerizing apparatus and polymerizing and hardening the materials. | 1 |
FIELD OF THE INVENTION
[0001] This application is a divisional of Ser. No. 10/178,838 filed Jun. 25, 2002; which is a continuation of Ser. No. 09/849,573 filed May 4, 2001; which is a continuation of Ser. No. 09/507,438 filed Feb. 19, 2000 issued as U.S. Pat. No. 6,294,039; which is a division of Ser. No. 09/258,999, filed Feb. 26, 1999, issued as U.S. Pat. No. 6,042,677; which is a division of Ser. No. 08/896,517, filed Jun. 16, 1997, issued as U.S. Pat. No. 5,910,250; which is a continuation-in-part application of Ser. No. 08/690,045, filed Jul. 31, 1996, issued as U.S. Pat. No. 5,783,083 which is a non-provisional of provisional application Serial No. 60/012,921 filed Mar. 5, 1996 and a continuation-in-part of Ser. No. 08/514,119, filed Aug. 11, 1995, issued as U.S. Pat. No. 5,639,373. PCT/CA96/00536 was filed on Aug. 8, 1996, published as WO97/006880, and claimed priority from U.S. Ser. Nos. 08/514,119 and 08/690,045. The disclosure of all the patents and applications listed in this paragraph are hereby incorporated by this reference to them as if they were fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a membrane device which is an improvement on a frameless array of hollow fiber membranes and a method of maintaining clean fiber surfaces while filtering a substrate to withdraw a permeate, which is also the subject of U.S. Pat. No. 5,248,424; and, to a method of forming a header for a skein of fibers. The term “vertical skein” in the title (hereafter “skein” for brevity), specifically refers to an integrated combination of structural elements including (i) a multiplicity of vertical fibers of substantially equal length; (ii) a pair of headers in each of which are potted the opposed terminal portions of the fibers so as to leave their ends open; and, (iii) permeate collection means held peripherally in fluid tight engagement with each header so as to collect permeate from the ends of the fibers.
[0003] The term “fibers” is used for brevity, to refer to “hollow fiber membranes” of porous or semipermeable material in the form of a capillary tube or hollow fiber. The term “substrate” refers to a multicomponent liquid feed. A “multicomponent liquid feed” in this art refers, for example, to fruit juices to be clarified or concentrated; wastewater or water containing particulate matter; proteinaceous liquid dairy products such as cheese whey, and the like. The term “particulate matter” is used to refer to micron-sized (from 1 to about 44 μm) and sub-micron sized (from about 0.1 μm to 1 μm) filterable matter which includes not only particulate inorganic matter, but also dead and live biologically active microorganisms, colloidal dispersions, solutions of large organic molecules such as fulvic acid and humic acid, and oil emulsions.
[0004] The term header is used to specify a solid body in which one of the terminal end portions of each one of a multiplicity of fibers in the skein, is sealingly secured to preclude substrate from contaminating the permeate in the lumens of the fibers. Typically, a header is a continuous, generally rectangular parallelpiped of solid resin (thermoplastic or thermosetting) of arbitrary dimensions formed from a natural or synthetic resinous material. In the novel method described hereinbelow, the end portions of individual fibers are potted in spaced-apart relationship in cured resin, most preferably by “potting” the end portions sequentially in at least two steps, using first and second potting materials. The second potting material (referred to as “fixing material”) is solidified or cured after it is deposited upon a “fugitive header” (so termed because it is removable) formed by solidifying the first liquid. Upon removing the fugitive header, what is left is the “finished” or “final” header formed by the second potting material. Of course, less preferably, any prior art method may be used for forming finished headers in which opposed terminal end portions of fibers in a stack of arrays are secured in proximately spaced-apart relationship with each other.
[0005] The '424 patent required potting the opposed ends of a frameless array of fibers and dispensed with the shell of a module; it was an improvement on two preceding configurations disclosed in U.S. Pat. Nos. 5,182,019, and 5,104,535, each of which used frameless arrays and avoided potting the fibers. The efficiency of gas-scrubbing a '424 array was believed to be due, at least in large part, to a substantial portion of the fibers of the fibers in the array lying in transverse relationship to a mass of rising bubbles, referred to herein as a “column of rising bubbles”, so as to intercept the bubbles. Specific examples are illustrated in FIGS. 9, 9A, 10 and 11 of the '424 patent.
[0006] A '424 “array” referred to a bundle of arcuate fibers the geometry of which array was defined by the position of a pair of transversely spaced headers in which the fibers were potted. In the '424 array, as in the array of this invention, each fiber is free to move independently of the others, but the degree of movement in the '424 is unspecified and arbitrary, while in the vertical skein of this invention, movement is critically restricted by the defined length of the fibers between opposed headers. Except for their opposed ends being potted, there is no physical restraint on the fibers of a skein. To avoid confusion with the term “array” as used for the '424 bundle of arcuate fibers, the term “skein fibers” is used herein to refer to plural arrays. An “array” in this invention refers to plural, essentially vertical fibers of substantially equal lengths, the one ends of each of which fibers are closely spaced-apart, either linearly in the transverse (y-axis herein) direction to provide at least one row, and typically plural rows of equidistantly spaced apart fibers. Less preferably, a multiplicity of fibers may be spaced in a random pattern. Typically, plural arrays are potted in a header and enter its face in a generally x-y plane (see FIG. 5). The width of a rectangular parallelpiped header is measured along the x-axis, and is the relatively shorter dimension of the rectangular upper surface of the header; and, the header's length, which is its relatively longer dimension, is measured along the y-axis.
[0007] This invention is particularly directed to relatively large systems for the microfiltration of liquids, and capitalizes on the simplicity and effectiveness of a configuration which dispenses with forming a module in which the fibers are confined. As in the '424 patent, the novel configuration efficiently uses a cleansing gas, typically air, discharged near the base of a skein to produce bubbles in a specified size range, and in an amount large enough to scrub the fibers, and to cause the fibers to scrub themselves against one another. Unlike in the '424 system, the fibers in a skein are vertical and do not present an arcuate configuration above a horizontal plane through the horizontal center-line of a header. As a result, the path of the rising bubbles is generally parallel to the fibers and is not crossed by the fibers of a vertical skein. Yet the bubbles scrub the fibers. The restrictedly swayable fibers, because of their defined length, do not get entangled, and do not abrade each other excessively, as is likely in the '424 array. The defined length of the fibers herein minimizes (i) shearing forces where the upper fibers are held in the upper header, (ii) excessive rotation of the upper portion of the fibers, as well as (iii) excessive abrasion between fibers. The fibers of this invention are confined so as to sway in a “zone of confinement” (or “bubble zone”) through which bubbles rise along the outer surfaces of the fibers. The side-to-side displacement of an intermediate portion of each fiber within the bubble zone is restricted by the fiber's length. The bubble zone, in turn, is determined by one or more columns of vertically rising gas bubbles, preferably of air, generated near the base of a skein.
[0008] Since there is no module in the conventional sense, the main physical considerations which affect the operation of a vertical skein in a reservoir of substrate relate to intrinsic considerations, namely, (a) the fiber chosen, (b) the amount of air used, and (c) the substrate to be filtered. Such considerations include the permeability and rejection properties of the fiber, the process flow conditions of substrate such as pressure, rate of flow across the fibers, temperature, etc., the physical and chemical properties of the substrate and its components, the relative directions of flow of the substrate (if it is flowing) and permeate, the thoroughness of contact of the substrate with the outer surfaces of the fibers, and still other parameters, each of which has a direct effect on the efficiency of the skein. The goal is to filter a slow moving or captive substrate in a large container under ambient or elevated pressure, but preferably under essentially ambient pressure, and to maximize the efficiency of a skein which does so (filters) practically and economically.
[0009] In the skein of this invention, all fibers in the plural rows of fibers, staggered or not, rise generally vertically while fixedly held near their opposed terminal portions in a pair of opposed, substantially identical headers to form the skein of substantially parallel, vertical fibers. This skein typically includes a multiplicity of fibers, the opposed ends of which are potted in closely-spaced-apart profusion and bound by potting resin, assuring a fluid-tight circumferential seal around each fiber in the header and presenting a peripheral boundary around the outermost peripheries of the outermost fibers. The position of one fiber relative to another in a skein is not critical, so long as all fibers are substantially codirectional through one face of each header, open ends of the fibers emerge from the opposed other face of each header, and substantially no terminal end portions of fibers are in fiber-to-fiber contact. We found that the skein of fibers, deployed to be restrictedly swayable, were as ruggedly durable as they were reliable in operation.
[0010] The fibers are stated to be “restrictedly swayable”, because the extent to which they may sway is determined by the free length of the fibers relative to the fixedly spaced-apart headers, and the turbulence of the substrate. When a large number of fibers is used in a skein, as is typically the case herein, the movement of a fiber adjacent to others may be modulated by the movement of the others, but the movement of fibers within a skein is constricted. This system is therefore limited to the use of a skein of fibers having a critically defined length relative to the vertical distance between headers of the skein. The defined length limits the side-to-side movement of the fibers in the substrate in which they are deployed, except near the headers where there is negligible movement.
[0011] In the prior art, a vertical skein of fibers in a substrate is typically avoided due to expected problems relating to channelling of the feed. However, because the fibers are restrictedly swayable in a “bubble zone” as described herebelow, the fibers are substantially evenly contacted over their individual surfaces with substrate and provide filtration performance based on a maximized surface which is substantially the sum of the surface areas of all fibers in contact with the substrate. Moreover, because of the ease with which the substrate coats the surfaces of the vertical fibers in a skein, and the accessibility of those surfaces by air bubbles, the fibers may be densely arranged in a header to provide a large membrane surface of up to 1000 m 2 and more.
[0012] One header of a skein is displaceable in any direction relative to the other, either longitudinally (x-axis) or transversely (y-axis), only prior to the headers being vertically fixed in spaced apart parallel relationship within a reservoir, for example, by mounting one header above another, against a vertical wall of the reservoir which functions as a spacer means. This is also true prior to spacing one header above another with other spacer means such as bars, rods, struts, I-beams, channels, and the like, to assemble plural skeins into a “bank of skeins” (“bank” for brevity), in which bank a row of lower headers is directly beneath a row of upper headers. After assembly into a bank, a segment intermediate the potted ends of each individual fiber is displaceable along either the x- or the y-axis, because the fibers are loosely held in the skein. There is essentially no tension on each fiber because the opposed faces of the headers are spaced apart at a distance less than the length of an individual fiber.
[0013] By operating at ambient pressure, mounting the headers of the skein within a reservoir of substrate, and by allowing the fibers restricted movement within the bubble zone in a substrate, we minimize damage to the fibers. Because, a header secures at least 10, preferably from 50 to 50,000 fibers, each generally at least 0.5 m long, in a skein, it provides a high surface area for filtration of the substrate.
[0014] The fibers divide a reservoir into a “feed zone” and a withdrawal zone referred to as a “permeate zone”. The feed of substrate is introduced externally (referred to as “outside-in” flow) of the fibers, and resolved into “permeate” and “concentrate” streams. The skein, or a bank of skeins of this invention is most preferably used for microfiltration with “outside-in” flow. Typically a bank is used in a relatively large reservoir having a volume in excess of 10 L (liters), preferably in excess of 1000 L, such as a flowing stream, more typically a reservoir (pond or tank). Most typically, a bank or plural banks with collection means for the permeate, are mounted in a tank under atmospheric pressure, and permeate is withdrawn from the tank.
[0015] Where a bank or plural banks of skeins are placed within a tank or bioreactor, and no liquid other than the permeate is removed the tank is referred to as a “dead end tank”. Alternatively, a bank or plural banks may be placed within a bioreactor, permeate removed, and sludge disposed of; or, in a tank or clarifier used in conjunction with a bioreactor, permeate removed, and sludge disposed of.
[0016] Operation of the system relies upon positioning at least one skein, preferably a bank, close to a source of sufficient air or gas to maintain a desirable flux, and, to enable permeate to be collected from at least one header. A desirable flux is obtained, and provides the appropriate transmembrane pressure differential of the fibers under operating process conditions. “Transmembrane pressure differential” refers to the pressure difference across a membrane wall, resulting from the process conditions under which the membrane is operating.
[0017] The relationship of flux to permeability and transmembrane pressure differential is set forth by the equation:
J=k▴P
[0018] wherein, J=flux; k=permeability constant;
[0019] ▴P=transmembrane pressure differential; and k=1/μRm where μ=viscosity of water and, Rm=membrane resistance.
[0020] The transmembrane pressure differential is preferably generated with a conventional non-vacuum pump if the transmembrane pressure differential is sufficiently low in the range from 0.7 kPa (0.1 psi) to 101 kPa (1 bar), provided the pump generates the requisite suction. The term “non-vacuum pump” refers to a pump which generates a net suction side pressure difference, or, net positive suction head (NPSH), adequate to provide the transmembrane pressure differential generated under the operating conditions. By “vacuum pump” we refer to one capable of generating a suction of at least 75 cm of Hg. A pump which generates minimal suction may be used if an adequate “liquid head” is provided between the surface of the substrate and the point at which permeate is withdrawn; or, by using a pump, not a vacuum pump. A non-vacuum pump may be a centrifugal, rotary, crossflow, flow-through, or other type. Moreover, as explained in greater detail below, once the permeate flow is induced by a pump, the pump may not be necessary, the permeate continuing to flow under a “siphoning effect”. Clearly, operating with fibers subjected to a transmembrane pressure differential in the range up to 101 kPa (14.7 psi), a non-vacuum pump will provide adequate service in a reservoir which is not pressurized; and, in the range from 101 kPa to about 345 kPa (50 psi), by superatmospheric pressure generated by a high liquid head, or, by a pressurized reservoir.
[0021] The fibers are not required to be subjected to a narrowly critical trans-membrane pressure differential though fibers which operate under a small trans-membrane pressure differential are preferred. A fiber which operates under a small transmembrane pressure differential in the range from about 0.7 kPa (0.1 psi) to about 70 kPa (10 psi) may produce permeate under gravity alone, if appropriately positioned relative to the location where the permeate is with-drawn. In the range from 3.5 kPa (0.5 psi) to about 206 kPa (30 psi) a relatively high liquid head may be provided with a pressurized vessel. The longer the fiber, which greater the area and the more the permeate.
[0022] In the specific instance where a bank is used in combination with a source of cleansing gas such as air, both to scrub the fibers and to oxygenate a mixed liquor substrate, most, if not all of the air required, is introduced either continuously or intermittently, near the base of the fibers near the lower header. The perforations through which the gas is discharged near the header are located close enough to the fibers so as to provide columns of relatively large bubbles, preferably larger than about 1 mm in nominal diameter, which codirectionally contact the fibers and flow vertically along their outer surfaces, scrubbing them. The outer periphery of the columns of bubbles define the zone of confinement in which the scrubbing force exerted by the bubbles on the fibers, keeps their surfaces sufficiently free of attached microorganisms and deposits of inanimate particles to provide a relatively high and stable flow of permeate over many weeks, if not months of operation. The significance of this improvement will be better appreciated when it is realized that the surfaces of fibers in conventional modules are cleaned nearly every day, and sometimes more often.
[0023] Because this system, like the '424 system, does away with using a shell, there is no void space within a shell to be packed with fibers; and, because of gas being introduced proximately to, and near the base of skein fibers, there is no need to maintain a high substrate velocity across the surface of the fibers to keep the surfaces of the fibers clean. As a result, there is virtually no limit to the number of restrictedly swayable fibers which may be used in a skein, the practical limit being set by (i) the ability to pot the ends of the fibers reliably; (ii) the ability to provide sufficient air to the surfaces of essentially all the fibers, and (iii) the number of banks which may be deployed in a tank, pond or lake, the number to be determined by the size of the body of water, the rate at which permeate is to be withdrawn, and, the cost of doing so.
[0024] Typically, a relatively large number of long fibers, at least 100, is used in a skein of restrictedly swayable fibers, the fibers operate under a relatively low transmembrane pressure differential, and permeate is withdrawn with a non-vacuum pump. If the liquid head, measured as the vertical distance between the level of substrate and the level from which permeate is to be withdrawn, is greater than the transmembrane pressure differential under which the fiber operates, the permeate will be separated from the remaining substrate, due to gravity.
[0025] Irrespective of whether a non-vacuum pump, vacuum pump, or other type of pump is used, or permeate is withdrawn with a siphoning effect, it is essential that the fibers in a skein be positioned in a generally vertical attitude, rising above the lower header. An understanding of how a vertical skein operates will make it apparent that, since fibers in a skein are anchored at the base of the skein by the lower header, the specific gravity of the fibers relative to that of the substrate is immaterial and will not affect their vertical disposition.
[0026] The unique method of forming a header disclosed herein allows one to position a large number of fibers, in closely-spaced apart relationship, randomly relative to one another, or, in a chosen geometric pattern, within each header of synthetic resinous material. It is preferred to position the fibers in arrays before they are potted to ensure that the fibers are spaced apart from each other precisely, and, to avoid wasting space on the face of a header; it is essential, for greatest reliability, that the fibers not be contiguous. By sequentially potting the terminal portions of fibers in stages as described herein, the fibers may be cut to length in an array, either after, or prior to being potted. The use of a razor-sharp knife, or scissors, or other cutting means to do so, does not decrease the open cross-sectional area of the fibers' bores (“lumens”). The solid resin forms a circumferential seal around the exterior terminal portions of each of the fibers, open ends of which protrude through the permeate-discharging face of each header, referred to as the “aft” face.
[0027] Further, one does not have to cope with the geometry of a frame, the specific function of which is to hold fibers in a particular arrangement within the frame. In a skein, the sole function of the header spacing means is to maintain a fixed vertical distance between headers which are not otherwise spaced apart. In a skein of this invention, there is no frame.
[0028] The skein of this invention is most preferably used to treat wastewater in combination with a source of an oxygen-containing gas which is bubbled within the substrate, near the base of a lower header, either within a skein or between adjacent skeins in a bank, for the specific purpose of scrubbing the fibers and oxygenating the mixed liquor in activated sludge, such as is generated in the bioremediation of wastewater. It was found that, as long as enough air is introduced near the base of each lower header to keep the fibers awash in bubbles, and the fibers are restrictedly swayable in the activated sludge, a build-up of growth of microbes on the surfaces of the fibers is inhibited while permeate is directly withdrawn from activated sludge, and excellent flow of permeate is maintained over a long period. Because essentially all surface portions of the fibers are contacted by successive bubbles as they rise, whether the air is supplied continuously or intermittently, the fibers are said to be “awash in bubbles.”
[0029] The use of an array of fibers in the direct treatment of activated sludge in a bioreactor, is described in an article titled “Direct Solid-Liquid Separation Using Hollow Fiber Membrane in an Activated Sludge Aeration Tank” by. Kazuo Yamamoto et al in Wat. Sci. Tech . Vol. 21, Brighton pp 43-54, 1989, and discussed in the '424 patent, the disclosure of which is incorporated by reference thereto as if fully set forth herein. The relatively poor performance obtained by Yamamoto et al was mainly due to the fact that they did not realize the critical importance of maintaining flux by aerating a skein of fibers from within and beneath the skein. They did not realize the necessity of thoroughly scrubbing substantially the entire surfaces of the fibers by flowing bubbles through the skein to keep the fibers awash in bubbles. This requirement becomes more pronounced as the number of fibers in the skein increases.
[0030] As will presently be evident, since most substrates are contaminated with micron and submicron size particulate material, both organic and inorganic, the surfaces of the fibers in any practical membrane device must be maintained in a clean condition to obtain a desirable specific flux. To do this, the most preferred use of the skein as a membrane device is in a bank, in combination with a gas-distribution means, which is typically used to distribute air, Or oxygen-enriched air between the fibers, from within the skein, or between adjacent skeins, at the bases thereof.
[0031] Tests using the device of Yamamoto et al indicate that when the air is provided outside the skein the flux decreases much faster over a period of as little as 50 hr, confirming the results obtained by them. This is evident in FIG. 1 described in greater detail below, in which the graphs show results obtained by Yamamoto et al, and the '424 array, as well as those with the vertical skein, all three assemblies using essentially identical fibers, under essentially identical conditions.
[0032] The investigation of Yamamoto et al with downwardly suspended fibers was continued and recent developments were reported in an article titled “Organic Stabilization and Nitrogen Removal in Membrane Separation Bio-reactor for Domestic Wastewater Treatment” by C. Chiemchaisri et al delivered in a talk to the Conference on Membrane Technology in Wastewater Management, in Cape Town, South Africa, Mar. 2-5, 1992, also discussed in the '424 patent. The fibers were suspended downwardly and highly turbulent flow of water in alternate directions, was essential.
[0033] It is evident that the disclosure in either the Yamamoto et al or the Chiemchaisri et al reference indicated that the flow of air across the surfaces of the suspended fibers did little or nothing to inhibit the attachment of micro-organisms from the substrate..
SUMMARY OF THE INVENTION
[0034] It has been discovered that bubbles of a fiber-cleansing gas (“scrubbing gas”) flowing parallel to fibers in a vertical skein are more effective than bubbles which are intercepted by arcuate fibers crossing the path of the rising bubbles. Bubbles of an oxygen-containing gas to promote growth of microbes unexpectedly fails to build-up growth of microbes on the surfaces of the fibers because the surfaces are “vertically air-scrubbed”. Deposits of animate and/or inanimate particles upon the surfaces of fibers are minimized when the restrictedly swayable fibers are kept awash in codirectionally rising bubbles which rise with sufficient velocity to exert a physical scrubbing force (momentum provides the energy) to keep the fibers substantially free of deleterious deposits. Thus, an unexpectedly high flux is maintained over a long period during which permeate is produced by outside-in flow through the fibers.
[0035] It has also been discovered that permeate may be efficiently withdrawn from a substrate for a surprisingly long period, in a single stage, essentially continuous filtration process, by mounting a pair of headers in vertically spaced apart relationship, one above another, within the substrate which directly contacts a multiplicity of long vertical fibers in a “gas-scrubbed assembly” comprising a skein and a gas-distribution means. The skein has a surface area which is at least >1 m 2 , and opposed spaced-apart ends of the fibers are secured in spaced-apart headers, so that the fibers, when deployed in the substrate, acquire a generally vertical profile therewithin and sway within the bubble zone defined by at least one column of bubbles. The length of fibers between opposed surfaces of headers from which they extend, is in a critical range from at least 0.1% (per cent) longer than the distance separating those opposed faces, but less than 5% longer. Usually the length of fibers is less than 2% longer, and most typically, less than 1% longer, so that sway of the fibers is confined within a vertical zone of movement, the periphery of which zone is defined by side-to-side movement of outer fibers in the skein; and, the majority of the fibers near the periphery move in a slightly larger zone than one defined by the projected area of one header upon the other. Though the distance between headers is fixed during operation, the distance is preferably adjustable to provide an optimum length of fibers, within the aforesaid ranges, between the headers. It has been found that for no known reason, fibers which are more than 5% but less than 10% longer than the fixed distance between the opposed faces of the headers of a skein, tend to shear off at the face; and those 10% longer tend to clump up in the bubble zone.
[0036] The terminal end portions of the fibers are secured non-contiguously in each header, that is, the surface of each fiber is sealingly separated from that of another adjacent fiber with cured potting resin. Preferably, for maximum utilization of space on a header, the fibers are deliberately set in a geometrically regular pattern. Typically permeate is withdrawn from the open ends of fibers which protrude from the permeate-discharging aft (upper) face of a header. The overall geometry of potted fibers is determined by a ‘fiber-setting form’ used to set individual fibers in an array. The skein operates in a substrate held in a reservoir at a pressure in the range from 1 atm to an elevated pressure up to about 10 atm in a pressurized vessel, without being confined within the shell of a module.
[0037] It is therefore a general object of this invention to provide a novel, economical and surprisingly trouble-free membrane device, for providing an alternative to both, a conventional module having plural individual arrays therewithin, and also to a frameless array of arcuate fibers; the novel device includes, (i) a vertical skein of a multiplicity of restrictedly swayable fibers, together having a surface area in the range from 1 m 2 to 1000 m 2 , preferably from 10 m 2 to 100 m 2 , secured only in spaced-apart headers; and (ii) a gas-scrubbing means which produces at least one column of bubbles engulfing the skein. A skein includes permeate pans disposed, preferably non-removably, within a substrate held in a reservoir of arbitrary proportions, the reservoir typically having a volume in excess of 100 L (liters), generally in excess of 1000 L. A fluid component is to be selectively removed from the substrate.
[0038] It is a specific object of this invention to provide a membrane device having hollow fibers for removing permeate from a substrate, comprising, a skein of a multiplicity of fibers restrictedly swayable in the substrate, the opposed terminal end portions of which fibers in spaced-apart relationship, are potted in a pair of headers, one upper and one lower, each adapted to be mounted in vertically spaced apart generally parallel relationship, one above the other, within the substrate; essentially all the ends of fibers in both headers are open so as to pass permeate through the headers; the fibers in a skein have a length in the range from at least 0.1% greater, but less than 5% greater than the direct distance between opposed faces of the upper and lower headers, so as to present the fibers, when they are deployed, in an essentially vertical configuration; permeate is collected in a collection means, such as a permeate pan; and, permeate is withdrawn through a ducting means including one or more conduits and appropriate valves.
[0039] It has also been discovered that skein fibers are maintained sufficiently free from particulate deposits with surprisingly little cleansing gas, so that the specific flux at equilibrium is maintained over a long period, typically from 50 hr to 1500 hr, because the skein is immersed so as to present a generally vertical profile, and, the skein is maintained awash in bubbles either continuously or intermittently generated by a gas-distribution means (“air-manifold”). The air-manifold is disposed adjacent the skein's lower header to generate a column of rising bubbles within which column the fibers are awash in bubbles. A bank of skeins is “gas-scrubbed” with plural air-tubes disposed between the lower headers of adjacent skeins, most preferably, also adjacent the outermost array of the first and last skeins, so that for “n” headers there are “n+1” air-manifolds. Each header is preferably in the shape of a rectangular parallelpiped, the upper and lower headers having the same transverse (y-axis) dimension, so that plural headers are longitudinally stackable (along the x-axis). Common longitudinally positioned linear air-tubes, or, individual, longitudinally spaced apart vertically rising air-tubes, service the bank, and one or more permeate tubes withdraw permeate.
[0040] It is therefore a general object of this invention to provide a gas-scrubbed assembly of fibers for liquid filtration, the assembly comprising, (a) bank of gas-scrubbed skeins of fibers which separate a desired permeate from a large body of multicomponent substrate having finely divided particulate matter in the range from 0.1 μm -44 μm dispersed therein, (b) each skein comprising at least fibers having upper and lower terminal portions potted spaced-apart, in upper and lower headers, respectively, the fibers being restrictedly swayable in a bubble zone, and (c) a shaped gas-distribution means adapted to provide a profusion of vertically ascending bubbles near the lower header, the length of the fibers being from at least 0.1% but less than 5% greater than the distance between the opposed faces of the headers. The gas-distribution means has through-passages therein through which gas is flowed at a flow rate which is proportional to the number of fibers. The flow rate is generally in the range from 0.47-14 cm 3 /sec per fiber (0.001-0.03 scfm/fiber) (standard ft 3 per minute per fiber), typically in the range from 1.4-4.2 cm 3 /sec/fiber (0.003 -0.009 scfm/fiber). The surface area of the fibers is not used to define the amount of air used because the air travels substantially vertically along the length of each fiber. The gas generates bubbles having an average diameter in the range from about 0.1 mm to about 25 mm, or even larger.
[0041] It is a specific object of this invention to provide the aforesaid novel gas-scrubbed assembly comprising, a bank of vertical skeins and a shaped gas-distribution means for use with the bank, in a substrate in which microorganisms grow, the assembly being used in combination with vertically adjustable spacer means for mounting the headers in vertically spaced apart relationship, and in open fluid communication with collection means for collecting the permeate; means for withdrawing the permeate; and, sufficient air is flowed through the shaped gas-distribution means to generate enough bubbles flowing upwardly through the skein, between and parallel to the fibers so as to keep the surfaces of the fibers substantially free from deposits of live microorganisms as well as small inanimate particles which may be present in the substrate.
[0042] It has still further been discovered that a system utilizing a bank of vertical skeins of fibers potted in headers vertically spaced-apart by spacer means, and deployed in a substrate containing particulate material, in combination with a proximately disposed gas-distribution means to minimize fouling of the membranes, may be operated to withdraw permeate under gravity alone, so that the cost of any pump to withdraw permeate is avoided, provided the net positive suction head corresponding to the vertical height between the level of substrate, and the location of withdrawal of permeate, provides the trans-membrane pressure differential under which the fibers function in the skein.
[0043] It is therefore a general object of this invention to provide the foregoing system in which opposed terminal end portions of skein fibers are essentially free from fiber-to-fiber contact after being potted in upper and lower headers kept vertically spaced-apart with spacer means, the skein being unconfined in a shell of a module and deployed in the substrate without the fibers being supported during operation except by the spacer means which support only the headers; the headers being mounted so that the fibers present a generally vertical profile yet are restrictedly swayable in a zone of confinement defined by rising bubbles; means for mounting each header in open fluid communication with collection means for collecting permeate, and, means for withdrawing the permeate; and, shaped gas-distribution means adapted to generate bubbles from micron-size to 25 mm in nominal diameter, most preferably in the size range from 1 mm to 20 mm, the bubbles flowing upwardly through and parallel to the fibers at a flow rate chosen from the range specified hereabove; whereby the fibers are scrubbed with bubbles and resist the attachment of growing microorganisms and any other particulate matter to the surfaces of the fibers, so as to maintain a desirable specific flux during operation.
[0044] Still further, a low cost process has been discovered for treating a multi-component substrate under pressure ranging from 1-10 atm in a pressurizable vessel, particularly for example, an aqueous stream containing finely divided inorganic matter such as silica, silicic acid, or, activated sludge, when the substrate is confined in a large tank or pond, by using a bank of vertical skeins each comprising restrictedly swayable unsupported fibers potted in headers in open fluid communication with a means for withdrawing permeate, in combination with a source of air which generates bubbles near the lower header.
[0045] It is therefore a general object of this invention to provide a process for maintaining relatively clean fiber surfaces in an array of a membrane device while separating a permeate from a substrate, the process comprising, submerging a skein of restrictedly swayable substantially vertical fibers within the substrate so that upper and lower headers of the skein are mounted one above the other with a multiplicity of fibers secured between said headers, the fibers having their opposed terminal portions in open fluid communication with permeate collecting means in fluid-tight connection with said headers; the fibers operating under a transmembrane pressure differential in the range from about 0.7 kPa (0.1 psi) to about 345 kPa (50 psi), and a length from at least 0.1% to about 2% greater than the direct distance between the opposed faces of upper and lower headers, so as to present, when the fibers are deployed, a generally vertical skein of fibers; maintaining an essentially constant flux substantially the same as the equilibrium flux initially obtained, indicating that the surfaces of the fibers are substantially free from further build-up of deposits once the equilibrium flux is attained; collecting the permeate; and, withdrawing the permeate.
[0046] It has still further been discovered that the foregoing process may be used in the operation of an anaerobic or aerobic biological reactor which has been retrofitted with the membrane device of this invention. The anaerobic reactor is a closed vessel and the scrubbing gas is a molecular oxygen-free gas, such as nitrogen.
[0047] It is therefore a general object of this invention to provide an aerobic biological reactor retrofitted with at least one gas-scrubbed bank of vertical skeins, each skein made with from 500 to 5000 fibers in the range from 1 m to 3 m long, in combination with a permeate collection means, and to provide a process for the reactor's operation without being encumbered by the numerous restrictions and limitations imposed by a secondary clarification system.
[0048] A novel composite header is provided for a bundle of hollow fiber membranes or “fibers”, the composite header comprising a molded, laminated body of arbitrary shape, having an upper lamina formed from a “fixing” (potting) material which is laminated to a lower lamina formed from a “fugitive” potting material. The terminal portions of the fibers are potted in the fugitive potting material when it is liquid, preferably forming a generally rectangular parallel-piped in which the open ends of the fibers (until potted) are embedded and plugged, keeping the fibers in closely spaced-apart substantially parallel relationship. The plugged ends of the fibers fail to protrude through the lower (aft) face of the lower lamina, while the remaining lengths of the fibers extend through the upper face of the lower lamina. The upper lamina extends for a height along the length of the fibers sufficient to maintain the fibers in the same spaced-apart relationship relative to one and another as their spaced-apart relationship in the lower portion. If desired, the composite header may include additional laminae, for example, a “cushioning” lamina overlying the fixing lamina, to cushion each fiber around its embedded outer circumference; and, a “gasketing” lamina to provide a suitable gasketing material against which the permeate collection means may be mounted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] The foregoing and additional objects and advantages of the invention will best be understood by reference to the following detailed description, accompanied by schematic illustrations of preferred embodiments of the invention, in which illustrations like reference numerals refer to like elements, and in which:
[0050] [0050]FIG. 1 is a graph in which the variation of flux is plotted as a function of time, showing three curves for three runs made with three different arrays, in each case, using the same amount of air, the identical membranes and the same membrane surface area. The results obtained by Yamamoto et al are plotted as curve 2 (under conditions modified to give them the benefit of doubt as to the experimental procedure employed, as explained below); the flux obtained using the gas-scrubbed assembly of the '424 patent is shown as curve 1 ; and the flux obtained using the gas-scrubbed assembly of this invention is shown as curve 3 .
[0051] [0051]FIG. 2 is a perspective exploded view schematically illustrating a membrane device comprising a skein of fibers, unsupported during operation of the device, with the ends of the fibers potted in a lower header, along with a permeate collection pan, and a permeate withdrawal conduit. By “unsupported” is meant ‘not supported except for spacer means to space the headers’.
[0052] [0052]FIG. 2A is an enlarged detail side elevational view of a side wall of a collection pan showing the profile of a header-retaining step atop the periphery of the pan.
[0053] [0053]FIG. 2B is a bottom plan view of the header showing a random pattern of open ends protruding from the aft face of a header when fibers are potted after they are stacked in rows and glued together before being potted.
[0054] [0054]FIG. 3 is a perspective view of a single array, schematically illustrated, of a row of substantially coplanarly disposed parallel fibers secured near their opposed terminal ends between spaced apart cards. Typically, multiple arrays are assembled before being sequentially potted.
[0055] [0055]FIG. 4 illustrates a side elevational view of a stack of arrays near one end where it is together, showing that the individual fibers (only the last fiber of each linear array is visible, the remaining fibers in the array being directly behind the last fiber) of each array are separated by the thickness of a strip with adhesive on it, as the stack is held vertically in potting liquid.
[0056] [0056]FIG. 5 is a perspective view schematically illustrating a skein with its integral finished header, its permeate collection pan, and twin air-tubes feeding an integral air distribution manifold potted in the header along an outer edge of the skein fibers.
[0057] [0057]FIG. 6 is a side elevational view of an integral finished header showing details of a permeate pan submerged in substrate, the walls of the header resting on the bottom of a reservoir, and multiple air-tubes feeding integral air distribution manifolds potted in the header along each outer edge of the skein fibers.
[0058] [0058]FIG. 7A is a perspective view schematically illustrating an air-manifold from which vertical air-tubes rise.
[0059] [0059]FIG. 7B is a perspective view schematically illustrating a tubular air-manifold having a transverse perforated portion, positioned by opposed terminal portions.
[0060] [0060]FIG. 8 is a perspective view of an integral finished header having plural skeins potted in a common header molded in an integral permeate collection means with air-tubes rising vertically through the header between adjacent skeins, and along the outer peripheries of the outer skeins.
[0061] [0061]FIG. 9 is a detail, not to scale, illustratively showing a gas distribution means discharging gas between arrays in a header, and optionally along the sides of the lower header.
[0062] [0062]FIG. 10 is a perspective view schematically illustrating a pair of skeins in a bank in which the upper headers are mounted by their ends on the vertical wall of a tank. The skeins in combination with a gas-distribution means form a “gas-scrubbing assembly” deployed within a substrate, with the fibers suspended essentially vertically in the substrate. Positioning the gas-distribution means between the lower headers (and optionally, on the outside of skein fibers) generate masses (or “columns”) of bubbles which rise vertically, codirectionally with the fibers, yet the bubbles scrub the outer surfaces of the fibers.
[0063] [0063]FIG. 11 is a perspective view of another embodiment of the scrubbing-assembly showing plural skeins (only a pair is shown) connected in a bank with gas-distribution means disposed between successive skeins, and, optionally, with additional gas-distribution means fore and aft the first and last skeins, respectively.
[0064] [0064]FIG. 12 is an elevational view schematically illustrating a bank of skeins mounted against the wall of a bioreactor, showing the convenience of having all piping connections outside the liquid.
[0065] [0065]FIG. 13 is a plan view of the bioreactor shown in FIG. 12 showing how multiple banks of skeins may be positioned around the circumference of the bioreactor to form a large permeate extraction zone while a clarification zone is formed in the central portion with the help of baffles.
[0066] [0066]FIG. 14 illustratively shows another embodiment of the skein in which the permeate tube is concentrically disposed within the air supply tube and both are potted, near their lower ends in the lower header. Ports in the lower end of the air supply tube provide air near the base of the skein fibres.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0067] The skein of this invention may be used in a liquid-liquid separation process of choice, and more generally, in various separation processes. The skein is specifically adapted for use in microfiltration processes used to remove large organic molecules, emulsified organic liquids and colloidal or suspended solids, usually from water. Typical applications are (i) in a membrane bioreactor, to produce permeate as purified water and recycle biomass; for (ii) tertiary filtration of wastewater to remove suspended solids and pathogenic bacteria; (iii) clarification of aqueous streams including filtration of surface water to produce drinking water (removal of colloids, long chain carboxylic acids and pathogens); (iv) separation of a permeable liquid component in biotechnology broths; (v) de-watering of metal hydroxide sludges; and, (vi) filtration of oily wastewater, inter alia.
[0068] The problem with using a conventional membrane module to selectively separate one fluid from another, particularly using the module in combination with a bioreactor, and the attendant costs of operating such a system, have been avoided. In those instances where an under-developed country or distressed community lacks the resources to provide membrane modules, the most preferred embodiment of this invention is adapted for use without any pumps. In those instances where a pump is conveniently used, a vacuum pump is unnecessary, adequate driving force being provided by a simple centrifugal pump incapable of inducing a vacuum of 75 cm Hg on the suction side.
[0069] The fibers used to form the skein may be formed of any conventional membrane material provided the fibers are flexible and have an average pore cross sectional diameter for microfilitration, namely in the range from about 1000 Å to 10000 Å. Preferred fibers operate with a transmembrane pressure differential in the range from 7 kPa (1 psi)-69 kPa (10 psi) and are used under ambient pressure with the permeate withdrawn under gravity. The fibers are chosen with a view to perform their desired function, and the dimensions of the skein are determined by the geometry of the headers and length of the fibers. It is unnecessary to confine a skein in a modular shell, and a skein is not.
[0070] Preferred fibers are made of organic polymers and ceramics, whether isotropic, or anisotropic, with a thin layer or “skin” on the outside surface of the fibers. Some fibers may be made from braided cotton covered with a porous natural rubber latex or a water-insoluble cellulosic polymeric material. Preferred organic polymers for fibers are polysulfones, poly(styrenes), including styrene-containing copolymers such as acrylonitrile-styrene, butadiene-styrene and styrene-vinylbenzylhalide copolymers, polycarbonates, cellulosic polymers, polypropylene, poly(vinyl chloride), poly(ethylene terephthalate), and the like disclosed in U.S. Pat. No. 4,230,463 the disclosure of which is incorporated by reference thereto as if fully set forth herein. Preferred ceramic fibers are made from alumina, by E. I. duPont deNemours Co. and disclosed in U.S. Pat. No. 4,069,157 .
[0071] Typically, there is no cross flow of substrate across the surface of the fibers in a “dead end” tank. If there is any flow of substrate through the skein in a dead end tank, the flow is due to aeration provided beneath the skein, or to such mechanical mixing as may be employed to maintain the solids in suspension. There is more flow through the skein in a tank into which substrate is being continuously flowed, but the velocity of fluid across the fibers is generally too insignificant to deter growing microorganisms from attaching themselves, or suspended particles, e.g. microscopic siliceous particles, from being deposited on the surfaces of the fibers.
[0072] For hollow fiber membranes, the outside diameter of a fiber is at least 20 μm and may be as large as about 3 mm, typically being in the range from about 0.1 mm to 2 mm. The larger the outside diameter the less desirable the ratio of surface area per unit volume of fiber. The wall thickness of a fiber is at least 5 μm and may be as much as 1.2 mm, typically being in the range from about 15% to about 60% of the outside diameter of the fiber, most preferably from 0.5 mm to 1.2 mm.
[0073] As in a '424 array, but unlike in a conventional module, the length of a fiber in a skein is essentially independent of the strength of the fiber, or its diameter, because the skein is buoyed both by bubbles and the substrate in which it is deployed. The length of fibers in the skein is preferably determined by the conditions under which the skein is to operate. Typically fibers range from 1 m to about 5 m long, depending upon the dimensions of the body of substrate (depth and width) in which the skein is deployed.
[0074] The fixing material to fix the fibers in a finished header is most preferably either a thermosetting or thermoplastic synthetic resinous material, optionally reinforced with glass fibers, boron or graphite fibers and the like. Thermoplastic materials may be crystalline, such as polyolefins, polyamides (nylon), polycarbonates and the like, semi-crystalline such as polyetherether ketone (PEEK), or substantially amorphous, such as poly(vinyl chloride) (PVC), polyurethane and the like. Thermosetting resins commonly include polyesters, polyacetals, polyethers, cast acrylates, thermosetting polyurethanes and epoxy resins. Most preferred as a “fixing” material (so termed because it fixes the locations of the fibers relative to each other) is one which when cured is substantially rigid in a thickness of about 2 cm, and referred to generically as a “plastic” because of its hardness. Such a plastic has a hardness in the range from about Shore D 50 to Rockwell R 110 and is selected from the group consisting of epoxy resins, phenolics, acrylics, polycarbonate, nylon, polystyrene, polypropylene and ultra-high molecular weight polyethylene (UHMW PE). Polyurethane such as is commercially available under the brand names Adiprene® from Uniroyal Chemical Company and Airthane® from Air Products, and commercially available epoxy resins such as Epon 828 are excellent fixing materials.
[0075] The number of fibers in an array is arbitrary, typically being in the range from about 1000 to about 10000 for commercial applications, and the preferred surface area for a skein is in the range from 10 m 2 to 100 m 2 .
[0076] The particular method of securing the fibers in each of the headers is not narrowly critical, the choice depending upon the materials of the header and the fiber, and the cost of using a method other than potting. However, it is essential that each of the fibers be secured in fluid-tight relationship within each header to avoid contamination of permeate. This is effected by potting the fibers essentially vertically, in closely-spaced relationship, either linearly in plural equally spaced apart rows across the face of a header in the x-y plane; or alternatively, randomly, in non-linear plural rows. In the latter, the fibers are displaced relative to one another in the lateral direction.
[0077] [0077]FIG. 1 presents the results of a comparison of three runs made, one using the teachings of Yamamoto in his '89 publication (curve 2 ), but using an aerator which introduced air from the side and directed it radially inwards, as is shown in Chiemchaisri et al. A second run (curve 1 ) uses the gas-scrubbed assembly of the '424 patent, and the third run (curve 3 ) uses the gas-scrubbed skein of this invention. The specific flux obtained with an assembly of an inverted parabolic array with an air distributor means (Yamamoto et al), as disclosed in Wat. Sci. Tech . Vol. 21, Brighton pp 43-54, 1989, and, the parabolic array by Cote et al in the '424 patent, are compared to the specific flux obtained with the vertical skein of this invention.
[0078] The comparison is for the three assemblies having fibers with nominal pore size 0.2 μm with essentially identical bores and surface area in 80 L tanks filled with the same activated sludge substrate. The differences between the stated experiment of Yamamoto et al, and that of the '424 patent are of record in the '424 patent, and the conditions of the comparison are incorporated by reference thereto as if fully set forth herein. The vertical skein used herein differs from the '424 skein only in the vertical configuration of the 280 fibers each of which was about 1% longer than the distance between the spaced apart headers during operation. The flow rate of air for the vertical skein is 1.4 m 3 /hr/m 2 using a coarse bubble diffuser.
[0079] It will be evident from FIG. 1 in which the specific flux, liters/meter 2 hr/kPa (conventionally written as (1 mh/kPa), is plotted as a function of operating time for the three assemblies, that the curve, identified as reference numeral 3 for the flux for the vertical skein, provides about the same specific flux as the parabolic skein, identified as reference numeral 1 . As can be seen, each specific flux reaches an equilibrium condition within less than 50 hr, but after about 250 hr, it is seen that the specific flux for the inverted parabolic array keeps declining but the other two assemblies reach an equilibrium.
[0080] Referring to FIG. 2 there is illustrated, in exploded view a portion of a membrane device referred to as a “vertical skein” 10 , comprising a lower header 11 of a pair of headers, the other upper header (not shown) being substantially identical; a collection pan 20 to collect the permeate; and, a permeate withdrawal conduit 30 . The header shown is a rectangular prism since this is the most convenient shape to make, if one is going to pot fibers 12 in a potting resin such as a polyurethane or an epoxy. Though the fibers 12 are not shown as close together as they would normally be, it is essential that the fibers are not in contact with each other but that they be spaced apart by the cured resin between them.
[0081] As illustrated, the open ends of the terminal portion 12 ′ of the fibers are in the same plane as the lower face. of the header 11 because the fibers are conventionally potted and the header sectioned to expose the open ends. A specific potting procedure in which the trough of a U-shaped bundle of fibers is potted, results in forming two headers. This procedure is described in the '424 patent (col 17, lines 44-61); however, even cutting the potted fibers with a thin, high-speed diamond blade, tends to damage the fibers and initiate the collapse of the circumferential wall. In another conventional method of potting fibers, described in U.S. Pat. No. 5,202,023, bundled fibers have their ends dipped in resin or paint to prevent potting resin penetration into the bores of the fibers during the potting process. The ends of the bundle are then placed in molds and uncured resin added to saturate the ends of the fiber bundle and fill the spaces between the individual fibers in the bundle and the flexible tubing in which the bundle is held. The cured molded ends are removed from the molds and the molded ends cut off (see, bridging cols 11 and 12). In each art method, sectioning the mold damages the embedded fibers.
[0082] Therefore a novel method is used to form a header 11 in the form of a rectangular prism. The method requires forming a composite header with two liquids. A first liquid fugitive material, when solidified (cured), forms a “fugitive lamina” of the composite header; a second liquid of non-fugitive fixing material forms a “fixing lamina”. By a “fugitive material” we refer to a material which is either (i) soluble in a medium in which the fibers and fixing material are not soluble, or (ii) fluidizable by virtue of having a melting point (if the material is crystalline) below that which might damage the fibers or fixing material; or, the material has a glass transition temperature Tg (if the material is non-crystalline), below that which might damage the fibers or material(s) forming the non-fugitive header; or (iii) both soluble and fluidizable.
[0083] The first liquid is poured around terminal portions of fibers, allowed to cool and solidify into a fugitive lamina; the fibers in the fugitive lamina are then again potted, this time by pouring the second liquid over the solid fugitive lamina.
[0084] In greater detail, the method for forming a finished header for skein fibers comprises,
[0085] forming a stack of at least two superimposed essentially coplanar and similar arrays, each array comprising a chosen number of fibers supported on a support means having a thickness corresponding to a desired lateral spacing between adjacent arrays;
[0086] holding the stack in a first liquid with terminal portions of the fibers submerged, until the liquid solidifies into a first shaped lamina, provided that the first liquid is unreactive with material of the fibers;
[0087] pouring a second liquid over the first shaped lamina to embed the fibers to a desired depth, and solidifying the second liquid to form a fixing lamina upon the first shaped lamina, the second liquid also being substantially unreactive with either the material of the fibers or that of the first shaped lamina;
[0088] whereby a composite header is formed in which terminal portions of the fibers are potted, preferably in a geometrically regular pattern, the composite header comprising a laminate of a fugitive lamina of fugitive material and a contiguous finished header of fixing lamina; and thereafter,
[0089] removing the first shaped lamina without removing a portion of the fixing lamina so as to leave the ends of the fibers open and protruding from the aft face of the header, the open ends having circular cross-section.
[0090] The step-wise procedure for forming an array “A” with the novel header is described with respect to an array illustrated in FIG. 3, as follows:
[0091] A desired number of fibers 12 are each cut to about the same length with a sharp blade so as to leave both opposed ends of each fiber with an essentially circular cross-section. The fibers are coplanarly disposed side-by-side in a linear array on a planar support means such as strips or cards 15 and 16 . Preferably the strips are coated with an adhesive, e.g. a commercially available polyethylene hot-melt adhesive, so that the fibers are glued to the strips and opposed terminal portions 12 ″ respectively of the fibers, extend beyond the strips. Intermediate portions 12 ′ of the fibers are thus secured on the strips. Alternatively, the strips may be grooved with parallel spaced-apart grooves which snugly accommodate the fibers. The strips may be flexible or rigid. If flexible, strips with fibers adhered thereto, are in turn, also adhered to each other successively so as to form a progressively stiffer stack for a header having a desired geometry of potted fibers. To avoid gluing the strips, a regular pattern of linear rows may be obtained by securing multiple arrays on rigid strips in a stack, with rubber bands 18 or other clamping means. The terminal portions 12 ″ are thus held in spaced-apart relationship, with the center to center distance of adjacent fibers preferably in the range from 1.2 (1.2d) to about 5 times (5d) the outside diameter ‘d’ of a fiber. Spacing the fibers further apart wastes space and spacing them closer increases the risk of fiber-to-fiber contact near the terminal end portions when the ends are potted. Preferred center-to-center spacing is from about 1.5d to 2d. The thickness of a strip and/or adhesive is sufficient to ensure that the fibers are kept spaced apart. Preferably, the thickness is about the same as, or relatively smaller than the outside diameter of a fiber, preferably from about 0.5d to 1d thick which becomes the spacing between adjacent outside surfaces of fibers in successive linear arrays.
[0092] Having formed a first array, a second array (not shown because it would appear essentially identical to the first) is prepared in a manner analogous to the first, strip 15 of the second array is overlaid upon the intermediate portions 12 ′ on strip 15 of the first array, the strip 15 of the second array resting on the upper surfaces of the fibers secured in strip 15 of the first array. Similarly, strip 16 of the second array is overlaid upon the intermediate portions 12 ′ on strip 16 of the first array.
[0093] A third array (essentially identical to the first and second) is prepared in a manner analogous to the first, and then overlaid upon the second, with the strips of the third array resting on the upper surfaces of the fibers of the second array.
[0094] Additional arrays are overlaid until the desired number of arrays are stacked in rows forming a stack of arrays with the adhesive-coated strips forming the spacing means between successive rows of fibers. The stack of arrays on strips is then held vertically to present the lower portion of the stack to be potted first.
[0095] Referring to FIG. 4, there is schematically illustrated a rectangular potting pan 17 the length and width dimensions of which correspond substantially to the longitudinal (x-axis) and transverse (y-axis) dimensions respectively, of the desired header. The lower stack is submerged in a first liquid which rises to a level indicated by L1, in the pan 17 . Most preferred is a liquid wax, preferably a water-soluble wax having a melting point lower than 75° C., such as a polyethylene glycol (PEG) wax.
[0096] The depth to which the first liquid is poured will depend upon whether the strips 15 are to be removed from, or left in the finished header.
[0097] A. First illustrated is the potting of skein fibers in upper and lower headers from which the strips will be removed.
[0098] (1) A first shaped lamina having a thickness L1 (corresponding to the depth to which the first liquid was poured) is formed to provide a fugitive lamina from about 5-10 cm thick. The depth of the first liquid is sufficient to ensure that both the intermediate portions 12 ′ on the strips and terminal portions 12 ″ will be held spaced apart when the first liquid solidifies and plugs all the fibers.
[0099] (2) The second liquid, a curable, water-insoluble liquid potting resin, or reactive components thereof, is poured over the surface of the fugitive lamina to surround the fibers, until the second liquid rises to a level L2. It is solidified to form the fixing lamina (which will be the finished header) having a thickness measured from the level L1 to the level L2 (the thickness is written “L1-L2”). The thickness L1-L2 of the fixing lamina, typically from about 1 cm to about 5 cm, is sufficient to maintain the relative positions of the vertical fibers. A first composite header is. thus formed having the combined thicknesses of the fugitive and fixing laminae.
[0100] (3) In a manner analogous to that described immediately hereinabove, a stack is potted in a second composite header.
[0101] (4) The composite headers are demolded from their potting pans and hot air blown over them to melt the fugitive laminae, leaving only the finished headers, each having a thickness L1-L2. The fugitive material such as the PEG wax, is then reused. Alternatively, a water-soluble fugitive material may be placed in hot water to dissolve the wax, and the material recovered from its water solution.
[0102] (5) The adhered strips and terminal portions of the fibers which were embedded within the fugitive lamina are left protruding from the permeate-discharging aft faces of the headers with the ends of the fibers being not only open, but essentially circular in cross section. The fibers may now be cut above the strips to discard them and the terminal portions of the fibers adhered to them, yet maintaining the circular open ends. The packing density of fibers, that is, the number of fibers per unit area of header preferably ranges from 4 to 50 fibers/cm 2 depending upon the diameters of the fibers.
[0103] B. illustrated second is the potting of skein fibers in upper and lower headers from which the strips will not be removed, to avoid the step of cutting the fibers.
[0104] (1) The first liquid is poured to a level L1′ below the cards, to a depth in the range from about 1-2.5 cm, and solidified, forming fugitive lamina L1′.
[0105] (2) The second liquid is then poured over the fugitive lamina to depth L2 and solidified, forming a composite header with a fixing lamina having a thickness L1-L2.
[0106] (3) The composite header is demolded and the fugitive lamina removed, leaving the terminal portions 12 ″ protruding from the aft face of the finished header, which aft face is formed at what had been the level L1′. The finished header having a thickness L1′-L2 embeds the strips 15 (along with the rubber bands 18 , if used).
[0107] C. Illustrated third is the potting of skein fibers to form a finished headers with a cushioning lamina embedding the fibers on the opposed (fore) faces of the headers from which the strips will be removed.
[0108] The restricted swayability of the fibers generates some intermittent ‘snapping’ motion of the fibers. This motion has been found to break the potted fibers around their circumferences, at the interface of the fore face and substrate. The hardness of the fixing material which forms a “fixing lamina” was found to initiate excessive shearing forces at the circumference of the fiber. The deleterious effects of such forces is minimized by providing a cushioning lamina of material softer than the fixing lamina. Such a cushioning lamina is formed integrally with the fixing lamina, by pouring cushioning liquid (so termed for its function when cured) over the fixing lamina to a depth L3 as shown in FIG. 4, which depth is sufficient to provide enough ‘give’ around the circumferences of the fibers to minimize the risk of shearing. Such cushioning liquid, when cured is rubbery, having a hardness in the range from about Shore A 30 to Shore D 45, and is preferably a polyurethane or silicone or other rubbery material which will adhere to the fixing lamina. Upon removal of the fugitive lamina, the finished header thus formed has the combined thicknesses of the fixing lamina and the cushioning lamina, namely L1-L3 when the strips 15 are cut away,
[0109] D. Illustrated fourth is the formation a finished header with a gasketing lamina embedding the fibers on the header's aft face, and a cushioning lamina embedding the fibers on the header's fore face; the strips are to be removed.
[0110] Whichever finished header is made, it is preferably fitted into a permeate pan 20 as illustrated in FIG. 2 with a peripheral gasket. It has been found that it is easier to seal the pan against a gasketing lamina, than against a peripheral narrow gasket. A relatively soft gasketing material having a hardness in the range from Shore A 40 to Shore D 45, is desirable to form a gasketing lamina integrally with the aft face of the finished header. In the embodiment in which the strips are cut away, the fugitive lamina is formed as before, and a gasketing liquid (so termed because it forms the gasket when cured) is poured over the surface of the fugitive lamina to a depth L4. The gasketing liquid is then cured. Upon removal of the fugitive lamina, when the strips 15 are cut away, the finished header thus formed has the combined thicknesses of the gasketing lamina (L1-L4, the fixing lamina (L4-L2) and the cushioning lamina (L2-L3), namely an overall L1-L3.
[0111] In another embodiment, to avoid securing the pan to the header with a gasketing means, and, to avoid positioning one or more gas-distribution manifolds in an optimum location near the base of the skein fibers after a skein is made, the manifolds are formed integrally with a header. Referring to FIG. 5 there is illustrated in perspective view an “integral single skein” referred to generally by reference numeral 100 . The integral single skein is so termed because it includes an integral finished header 101 and permeate pan 102 . The pan 102 is provided with a permeate withdrawal nipple 106 , and fitted with vertical air-tubes 103 which are to be embedded in the finished header. The air-tubes are preferably manifolded on either side of the skein fibers, to feeder air-tubes 104 and 105 which are snugly inserted through grommets in the walls of the pan. The permeate nipple 106 is then plugged, and a stack of arrays is held vertically in the pan in which a fugitive lamina is formed embedding both the ends of the fibers and the lower portion of the vertical air-tubes 103 . A fixing lamina is then formed over the fugitive lamina, embedding the fibers to form a fixing lamina through which protrude the open ends of the air-tubes 103 . The fugitive lamina is then melted and withdrawn through the nipple 106 . In operation, permeate collects in the permeate pan and is withdrawn through nipple 106 .
[0112] [0112]FIG. 6 illustrates a cross-section of an integral single skein 110 with another integral finished header 101 having a thickness L1-L2, but without a cushioning lamina, formed in a procedure similar to that described hereinabove. A permeate pan 120 with outwardly flared sides 120 ′ and transversely spaced-apart through-apertures therein, is prefabricated between side walls 111 and 112 so the pan is spaced above the bottom of the reservoir.
[0113] A pair of air-manifolds 107 such as shown in FIGS. 7A or 7 B, is positioned and held in mirror-image relationship with each other adjacent the permeate pan 120 , with the vertical air-tubes 103 protruding through the apertures in sides 120 ′, and the ends 104 and 105 protrude from through-passages in the vertical walls on either side of the permeate pan. Permeate withdrawal nipple 106 (FIG. 6) is first temporarily plugged. The stack of strips 15 is positioned between air-tubes 103 , vertically in the pan 120 which is filled to level L1 to form a fugitive lamina, the level being just beneath the lower edges of the strips 15 which will not be removed. When solidified, the fugitive lamina embeds the terminal portions of the fibers 12 and also fills permeate tube 106 . Then the second liquid is poured over the upper surface of the fugitive lamina until the liquid covers the strips 15 but leaves the upper ends of the air-tubes 103 open. The second liquid is then cured to form the fixing lamina of the composite header which is then heated to remove the fugitive material through the permeate nozzle 106 after it is unplugged.
[0114] [0114]FIG. 7A schematically shows in perspective view, an air-manifold 107 having vertical air-tubes 103 rising from a transverse header-tube which has longitudinally projecting feeder air-tubes 104 and 105 . The bore of the air-tubes which may be either “fine bubble diffusers”, or “coarse bubble diffusers”, or “aerators”, is chosen to provide bubbles of the desired diameter under operating conditions, the bore typically being in the range from 0.1 mm to 5 mm. Bubbles of smaller diameter are preferably provided with a perforated transverse tube 103 ′ of an air-manifold 107 ′ having feeder air-tubes 104 ′ and 105 ′, illustrated in FIG. 7B. In each case, the bubbles function as a mechanical brush.
[0115] The skein fibers for the upper header of the skein are potted in a manner analogous to that described above in a similar permeate pan to form a finished header, except that no air manifolds are inserted.
[0116] Referring to FIG. 8 there is schematically illustrated, in a cross-sectional perspective view, an embodiment in which a bank of two skeins is potted in a single integral finished header enclosure, referred to generally by reference numeral 120 b . The term “header enclosure” is used because its side walls 121 and 122 , and end walls (not shown) enclose a plenum in which air is introduced. Instead of a permeate pan, permeate is collected from a permeate manifold which serves both skeins. Another similar upper enclosure 120 u (not shown), except that it is a flat-bottomed channel-shaped pan (inverted for use as the upper header) with no air-tubes molded in it, has the opposed terminal portions of all the skein fibers potted in the pan. For operation, both the lower and upper enclosures 120 b and 120 u , with their skein fibers are lowered into a reservoir of the substrate to be filtered. The side walls 121 and 122 need not rest on the bottom of the reservoir, but may be mounted on a side wall of the reservoir.
[0117] The side walls 121 and 122 and end walls are part of an integrally molded assembly having a platform 123 connecting the walls, and there are aligned multiple risers 124 molded into the platform. The risers resemble an inverted test-tube, the diameter of which need only be large enough to have an air-tube 127 inserted through the top 125 of the inverted test-tube. As illustrated, it is preferred to have “n+1” rows of air-tubes for “n” stacks of arrays to be potted. Crenelated platform 123 includes risers 124 between which lie channels 128 and 129 . Channels 128 and 129 are each wide enough to accept a stack of arrays of fibers 12 , and the risers are wide enough to have air-tubes 127 of sufficient length inserted therethrough so that the upper open ends 133 of the air-tubes protrude from the upper surface of the fixing material 101 . The lower ends 134 of the air-tubes are sectioned at an angle to minimize plugging, and positioned above the surface S of the substrate. The channel 129 is formed so as to provide a permeate withdrawal tube 126 integrally formed with the platform 123 . Side wall 122 is provided with an air-nipple 130 through which air is introduced into the plenum formed by the walls of the enclosure 120 b , and the surface S of substrate under the platform 123 . Each stack is potted as described in relation to FIG. 6 above, most preferably by forming a composite header of fugitive PEG wax and epoxy resin around the stacks of arrays positioned between the rows of risers 124 , making sure the open ends of the air-tubes are above the epoxy fixing material, and melting out the wax through the permeate withdrawal tube 126 . When air is introduced into the enclosure the air will be distributed through the air-tubes between and around the skeins.
[0118] Referring to FIG. 9 there is shown a schematic illustration of a skein having upper and lower headers 41 u and 41 b respectively, and in each, the protruding upper and lower ends 12 u ″ and 12 b ″ are evidence that the face of the header was not cut to expose the fibers. The height of the contiguous inter-mediate portions 12 u ′ and 12 b ′ respectively, corresponds to the cured depth of the fixing material.
[0119] It will now be evident that the essential feature of the foregoing potting method is that a fugitive lamina is formed which embeds the openings of the terminal portions of the fibers before their contiguous intermediate portions 12 u ′ and 12 u ″ and 12 b ′ and 12 b ″ respectively are fixed in a fixing lamina of the header. An alternative choice of materials is the use of a fugitive potting compound which is soluble in a non-aqueous liquid in which the fixing material is not soluble. Still another choice is to use a water-insoluble fugitive material which is also insoluble in non-aqueous liquids typically used as solvents, but which fugitive material has a lower melting point than the final potting material which may or may not be water-soluble.
[0120] The fugitive material is inert relative to both, the material of the fibers as well as the final potting material to be cast, and the fugitive material and fixing material are mutually insoluble. Preferably the fugitive material forms a substantially smooth-surfaced solid, but it is critical that the fugitive material be at least partially cured, sufficiently to maintain the shape of the header, and remain a solid above a temperature at which the fixing material is introduced into the header mold. The fugitive lamina is essentially inert and insoluble in the final potting material, so that the fugitive lamina is removably adhered to the fixing lamina.
[0121] The demolded header is either heated or solvent extracted to remove the fugitive lamina. Typically, the fixing material is cured to a firm solid mass at a first curing temperature no higher than the melting point or Tg of the fugitive lamina, and preferably at a temperature lower than about 60° C.; the firm solid is then post-cured at a temperature high enough to melt the fugitive material but not high enough to adversely affect the curing of the fixing material or the properties of the fibers. The fugitive material is removed as described hereinafter, the method of removal depending upon the fugitive material and the curing temperature of the final potting material used.
[0122] Since, during operation, a high flux is normally maintained if cleansing air contacts substantially all the fibers, it will be evident that when it is desirable to have a skein having a cross-section which is other than generally rectangular, for example elliptical or circular, or having a geometrically irregular periphery, and it is desired to have a large number of skein fibers, it will be evident that the procedure for stacking consecutive peripheral arrays described above will be modified. Further, the transverse central air-tube 52 (see FIG. 9) is found to be less effective in skeins of non-rectangular cross-section than a vertical air-tube which discharges air radially along its vertical length and which vertical air-tube concurrently serves as the spacing means. Such skeins with a generally circular or elliptical cross-section with vertical air-tubes are less preferred to form a bank, but provide a more efficient use of available space in a reservoir than a rectangular skein.
[0123] Referring further to FIG. 2, the header 11 has front and rear walls defined by vertical (z-axis) edges 11 ′ and longitudinal (x-axis) edges 13 ′; side walls defined by edges 11 ′ and transverse (y-axis) edges 13 ″; and a base 13 defined by edges 13 ′ and 13 ″.
[0124] The collection pan 20 is sized to snugly accommodate the base 13 above a permeate collection zone within the pan. This is conveniently done by forming a rectangular pan having a base 23 of substantially the same length and width dimensions as the base 13 . The periphery of the pan 20 is provided with a peripheral step as shown in FIG. 2A, in which the wall 20 ′ of the pan terminates in a step section 22 , having a substantially horizontal shoulder 22 ″ and a vertical retaining wall 22 ′.
[0125] [0125]FIG. 2B is a bottom plan view of the lower face of header 13 showing the open ends of the fibers 12 ′ prevented from touching each other by potting resin. The geometrical distribution of fibers provides a regular peripheral boundary 14 (shown in dotted outline) which bounds the peripheries of the open ends of the outermost fibers.
[0126] Permeate flows from the open ends of the fibers onto the base 23 of the pan 20 , and flows out of the collection zone through a permeate withdrawal conduit 30 which may be placed in the bottom of the pan in open flow communication with the inner portion of the pan. When the skein is backwashed, back-washing fluid flows through the fibers and into the substrate. If desired, the withdrawal conduit may be positioned in the side of the pan as illustrated by conduit 30 ′. Whether operating under gravity alone, or with a pump to provide additional suction, it will be apparent that a fluid-tight seal is necessary between the periphery of the header 11 and the peripheral step 22 of the pan 20 . Such a seal is obtained by using any conventional means such as a suitable sealing gasket or sealing compound, typically a polyurethane or silicone resin, between the lower periphery of the header 11 and the step 22 . As illustrated in FIG. 2, permeate drains downward, but it could also be withdrawn from upper permeate port 45 u in the upper permeate pan 43 u (see FIG. 9).
[0127] It will now be evident that a header with a circular periphery may be constructed, if desired. Headers with geometries having still other peripheries (for example, an ellipse) may be constructed in an analogous manner, if desired, but rectangular headers are most preferred for ease of construction with multiple linear arrays.
[0128] Referring to FIGS. 9 and 2A, six rows of fibers 12 are shown on either side of a gas distribution line 52 which traverses the length of the rows along the base of the fibers. The potted terminal end portions 12 b ″ open into permeate pan 43 b . Because portions 12 u ′ and 12 b ′ of individual fibers 12 are potted, and the fibers 12 are preferably from 1% to 2% longer than the fixed distance between upper and lower headers 41 u and 41 b , the fibers between opposed headers are generally parallel to one another, but are particularly parallel near each header. Also held parallel are the terminal end portions 12 u ″ and 12 b ″ of the fibers which protrude from the headers with their open ends exposed. The fibers protrude below the lower face of the bottom header 41 b , and above the upper face of the upper header 41 u . The choice of fiber spacing in the header will determine packing density of the fibers near the headers, but fiber spacing is not a substantial consideration because spacing does not substantially affect specific flux during operation. It will be evident however, that the more fibers, the more tightly packed they will be, giving more surface area.
[0129] Since the length of fibers tends to change while in service, the extent of the change depending upon the particular composition of the fibers, and the spacing between the upper and lower headers is critical, it is desirable to mount the headers so that one is adjustable in the vertical direction relative to the other, as indicated by the arrow V. This is conveniently done by attaching the pan 43 u to a plate 19 having vertically spaced apart through-passages 34 through which a threaded stud 35 is inserted and secured with a nut 36 . Threaded stud 35 is in a fixed mounting block 37 .
[0130] The density of fibers in a header is preferably chosen to provide the maximum membrane surface area per unit volume of substrate without adversely affecting the circulation of substrate through the skein. A gas-distribution means 52 such as a perforated air-tube, provides air within the skein so that bubbles of gas (air) rise upwards while clinging to the outer surfaces of the fibers, thus efficiently scrubbing them. If desired, additional air-tubes 52 ′ may be placed on either side of the skein near the lower header 41 b , as illustrated in phantom outline, to provide additional air-scrubbing power. Whether the permeate is withdrawn from the upper header through port 45 u or the lower header through port 45 b , or both, depends upon the particular application, but in all instances, the fibers have a substantially vertical orientation.
[0131] The vertical skein is deployed in a substrate to present a generally vertical profile, but has no structural shape. Such shape as it does have changes continuously, the degree of change depending upon the flexibility of the fibers, their lengths, the overall dimensions of the skein, and the degree of movement imparted to the fibers by the substrate and also by the oxygen-containing gas from the gas-distribution means.
[0132] Referring to FIG. 10 there is illustrated a typical assembly referred to as a “wall-mounted bank” which includes at least two side-by-side skeins, indicated generally by reference numerals 40 and 40 ′ with their fibers 42 and 42 ′; fibers 42 are potted in upper and lower headers 41 u and 41 b respectively; and fibers 42 ′ in headers 41 u ′ and 41 b ′; headers 41 u and 41 b are fitted with permeate collecting means 46 u and 46 b respectively; headers 41 u ′ and 41 b ′ are fitted with permeate collecting means 46 u ′ and 46 b ′ respectively; and, the skeins share a common gas-distribution means 50 . A “bank” of skeins is typically used to retrofit a large, deep tank from which permeate is to be withdrawn using a vacuum pump. In a large reservoir, several banks of skeins may be used in side-by-side relationship within a tank. Each skein includes multiple rows (only one row is shown) of fibers 42 and 42 ′ in upper headers 41 u and 41 u ′, and lower headers 41 b and 41 b ′ respectively, and arms 51 and 51 ′ of gas-distribution means 50 are disposed between the lower headers 41 b and 41 b ′, near their bases. The upper headers 44 u and 44 u ′ are mounted by one of their ends to a vertical interior surface of the wall W of a tank, with mounting brackets 53 and 53 ′ and suitable fastening means such as bolts 54 . The wall W thus functions as a spacer means which fixes the distance between the upper and lower headers.
[0133] Each upper header is provided with a permeate collection pan 43 u and 43 u ′, respectively, connected to permeate withdrawal conduits 45 u and 45 u ′ and manifolded to permeate manifold 46 u through which permeate being filtered into the collection pans is continuously withdrawn. Each header is sealingly bonded around its periphery, to the periphery of each collection pan.
[0134] The skein fibers (only one array of which is shown for clarity) shown in this perspective view have an elongated rectangular parallelpiped shape the sides of which are irregularly shaped when immersed in a substrate, because of the random side-to-side displacement of fibers as they sway. An elongated rectangular parallelpiped shape is preferred since it permits a dense packing of fibers, yet results in excellent scrubbing of the surfaces of the fibers with bubbles. With this shape, a skein may be formed with from 10 to 50 arrays of fibers across the longitudinal width ‘w’ of the headers 41 u , 41 b , and 41 u ′, 41 b ′ with each array having fibers extending along the transverse length ‘1’ of each header. Air-tubes on either side of a skein effectively cleanse the fibers if there are less than about 30 arrays between the air-tubes. A skein having more than 30 arrays is preferably also centrally aerated as illustrated by the air-tube 52 in FIG. 9.
[0135] Thus, if there are about 100 fibers closely spaced-apart along the transverse length ‘1’ of an array, and there are 25 arrays in a skein in a header of longitudinal width ‘w’, then the opposed terminal end portions of 2500 fibers are potted in headers 41 u and 41 b . The open ends of all fibers in headers 41 b and 41 b ′ point downwards into collection zones in collection pans 43 b and 43 b ′ respectively, and those of all fibers in headers 41 u and 41 u ′ point upwards into collection zones in collection pans 43 u and 43 u ′ respectively. Withdrawal conduits 45 u and 45 u ′ are manifolded to permeate manifold 46 u through which permeate collecting in the upper collection pans 43 u and 43 u ′ is typically continuously withdrawn. If the permeate flow is high enough, it may also be withdrawn from the collection pans 43 b and 43 b ′ through withdrawal conduits 45 b and 45 b ′ which are manifolded to permeate manifold 46 b . When permeate is withdrawn in the same plane as the permeate withdrawal conduits 45 u , 45 u ′ and manifold 46 u , and the transmembrane pressure differential of the fibers is in the range from 35-75 kPa (5-10 psi), manifold 46 u may be connected to the suction side of a centrifugal pump which will provide adequate NPSH.
[0136] In general, the permeate is withdrawn from both the upper and lower headers, until the flux declines to so low a level as to require that the fibers be backwashed. The skeins may be backwashed by introducing a backwashing fluid through the upper permeate collection manifold 46 u , and removing the fluid through the lower manifold 46 b . Typically, from 3 to 30 skeins may be coupled together for internal fluid communication with one and another through the headers, permeate withdrawal means and the fibers; and, for external fluid communication with one another through an air manifold. Since the permeate withdrawal means is also used for backflushing it is generally referred to as a ‘liquid circulation means’, and as a permeate withdrawal means only when it is used to withdraw permeate.
[0137] When deployed in a substrate containing suspended and dissolved organic and inorganic matter, most fibers of organic polymers remain buoyant in a vertical position. The fibers in the skein are floatingly buoyed in the substrate with the ends of the fibers anchored in the headers. This is because (i) the permeate is essentially pure water which has a specific gravity less than that of the substrate, and most polymers from which the fibers are formed also have a specific gravity less than 1, and, (ii) the fibers are buoyed by bubbles which contact them. Fibers made from ceramic, or, glass fibers are heavier than water.
[0138] Adjacent the skeins, an air-distribution manifold 50 is disposed below the base of the bundle of fibers, preferably below the horizontal plane through the horizontal center-lines of the headers. The manifold 50 is preferably split into two foraminous arms 51 and 51 ′ adjacent the bases of headers 41 b and 41 b ′ respectively, so that when air is discharged through holes in each portion 51 and 51 ′, columns of bubbles rise adjacent the ends of the fibers and thereafter flow along the fibers through the skeins. If desired, additional portions (not shown) may be used adjacent the bases of the lower headers but located on the outside of each, so as to provide additional columns of air along the outer surfaces of the fibers.
[0139] The type of gas (air) manifold is not narrowly critical provided it delivers bubbles in a preferred size range from about 1 mm to 25 mm, measured within a distance of from 1 cm to 50 cm from the through-passages generating them. If desired, each portion 51 and 51 ′ may be embedded in the upper surface of each header, and the fibers potted around them, making sure the air-passages in the portions 51 and 51 ′ are not plugged with potting compound. If desired, additional arms of air-tubes may be disposed on each side of each lower header, so that fibers from each header are scrubbed by columns of air rising from either transverse side.
[0140] The air may be provided continuously or intermittently, better results generally being obtained with continuous air flow. The amount of air provided depends upon the type of substrate, the requirements of the type of microorganisms, if any, and the susceptibility of the surfaces of the fibers to be plugged, there always being sufficient air to produce desired growth of the microorganisms when operated in a substrate where maintaining such growth is essential.
[0141] Referring to FIG. 11, there is schematically illustrated another embodiment of an assembly, referred to as a “stand-alone bank” of skeins, two of which are referenced by numeral 60 . The bank is referred to as being a “stand-alone” because the spacer means between headers is supplied with the skeins, usually because mounting the skeins against the wall of a reservoir is less effective than placing the bank in spaced-apart relationship from a wall. In other respects, the bank 60 is analogous to the wall-mounted bank illustrated in FIG. 10.
[0142] Each bank 60 with fibers 62 (only a single row of the multiple, regularly spaced apart generally vertical arrays is shown for the sake of clarity) is deployed between upper and lower headers 61 u and 61 b in a substrate ‘S’. The lower headers rest on the floor of the reservoir. The upper headers are secured to rigid vertical air tubes 71 and 71 ′ through which air is introduced into a tubular air manifold identified generally by reference numeral 70 . The manifold 70 includes (i) the vertical tubular arms 71 and 71 ′; (ii) a lower transverse arm 72 which is perforated along the length of the lower header 61 b and secured there-to; the arm 72 communicates with longitudinal tubular arm 73 , and optionally another longitudinal arm 73 ′ (not shown) in mirror-image relationship with arm 73 on the far side of the headers; and (iii) transverse-arms 74 and 74 ′ in open communication with 72 and 73 ; arms 74 and 74 ′ are perforated along the visible transverse faces of the headers 61 b an 61 b ′, and 74 and 74 ′ may communicate with tubular arm 73 ′ if it is provided. The vertical air-tubes 71 and 71 ′ conveniently provide the additional function of a spacer means between the first upper header and the first lower header, and because the remaining headers in the bank are also similarly (not shown) interconnected by rigid conduits, the headers are maintained in vertically and transversely spaced-apart relationship. Since all arms of the air manifold are in open communication with the air supply, it is evident that uniform distribution of air is facilitated.
[0143] As before, headers 61 u and 61 u ′ are each secured in fluid-tight relationship with collection zones in collection pans 63 u and 63 u ′ respectively, and each pan has withdrawal conduits 65 u and 65 u ′ which are manifolded to longitudinal liquid conduits 81 and 81 ′. Analogously, headers 61 b and 61 b ′ are each secured in fluid-tight relationship with collection zones in collection pans 63 b and 63 b ′ respectively, and each pan has withdrawal conduits 65 b and 65 b ′ which are manifolded to longitudinal conduits 82 and 82 ′. As illustrated, withdrawal conduits are shown for both the upper and the lower headers, and both fore and aft the headers. In many instances, permeate is withdrawn from only an upper manifold which is provided on only one side of the upper headers. A lower manifold is provided for backwashing. Backwashing fluid is typically flowed through the upper manifold, through the fibers and into the lower manifold. The additional manifolds on the aft ends of the upper and lower headers not only provides more uniform distribution of backwashing fluid but support for the interconnected headers. It will be evident that, absent the aft interconnecting upper conduit 81 ′, an upper header such as 61 u will require to be spaced from its lower header by some other interconnection to header 61 u ′ or by a spacer strut between headers 61 u and 61 b.
[0144] In the best mode illustrated, each upper header is provided with rigid PVC tubular nipples adapted to be coupled with fittings such as ells and tees to the upper conduits 81 and 81 ′ respectively. Analogously, each lower header is connected to lower conduits 82 and 82 ′ (not shown) and/or spacer struts are provided to provide additional rigidity, depending upon the number of headers to be interconnected. Permeate is withdrawn through an upper conduit, and all piping connections, including the air connection, are made above the liquid level in the reservoir.
[0145] The length of fibers (between headers) in a skein is generally chosen to obtain efficient use of an economical amount of air, so as to maintain optimum flux over a long period of time. Other considerations include the depth of the tank in which the bank is to be deployed, the positioning of the liquid and air manifolds, and the convection patterns within the tank, inter alia.
[0146] In another embodiment of the invention, a bioreactor is retrofitted with plural banks of skeins schematically illustrated in the elevational view shown in FIG. 12, and the plan view shown in FIG. 13. The clarifier tank is a large circular tank 90 provided with a vertical, circular outer baffle 91 , a vertical circular inner baffle 92 , and a bottom 93 which slopes towards the center (apex) for drainage of accumulating sludge. Alternatively, the baffles may be individual, closely spaced rectangular plates arranged in outer and inner circles, but continuous cylindrical baffles (shown) are preferred. Irrespective of which baffles are used, the baffles are located so that their bottom peripheries are located at a chosen vertical distance above the bottom. Feed is introduced through feed line 94 in the bottom of the tank 90 until the level of the substrate rises above the outer baffle 91 .
[0147] A bank 60 of plural skeins 10 , analogous to those in the bank depicted in FIG. 10, each of which skeins is illustrated in FIG. 9, is deployed against the periphery of the inner wall of the bioreactor with suitable mounting means in an outer annular permeate extraction zone 95 ′ (FIG. 13) formed between the circular outer baffle 91 and the wall of the tank 90 , at a depth sufficient to submerge the fibers. A clarification zone 91 ′ is defined between the outer circular baffle 91 and inner circular baffle 92 . The inner circular baffle 92 provides a vertical axial passage 92 ′ through which substrate is fed into the tank 90 . The skeins form a dense curtain of fibers in radially extending, generally planar vertical arrays as illustrated in FIG. 9, potted between upper and lower headers 41 u and 41 b . Permeate is withdrawn through manifold 46 u and air is introduced through air-manifold 80 , extending along the inner wall of the tank, and branching out with air-distribution arms between adjacent headers, including outer distribution arms 84 ′ on either side of each lower header 41 b at each end of the bank. The air manifold 80 is positioned between skeins in the permeate extraction zone 95 ′ in such a manner as to have bubbles contact essentially the entire surface of each fiber which is continuously awash with bubbles. Because the fibers are generally vertical, the air is in contact with the surfaces of the fibers longer than if they were arcuate, and the air is used most effectively to maintain a high flux for a longer period of time than would otherwise be maintained.
[0148] It will be evident that if the tank is at ground level, there will be insufficient liquid head to induce a desirable liquid head under gravity alone. Without an adequate siphoning effect, a centrifugal pump may be used to produce the necessary suction. Such a pump should be capable of running dry for a short period, and of maintaining a vacuum on the suction side of from cm (10″) -51 cm (20″) of Hg, or −35 kPa (−5 psi) to −70 kPa (−10 psi). Examples of such pumps rated at 18.9 L/min (5 gpm) @ 15″ Hg, are (i) flexible impeller centrifugal pumps, e.g. Jabsco #30510-2003; (ii) air operated diaphragm pumps, e.g. Wilden M2; (iii) progressing cavity pumps, e.g. Ramoy 3561; and (iv) hosepumps, e.g. Waukesha SP 25.
[0149] The skein may also be potted in a header which is not a rectangular prism, preferably in cylindrical upper and lower headers in which substantially concentric arrays of fibers are non-removably potted in cylindrical permeate pans, and the headers are spaced apart by a central gas tube which functions as both the spacer means and the gas-distribution means which is also potted in the headers. As before, the fibers are restrictedly swayable, but permeate is withdrawn from both upper and lower headers through a single permeate pan so that all connections for the skein, when it is vertically submerged, are from above. Permeate is preferably withdrawn from the lower permeate pan through a central permeate withdrawal tube which is centrally axially held within the central gas (air) tube. The concentric arrays are formed by wrapping successive sheets of flat arrays around the central air-tube, and gluing them together before they are potted. This configuration permits the use of more filtration surface area per unit volume of a reservoir, compared to skeins with rectangular prism headers, using the same diameter and length of fibers.
[0150] FIGS. 14 - 17 specifically illustrate preferred embodiments of the cylindrical vertical skein. Referring to FIG. 14 there is schematically illustrated, in cross-sectional elevational view a vertical cylindrical skein 210 resting on the floor F of a tank, the skein comprising a pair of similar upper and lower cylindrical end-caps 221 and 222 respectively, which serve as permeate collection pans. Bores 226 and 227 in the upper and lower end-caps have permeate withdrawal tubes 231 and 232 , respectively, connected in fluid-tight engagement therein. Permeate withdrawn through the tubes is combined in a permeate withdrawal manifold 230 . Each end-cap has a finished upper/lower header formed directly in it, upper header 223 being substantially identical to lower header 224 . Each header is formed by potting fibers 212 in a potting resin such as a polyurethane or an epoxy of sufficient stiffness to hold and seal the fibers under the conditions of use. A commercially available end-cap for poly (vinyl chloride) “PVC” pipe is most preferred; for large surface area skeins, larger headers are provided by commercially available glass fiber reinforced end-caps for cylindrical tanks. It is essential that the fibers are not in contact with each other, but spaced apart by cured resin. It is also essential that the cured resin adhere to and seal the lower portions 212 ′ of each of the fibers against leakage of fluid under operating conditions of the skein. Visual confirmation of a seal is afforded by the peripheries of the fibers being sealed at the upper (fore) and lower (aft) faces 223 u and 223 b respectively of the upper header 223 , and the fore and aft faces 224 u and 224 b respectively of the lower header 224 . A conventional finished header may be used in which the ends 212 ″ of the fibers would be flush (in substantially the same plane) as the lower face 224 b . In the best mode, though not visible through an opaque end-cap, the open ends 212 ″ of the fibers protrude from the headers' lower (aft or bottom) face 224 b.
[0151] The finished upper header 223 (fixing lamina) is left adhered to the periphery of the end-cap 221 when the fugitive lamina is removed through bore 226 in the upper header; and analogously, the finished lower header 224 is left adhered to the periphery of the end-cap 222 when the fugitive lamina is removed through a bore 227 .
[0152] Skein fibers 212 are preferably in arrays bundled in a geometric configuration such as a spiral roll. A header is formed in a manner analogous to that described in relation to FIG. 4, by potting the lower end of the spiral roll. FIG. 14A, showing a bottom plan view of the aft face 224 b of header 224 , illustrates the spiral pattern of openings in the ends 212 ″ of the fibers. It is preferred, before an array is rolled into a spiral, to place a sparger 240 (shown in FIG. 15A) with a rigid air-supply tube 242 in the array so that upon forming a spiral roll the air-supply tube is centrally axially held within the roll.
[0153] Illustrated in FIG. 14B is a bottom plan view of aft face 224 b with another configuration, wherein a series of successively larger diameter circular arrays are formed, each a small predetermined amount larger than the preceding one, and the arrays secured, preferably adhesively, one to the next, near their upper and lower peripheries respectively to form a dense cylindrical mass of fibers. In such a mass of fibers, referred to as a series of annular rings, each array is secured both to a contiguous array having a next smaller diameter, as well as to a contiguous array having a next larger diameter, except for the innermost and outermost arrays which have the smallest and largest diameters, respectively. The pattern in header 224 illustrates the ends 212 ″ of the fibers after the nested arrays are potted.
[0154] Illustrated in FIG. 14C is a bottom plan view of lower (aft) face 224 b with plural arrays arranged chord-like within the header 224 , Arrays are formed on pairs of strips, each having a length corresponding to its position as a chord within a potting ring in which the skein fibers are to be potted. That is, each array is formed on strips of diminishing width, measured from the central array which is formed on a strip having a width slightly less than the inner diameter of the potting ring in which the stack is to be potted. The arrays are stacked within the ring, the widest array corresponding in position to the diameter of the ring. For a chosen fiber 212 , the larger the surface area required in a skein, the greater the number of fibers in each array, the bigger the diameter of the ring, and the wider each chord-like array. The plural arrays are preferably adhered one to the other by coating the surfaces of fibers with adhesive prior to placing a strip of the successive array on the fibers. Alternatively, the bundled arrays may be held with a rubber band before being inserted in the potting ring. The resulting chord-like pattern in header 224 illustrates the ends 212 ″ of the fibers after the nested arrays are potted.
[0155] A detail of a sparger 240 is provided in FIG. 15A. The star-shaped sparger 240 having radially outwardly extending tubular arms 241 and a central supply stub 242 , supplies air which is directed into the tubular arms and discharged into the substrate through air passages in the walls of the arms. An air feed tube 244 connected to the central supply stub 242 provides air to the sparger 240 . The lower end of the central stub 242 is provided with short projecting nipples 245 the inner ends of which are brazed to the stub. The outer ends of the nipples are threaded. The central stub and nipples are easy to insert into the center of the mass of skein fibers. When centrally positioned; arms 241 which are threaded at one end, are threadedly secured to the outer ends of the nipples.
[0156] As illustrated in FIG. 14, lower end-cap 222 rests on the floor F of a tank, near a vertical wall W to which is secured a vertical mounting strut 252 with appropriate fastening means such as a nut 253 and bolt 254 . A U-shaped bracket 251 extends laterally from the base of the mounting strut 252 . The arms of the U-shaped bracket support the periphery of upper end-cap 221 , and to ensure that the end-cap stays in position, it is secured to the U-shaped bracket with a right angle bracket and fastening means (not shown). A slot in mounting strut 252 permits the U-shaped bracket to be raised or lowered so that the desired distance between the opposed faces 223 b and 224 u of the upper and lower headers respectively is less than the length of any potted fiber, measured between those faces, by a desired amount. Adjustability is particularly desirable if the length of the fibers tends to change during service.
[0157] As illustrated in FIG. 14, if it is desirable to withdraw permeate from only the upper tube 231 , a permeate connector tube 233 (shown in phantom outline), is inserted within the mass of skein fibers 212 through the headers 223 and 224 , connecting the permeate collection zone 229 in the lower end-cap in open fluid communication with the permeate collection zone 228 in the upper end-cap; and, bore 227 is plugged with a plug 225 as shown in FIG. 15. Since, under such circumstances, it does not matter if the lower ends 212 ″ of the fibers are plugged, and permeate collection zone 229 serves no essential function, the zone 229 may be filled with potting resin.
[0158] Referring to FIG. 16 there is illustrated a skein 270 with upper and lower end-caps in which are sealed upper and lower ring headers formed in upper and lower rings 220 u and 220 b respectively, after the fibers in the skein are tested to determine if any is defective. A rigid air-supply tube 245 is positioned in the spiral roll as described above, and the lower end of the roll is potted forming a lower finished header 274 in which the lower end 246 of the air-supply tube is potted, fixing the position of the arms 241 of the sparger just above the upper face 274 u of the header 274 .
[0159] In an analogous manner, an upper header 273 is formed in ring 220 u and upper end 247 of air-supply tube 245 is inserted through an axial bore 248 within upper end-cap 271 which is slipped over the ring 220 u the outer periphery of which is coated with a suitable adhesive, to seal the ring 220 u in the end-cap 271 . The periphery of the upper end 247 is sealed in the end cap 271 with any conventional sealing compound.
[0160] Referring to FIG. 17 there is schematically illustrated another embodiment of a skein 280 in which rigid permeate tube 285 is held concentrically within a rigid air-supply tube 286 which is potted axially within skein fibers 212 held between opposed upper and lower headers 283 and 284 in upper and lower rings 220 u and 220 b which are in turn sealed in end-caps 281 and 282 respectively. For ease of manufacture, the lower end 285 b of permeate tube 285 is snugly fitted and sealed in a bushing 287 . The bushing 287 and end 285 b are then inserted in the lower end 286 b of the air supply tube 286 and sealed in it so that the annular zone between the outer surface of permeate tube 285 and the inner surface of air supply tube 286 will duct air to the base of the fibers but not permit permeate to enter the annular zone. The air supply tube is then placed on an array and the array is rolled into a spiral which is held at each end with rubber bands. The lower end of the roll is placed in a ring 220 b and a lower ring header is formed with a finished header 284 as described above. It is preferred to use a relatively stiff elastomer having a hardness in the range from 50 Shore A to about 20 Shore D, and most preferred to use a polyurethane having a hardness in the range from 50 Shore A to about 20 Shore D, measured as set forth in ASTM D-790, such as PTU-921 available from Canadian Poly-Tech Systems. To form the upper finished header 283 the air supply tube is snugly inserted through an O-ring held in a central bore in a plate such as used in FIG. 5, to avoid loss of potting resin from the ring, and the fugitive resin and finishing resins poured and cured, first one then the other, in the ring. Lower finished header 284 is formed with intermediate portions 212 b ′ embedded, and terminal portions 212 b ″ protruding from the header's aft face. Upper finished header 283 is formed with intermediate portions 212 u ′ embedded, and terminal portion 212 u ″ protruding from the header's fore face. After the finished headers 283 and 284 are formed and the fibers checked for defects, the upper end 286 u of the air supply tube 286 is inserted through a central bore 288 in upper end-cap 281 and sealed within the bore with sealing compound or a collar 289 . Preferably the permeate tube 285 , the air supply tube 286 and the collar 289 are all made of PVC so that they are easily cemented together to make leak-proof connections.
[0161] As shown, permeate may be withdrawn through the permeate tube 285 from the permeate collection zone in the lower end-cap 282 , and separately from the upper end-cap 281 through permeate withdrawal port 281 p which may be threaded for attaching a pipe fitting. Alternatively, the permeate port 281 p may be plugged and permeate withdrawn from both end-caps through the permeate tube 285 .
[0162] Upper end 285 u and upper end 286 u of air supply tube 286 are inserted through a T-fitting 201 through which air is supplied to the air supply tube 286 . The lower end 201 b of one of the arms of the T 201 is slip-fitted and sealed around the air supply tube. The upper end 201 u of the other arm is inserted in a reducing bushing 202 and sealed around the permeate tube. Air supplied to intake 203 of the T 201 travels down the annular zone between the permeate tube and the air supply tube and exits through opposed ports 204 in the lower portion of the air supply tube, just above the upper face 284 u of the lower header 284 . It is preferred to thread ports 204 to threadedly secure the ends of arms 241 to form a sparger which distributes air substantially uniformly across and above the surface 284 u . Additional ports may be provided along the length of the vertical air supply tube, if desired.
EXAMPLE 1
[0163] Microfiltration of an activated sludge at 30° C. having a concentration of 25 g/L (2..5% TSS) is carried out with a skein of polysulfone fibers in a pilot plant tank. The fibers are “air scrubbed” at a flow rate of 12 CFM (0.34 m3/min) with a coarse bubble diffuser generating bubbles in the range from about 5 mm to 25 mm in nominal diameter. The air is sufficient no only for the oxidation requirements of the biomass but also for adequate scrubbing. The fibers have an outside diameter of 1.7 mm, a wall thickness of about 0.5 mm, and a surface porosity in the range from about 20% to 40% with pores about 0.2 μm in diameter, both latter physical properties being determined by a molecular weight cut off at 200,000 Daltons. The skein which has 1440 fibers with a surface area of 12 m 2 is wall-mounted in the tank, the vertical spaced apart distance of the headers being about 1% less than the length of a fiber in the skein. The opposed ends of the fibers are potted in upper and lower headers respectively, each about 41 cm long and 10 cm wide. The fixing material of the headers is an epoxy having a hardness of about 70 Shore D with additional upper and lower laminae of softer polyurethane (about 60 shore A and 30 Shore D respectively) above and below the epoxy lamina, and the fibers are potted to a depth sufficient to have their open ends protrude from the bottom of the header. The average transmembrane pressure differential is about 34.5 kPA (5 psi). Permeate is withdrawn through lines connected to the collection pan of each header with a pump generating about 34.5 kPa (5 psi) suction. Permeate is withdrawn at a specific flux of about 0.7 lm 2 h/kPa yielding about 4.8 l/min of permeate which has an average turbidity of <0.8 NTU, which is a turbidity not discernible to the naked eye.
EXAMPLE 2
Comparison of Operation of a Vertical Skein (ZW 72) in Different Orientations
[0164] In the following comparison, three pairs of identical skeins with equally slack fibers are variously positioned (as designated) above aerators in a bioreactor. Each pair is subjected to the same discharge of air through identical aerators. Rectangular but not square headers are chosen to determine whether there is a difference between each of two flat horizontal orientations, which difference would not exist in a horizontal skein with cylindrical headers. A pair of identical rectangular skeins, each having headers 41.66 cm (16.4 in) in length (x-axis), 10.16 cm (4 in) in width (y-axis) and 7.62 cm (3 in) in height (z-axis), in which are potted 1296 Zenon® MF200 microfiltration fibers presenting a nominal fiber surface area of 625 m 2 , were tested in three different orientations in a bioreactor treating domestic wastewaters. The fibers used are the same as those used in Example 1 above. The distance between opposed faces of headers is 90 cm (35.4 in) which is about 2% less than the length of each fiber potted in those headers.
[0165] In a first test, the two (first and second) skeins were stacked laterally, each in the same direction along the longitudinal axis, with a 2.5 cm (1 in) thick spacer between the headers, the headers of each skein being in a horizontal flat orientation (area 41.66 cm×7.62 cm) is spaced apart 7.62 cm (3 in) above the floor on which lies the aerators in the form of three side-by-side linear tubes with 3 mm (0.125″) openings. The first skein which is directly above the aerators is therefore referred to as the “lower skein”.
[0166] In a second test, the same first and second skeins are each rotated 90° about the longitudinal x-axis and placed contiguously one beside the other. In this “horizontal 90°” orientation (area defined by 10.16 cm×7.62 cm) is spaced apart from the aerators as in the prior test.
[0167] In a third test, the first and second skeins are placed side-by-side in vertical orientations as shown in FIG. 9 except there is no internal aerator.
[0168] Each test provides the fibers in each orientation with the identical amount of air. Permeate was withdrawn with a pump with a NPSH of 0.3 bar (10″ of Hg). The conditions were held constant until it was observed that the flux obtained for each test was substantially constant, this being the equilibrium value. After this occurred, each skein was back pulsed for 30 sec with permeate every 5 minutes to maintain the flux at the equilibrium value. The test conditions for each of the above three runs were as follows:
TSS in bioreactor 8 g/L; Temperature of biomass 19° C. Flow rate of air 0.2124 m 3 / Suction on fibers 25.4 cm min/skein; of Hg
[0169] [0169]FIG. 18 is a bar graph which shows the average flux over a 24 hr period for each orientation of the skein as follows:
Orientation Average flux L/m2/hr over 24 hr Horizontal flat 21.2 LMH Horizontal 90° 17.8 LMH Vertical 27.7 LMH
[0170] This conclusively demonstrates that the vertical orientation of the skein fibers produces the highest overall flux.
EXAMPLE 3
Comparison of Positions of Aerator Inside and Outside the Skein Fibers
[0171] In this test the difference in flux is measured in a bioreactor treating wastewater contaminated with ethylene glycol, the difference depending upon how a single cylindrical vertical skein (ZW 172) having a nominal surface area of 16 m 2 is aerated with 3.5 L/min (7.5 scfm). The skein is formed as shown in FIG. 16 around a central PVC pipe having an o.d. of 75 cm, the fibers being disposed in an annular zone around the central support, the radial width of the annular zone being about 75 cm, so that the o.d. of the skein is about 11.25 cm.
[0172] In a first test, air is introduced within the skein; in a second test, air is introduced around the periphery of the skein. After equilibrium is reached, operation is typically continued by back pulsing the skein with permeate at chosen intervals of time, the interval depending upon how quickly the fibers foul sufficiently to decrease the flux substantially.
[0173] The process conditions, which were held constant over the period of the test, were as follows:
TSS 17 g/L; Temperature of biomass 10.5° C. Flow rate of air 0.2124 m 3 /min; Suction on fibers 25.4 cm of Hg
[0174] For External Aeration:
[0175] A perforated flexible tube with holes about 3 mm in diameter spaced about 2.5 cm apart was wrapped around the base of the ZW 72 skein and oriented so that air is discharged in a horizontal plane, so that bubbles enter laterally into the skein, between fibers. Thereafter the bubbles rise vertically through the skein fibers. Lateral discharge helps keep the holes from plugging prematurely.
[0176] For Internal Aeration:
[0177] The central tubular support was used as the central air distribution manifold to duct air into five 4″ lengths of ¼″ pipe with ⅛″ holes at 1″ intervals, plugged at one end, in open flow communication with the central pipe, forming a spoke-like sparger within the skein, at the base. The number of holes is about the same as the number in the external aerator, and the flow rate of air is the same. As before the holes discharge the air laterally within the skein, and the air bubbles rise vertically within the skein, and exit the skein below the upper header.
[0178] [0178]FIG. 19 is a plot of flux as a function of time, until the flux reaches an equilibrium value. Thereafter the flux may be maintained by back pulsing at regular intervals. As is evident, the equilibrium flux with external aeration is about 2.6 LMH, while the flux with internal aeration is about 9.9 LMH which is nearly a four-fold improvement From the foregoing it will be evident that, since it is well-known that flux is a function of the flow rate of air, all other conditions being the same during normal operation, a higher flux is obtained with internal aeration with the same flow of air.
EXAMPLE 4
Comparison of Skeins in Which One has Swayable Fibers, the Other Does Not
[0179] The slackness in the fibers is adjusted by decreasing the distance between headers. Essentially no slack is present (fibers are taut) when the headers are spaced at a distance which is the same as the length of a fiber between its opposed potted ends. A single ZW 72 skein is used having a nominal surface area of 6.7 m 2 is used in each test, in a bioreactor to treat wastewater contaminated with ethylene glycol. Aeration is provided as shown in FIG. 9 (no internal aeration) with lateral discharge of air bubbles into the skein fibers through which bubbles rose to the top.
[0180] In the first test the headers are vertically spaced apart so that the fibers are taut and could not sway.
[0181] In the second test, the headers were brought closer by 2 cm causing a 2.5% slackness in each fiber, permitting the slack fibers to sway.
[0182] As before the process conditions, which were held constant over the period of the test, were as follows:
Suspended solids 17 g/L Temperature of biomass 10.5° C. Flow rate of air 0.2124 m 3 /min; Suction on fibers 25.4 cm of Hg
[0183] [0183]FIG. 20 is a plot of flux as a function of time, until the flux reaches an equilibrium value. Thereafter the flux may be maintained by back pulsing at regular intervals as before in example 3. As is evident, the equilibrium flux with no swayability is about 11.5 LMH, while the flux with 2.5% slack is about 15.2 LMH, which is about a 30% improvement.
EXAMPLE 5
Filtration of Water with a Vertical Cylindrical Skein to Obtain Clarity
[0184] A cylindrical skein is constructed as in FIG. 16 with Zenon® MF200 fibers 180 cm long, which provide a surface area of 25 m 2 in cylindrical headers having a diameter of 28 cm held in end-caps having an o.d. of 30 cm. Aeration is provided with a spider having perforated cross-arms with 3 mm (0.125″) dia. openings which discharge about 10 liter/min (20 scfm, standard ft 3 /min) of air. This skein is used in four typical applications, the results of which are provided below. In each case, permeate is withdrawn with a centrifugal pump having a NPSH of about 0.3 bar (10″ Hg), and after equilibrium is reached, the skein is backflushed for 30 sec with permeate every 30 min.
[0185] A. Filtration of Surface (Pond) Water having 10 mg/L TSS:
[0186] Result—permeate having 0.0 mg/L TSS is withdrawn at a rate of 2000 liters/hr (LPH) with a turbidity of 0.1 NTU. A “5 log” reduction (reduction of original concentration by five orders of magnitude) of bacteria, algae, giardia and cryptosporidium may be obtained, thus providing potable water.
[0187] B. Filtration of Raw Sewage with 100 mg/L TSS:
[0188] Result—permeate having 0.0 mg/L suspended solids is withdrawn at a rate of 1000 LPH (liters/hr) with a turbidity of 0.2 NTU. Plural such skeins may be used in a bank in the full scale treatment of industrial wastewater.
[0189] C. Filtration of a Mineral Suspension Containing 1000 mg/L TSS of Iron Oxide Particles:
[0190] Result—permeate having 0.0 mg/L suspended solids is withdrawn at a rate of 3000 LPH (liters/hr) with a turbidity of 0.1 NTU. High flux is maintained with industrial wastewater containing mineral particles.
[0191] D. Filtration of Fermentation Broth with 10,000 mg/L Bacterial Cells:
[0192] Result—permeate having 0.0 mg/L suspended solids is withdrawn at a rate of 1000 LPH (liters/hr) with a turbidity of 0.1 NTU. The broth with a high biomass concentration is filtered non-destructively to yield the desired permeate, as well as to save living cells for reuse.
EXAMPLE 6
Special Purpose Mini-Skein
[0193] The following examples illustrate the use of a mini-skein for typical specific uses such as filtration of (i) raw sewage to obtain solids-free water samples for colorimetric analyses, (ii) surface water for use in a recreational vehicle (“camper”) or motor home, or (iii) water from a small aquarium for fish or other marine animals.
[0194] A cylindrical mini-skein is constructed as shown in FIG. 16, with cylindrical headers having an o.d. of 5 cm (2″) and a thickness of 2 cm (0.75″) with 30 fibers, each 60 cm long to provide a surface area of 0.1 m 2 . The skein is mounted on a base on which is also removably disposed a blower to discharge 15 L/min of air at 12 kPa (3 psig) through a sparger which has 1.6 mm (0.0625″) openings, the air flowing through the skein upwards along the fibers. Also removably mounted on the base is a peristaltic pump which produces a vacuum of 0.3 bar (10″ Hg). In each application, the self-contained skein with integral permeate pump and gas-discharge means, is placed, for operation, in a cylindrical container of the substrate to be filtered.
[0195] The results with each application (A)-(D) are listed below:
[0196] (i) Raw sewage contains 100 mg/L TSS; permeate containing 0.0 mg/L TSS having a turbidity of 0.2 NTU, is withdrawn at 0.1 LPH.
[0197] (ii) Aquarium water withdrawn contains 20 mg/L TSS, including algae, bacteria, fungus and fecal dendritus; permeate containing 0.0 mg/L TSS having a turbidity of 0.2 NTU, is withdrawn at 0.1 LPH.
[0198] (iii) Pond water withdrawn contains 10 mg/L TSS; permeate containing 0.0 mg/L TSS having a turbidity of 0.2 NTU, is withdrawn at 0.1 LPH.
[0199] It will now be evident that the membrane device and basic separation process of this invention may be used in the recovery and separation of a wide variety of commercially significant materials, some of which, illustratively referred to, include the recovery of water from ground water containing micron and submicron particles of siliceous materials, preferably “gas scrubbing” with carbon dioxide; or, the recovery of solvent from paint-contaminated solvent. In each application, the choice of membrane will depend upon the physical characteristics of the materials and the separation desired. The choice of gas will depend on whether oxygen is needed in the substrate.
[0200] In each case, the simple process comprises, disposing a skein of a multiplicity of hollow fiber membranes, or fibers each having a length >0.5 meter, together having a surface area >1 m 2 , in a body of substrate which is unconfined in a modular shell, so that the fibers are essentially restrictedly swayable in the substrate. The substrate is typically not under pressure greater than atmospheric. The fibers have a low transmembrane pressure differential in the range from about 3.5 kPa (0.5 psi) to about 350 kPa (50 psi), and the headers, the terminal portions of the fibers, and the ends of the fibers are disposed in spaced-apart relationship as described herinabove, so that by applying a suction of the aft face of at least one of the headers, preferably both, permeate is withdrawn through the collection means in which each header is mounted in fluid-tight communication.
[0201] Having thus provided a general discussion, and specific illustrations of the best mode of constructing and deploying a membrane device comprising a skein of long fibers in a substrate from which a particular component is to be produced as permeate, how the device is used in a gas-scrubbed skein, and having provided specific illustrative systems and processes in which the skein is used, it is to be understood that no undue restrictions are to be imposed by reason of the specific embodiments illustrated and discussed, and particularly that the invention is not restricted to a slavish adherence to the details set for the herein. | An apparatus is described for withdrawing filtered permeate from a substrate contained in a reservoir at ambient pressure. The apparatus includes a plurality of membrane assemblies. Each assembly has a plurality of hollow fiber filtering membranes, immersed in the reservoir, at least one permeating header with the membranes sealingly secured therein, and a permeate collector to collect the permeate sealingly connected to the at least one permeating header and in fluid communication with lumens of the membranes. The membranes of each assembly extend generally vertically upwards from a first header during permeation. One or more sources of suction are provided in fluid communication with the lumens of the membranes of each assembly through the permeate collectors and apply sufficient suction to withdraw permeate from the lumens of the membranes. An aeration system for discharging bubbles assists in keeping the membranes clean. In other aspects, a method of removing fouling materials from the surface of a plurality of porous membranes includes providing, from within a membrane module, gas bubbles in a uniform distribution relative to the membranes. The bubbles move past the surfaces of the membranes to dislodge fouling materials from them. The membranes are arranged in close proximity to one another and mounted to prevent excessive movement. | 8 |
FIELD OF THE INVENTION
The present invention relates generally to an active-hydrogen-containing phosphorus compound for cross-linking a resin and for imparting flame-retardancy to the cured resin, and in particular to a cured frame-retardant epoxy resin prepared by reacting the hardener with a di- or poly-functional epoxy resin via an addition reaction between the active hydrogen and the epoxide group. It also relates to an epoxy resin made from the active-hydrogen-containing phosphorus compound and epihalohydrin.
BACKGROUND OF THE INVENTION
Typical hardeners for epoxy resins and advanced epoxy resins are phenol-formaldehyde novolac resin, dicyandiamide, methylenedianiline, diaminodiphenyl sulfone, phthalic anhydride, and hexahydrophthalic anhydride, etc. The advanced epoxy resins and cured epoxy resins prepared with these hardeners do not have flame retardancy, and thus can not meet the safety requirements.
Several approaches for modification of epoxy backbone for enhancing the thermal properties of epoxy resins have been reported. Aromatic bromine compounds in conjunction with antimony oxide are widely used as a flame retardant for epoxy resins. Tetrabromobisphenol A is a typical example of the aromatic bromine compounds used as a flame retardant for epoxy resins. An excess amount of epoxy resin is reacted with tetrabromobisphenol A to prepare an advanced epoxy resin having two terminal epoxide groups, as shown in the following formula:
wherein Ep is a bi-radical group of the backbone of the epoxy resin, and m is an integer of 1-10. The advanced epoxy resin can be used in preparing a flame-retardant printed circuit board (FR-4) by impregnating glass fibers with the advanced epoxy resin and heating the resulting composite to cure the advanced epoxy resin. Furthermore, the advanced epoxy resin can be employed to encapsulate microelectronic devices, in which the advanced epoxy resin is cured at a high temperature with a curing agent, so that an encapsulant having a flame-retardant property is formed. Typical examples can be found in U.S. Pat. No. 3,040,495 (1961); U.S. Pat. No. 3,058,946 (1962); U.S. Pat. No. 3,294,742 (1966); U.S. Pat. No. 3,929,908 (1975); U.S. Pat. No. 3,956,403 (1976); U.S. Pat. No. 3,974,235 (1976); U.S. Pat. No. 3,989,531 (1976); U.S. Pat. No. 4,058,507 (1997); U.S. Pat. No. 4,104,257 (1978); U.S. Pat. No. 4,170,711 (1979); and U.S. Pat. No. 4,647,648(1987)].
Although the tetrabromobisphenol A-containing advanced epoxy resin shows flame retardant property, major problems encountered with this system are concerned with the generation of toxic and corrosive fumes during combustion such as dioxin and benzofuran.
The flame retardant having a small molecular weight tends to lower the mechanical properties of the epoxy resins, and migrate/vaporize from the epoxy resins such that the flame retardancy thereof diminishes.
It is an object of this invention to provide a phosphorus-containing flame retardant hardener for cross-linking a resin and for imparting flame-retardancy to the cured resin.
It is another object of this invention to provide advanced epoxy resins and cured epoxy resins with good thermal stability, superior heat resistance, and without environmental problem, which are suitable for use in making printed circuit boards and in semiconductor encapsulation applications.
It is also an object of this invention to provide phosphorus-containing flame-retardant epoxy resins which are suitable for use in making printed circuit boards and in semiconductor encapsulation applications.
SUMMARY OF THE INVENTION
In order to accomplish the aforesaid objects, a flame-retardant hardener containing one of the following phosphorus-containing rigid groups was synthesized in the present invention:
wherein R 1 and R 2 independently are H, C1˜C18 alkyl, C6˜C18 aryl, C6˜C18 substituted aryl, C6˜C18 aryl methylene, or C6˜C18 substituted aryl methylene; and Ar is an un-substituted or substituted phenyl or phenoxy radical. The hardener of the present invention is prepared by bounding the phosphorus-containing rigid group to bisphenol-A (BPA), diamonodiphenyl methane (DDM), diaminodiphenyl sulfone (DDS), melamine (MA) or dicyandiamide (DICY). The phosphorus-containing bisphenol-A of the hardeners of the present invention can be reacted with an excess amount of epoxy resin to prepare a flame-retardant advanced epoxy, which is suitable for use in making printed circuit boards.
The present invention also provides a flame-retardant epoxy resin by reacting the hardener of the present invention with an excess of epihalohydrin in the presence of an alkali metal hydroxide.
The present invention also provides a cured flame-retardant epoxy resin by using the hardener of the present invention and a cured flame-retardant epoxy resin from the flame-retardant epoxy resin of the present invention. The cured flame-retardant epoxy resins so prepared have a high glass transition temperature (Tg), high decomposition temperature and high elastic modulus, and are free of toxic and corrosive fumes during combustion, and thus are suitable for printed circuit board and semiconductor encapsulation applications.
DETAILED DESCRIPTION OF THE INVENTION
A phosphorus-containing compound prepared in accordance with the present invention has a formula selecting from the group consisting of (A) to (I):
wherein
l and m independently are 0, 1 or 2, and l+m>0; i and j independently are 0, 1 or 2, and 0<i+j<4; k is 0 or 1, and i+k<3;
Z is —NH 2 , —CH 3 or phenyl;
wherein
R 1 , R 2 independently are H, C1˜C18 alkyl, C6˜C18 aryl, C6˜C18 substituted aryl, C6˜C18 aryl methylene, or C6˜C18 substituted aryl methylene;
wherein R is C1-C4 alkyl or C6-C18 aryl; and n is an integer of 0 to 5.
Preferably, the phosphorus-containing compound of the present invention has a structure of the formula (A).
Preferably, the phosphorus-containing compound of the present invention has a structure of the formula (B).
Preferably, the phosphorus-containing compound of the present invention has a structure of the formula (C).
Preferably, the phosphorus-containing compound of the present invention has a structure of the formula (D).
Preferably, the phosphorus-containing compound of the present invention has a structure of the formula (E) or (F).
Preferably, the phosphorus-containing compound of the present invention has a structure of the formula (G).
Preferably, the phosphorus-containing compound of the present invention has a structure of the formula (H) or (I).
Preferably, R 1 and R 2 are hydrogen. Preferably, n is 0.
Preferably, X is
when the phosphorus-containing compound of the present invention has a structure of the formula (A).
Preferably, X is —CH 2 — or
when the phosphorus-containing compound of the present invention has a structure of the formula (B).
Preferably, Ar is phenoxy, when the phosphorus-containing compound of the present invention has a structure of one of the formulas (A) to (D).
Preferably, Ar is phenyl, when the phosphorus-containing compound of the present invention has a structure of one of the formulas (F) to (I).
Preferably, i and j are 0 or 1.
Preferably, Z is —NH 2 .
Preferably, k is 0.
The present invention also discloses a phosphorus-containing frame-retardant advanced epoxy resin and cured epoxy resin having the following formula (J):
wherein
0<h<10;
T=L or M, wherein
the formula (J) represents the advanced epoxy resin, when T=L; and
the formula (J) represents the cured epoxy resin, when T=M;
A′ is
wherein Q, X, l and m are defined as above; and
Ep is
or a phenol-aldehyde novolac epoxy resin backbone, and when Ep is the phenol-aldehyde novolac epoxy resin backbone, the flame-retardant advanced epoxy resin and the cured epoxy resin represented by the formula (J) is prepared by reacting the phosphorus-containing compound (A) with a phenol-aldehyde novolac epoxy resin having the following formula (II)
wherein R 3 is hydrogen, or —CH 3 , and g is an integer of 1-6.
Preferably, Ep in the formula (J) is
wherein Y is —C(CH 3 ) 2 —.
Preferably, Ep in the formula (J) is the phenol-aldehyde novolac epoxy resin backbone, wherein R 3 in the phenol-aldehyde novolac epoxy resin (II) is —CH 3 .
A suitable process for preparing the flame-retardant advanced epoxy resin (J) comprises reacting the phosphorus-containing compound (A) with an excess amount of an epoxy resin having the following formula:
wherein Ep is defined as above.
The phosphorus-containing compounds (A) to (I) of the present invention can be used as a flame-retardant hardener for an epoxy resin, when there is more than one active hydrogen contained therein; and can be used as a flame retardant for the epoxy resin, if there is only one active hydrogen contained therein.
Suitable processes for preparing the phosphorus-containing compounds (A)-(I) of the present invention include (but not limited) processes utilizing the following reactions:
Compounds (A)-(D): Substituted BPA, DDM, DDS, MA and DICY types
Compounds (E) and (F): Dicyandiamide addition product types
Compounds (G)-(I): Substited melamine and dicyandiamide types
l, m, i, j, k, Z, X, Q and Q′ in the aforesaid reactions for synthesizing the phosphorus-containing compounds (A)-(I) are defined as above.
The QOH reactant used in the aforesaid reactions for synthesizing the phosphorus-containing compounds (A)-(D) may be prepared by the following reactions (1) and (2):
wherein DOPO is an abbreviation of 9,10-dihydro-9-oxa-10-phosphaphenanthrene 10-oxide, R 1 and R 2 are defined as above. 2-(6-Oxid-6H-dibenz<c,e><1,2>oxa-phosphorin-6-yl)methanol (abbreviated as ODOPM) can be synthesized when R 1 and R 2 in the reaction (1) are both hydrogen.
R 1 , R 2 and Ar in the reaction (2) are defined as above. Diphenoxy phosphoryl methanol (abbreviated as DPOM) can be synthesized when R 1 , R 2 are both hydrogen, and Ar is phenoxy in the reaction (2).
The Q′Cl reactant used in the aforesaid reactions for synthesizing the phosphorus-containing compounds (G)-(I) may be prepared by the following reactions (3) and (4):
wherein ODOPC in the reaction (3) is an abbreviation of 2-(6-oxid-6H-dibenz<c,e><1,2>oxa-phosphorin-6-yl)chloride;
wherein R, n and Ar In the reaction (4) are defined as above. Diphenyl phosphoryl chloride (abbreviated as DPC) can be synthesized, when R is hydrogen and Ar is phenyl in the reaction (4).
The present invention further synthesized a phosphorus-containing flame-retardant cured epoxy resin by curing an epoxy resin or advanced epoxy resin with the hardener of the present invention alone or together with the conventional curing agent for the epoxy resin in a molten state. The conventional curing agent for the epoxy resin preferably is selected from the group consisting of phenol-formaldehyde novolac resin, dicyandiamide, methylenedianiline, diaminodiphenyl sulfone, phthalic anhydride and hexahydrophthalic anhydride. Preferably, the curing reaction is carried out at a temperature higher than 150° C. and with a stoichiometric amount of the hardener and the curing agent, i.e. the equivalent ratio of the epoxide group in the epoxy resin and/or advance epoxy resin and the functional groups in the hardener and the curing agent is about 1:1. More preferably, the curing reaction is carried out in the presence of a curing promoter such as triphenylphosphine, and in an amount of 0.01-10.0 parts by weight of the curing promoter per 100 parts by weight of the epoxy resin and/or advance epoxy resin. The phosphorus-containing flame-retardant cured epoxy resin of the present invention is suitable for use in making a flame-retardant printed circuit board as a matrix resin and in semiconductor encapsulation.
Preferably, the phosphorus-containing flame-retardant cured epoxy resin of the present invention contains 0.5-30 wt %, and more preferably 0.5-5 wt %, of phosphorus.
A suitable epoxy resin for use in the present invention can be any known epoxy resin, for examples those having two epoxide groups such as bisphenol A epoxy resin, bisphenol F epoxy resin, bisphenol S epoxy resin and biphenol epoxy resin, and those having more than two epoxide groups such as phenol formaldehyde novolac epoxy and cresol formaldehyde novolac epoxy (CNE) with 4-18 functional groups, and mixtures thereof.
An advanced epoxy resin suitable for use in the present invention can be prepared by conducting a curing reaction of the conventional curing agent for an epoxy resin and using an excess amount of an epoxy resin in a molten state.
Preparation of Phosphorus-containing Hardeners
i). Substituted bisphenol-A (BPA), diamonodiphenyl methane (DDM), diaminodiphenyl sulfone (DDS), melamine (MA) or dicyandiamide (DICY) types
Preparation Example 1-A (P-1-A, ODOPM-BPA-A)
To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 1 mole (228 g) bisphenol-A (BPA) was added, heated to 170° C. and then stirred to a molten state. 0.7 g (0.3 wt %) potassium acetate was mixed with the molten BPA followed by adding slowly 1 mole (246 g) 2-(6-oxid-6H-dibenz<c,e><1,2>oxa-phosphorin-6-yl)methanol (ODOPM). The mixture was heated gradually to a temperature of 220° C. when the addition of ODOPM was completed. The substitution reaction was continued for 6 hours. The reaction product was dissolved in cyclohexanone, and washed with water several times before the solvent was evaporated under vacuum to obtain ODOPM-BPA-A (P-1-A). Yield, 98%; softening temperature, 125-132° C. Phosphorus content: 6.79%.
Preparation Example 1-B (P-1-B, ODOPM-BPA-A)
To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 1 mole (228 g) bisphenol-A (BPA) was added, heated to 170° C. and then stirred to a molten state. 1.14 g (0.5 wt %) potassium acetate was mixed with the molten BPA followed by adding slowly 1.5 mole (369 g) ODOPM. The mixture was heated gradually to a temperature of 220° C. when the addition of ODOPM was completed. The substitution reaction was continued for 8 hours. The reaction product was dissolved in cyclohexanone, and washed with water several times before the solvent was evaporated under vacuum to obtain ODOPM-BPA-B (P-1-B). Yield, 96%; softening temperature, 136-140° C. Phosphorus content: 8.16%.
Preparation Example 1-C (P-1-C, ODOPM-BPA-A)
To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 1 mole (228 g) bisphenol-A (BPA) was added, heated to 170°C. and then stirred to a molten state. 1.14 g (0.5 wt %) potassium acetate was mixed with the molten BPA followed by adding slowly 2 mole (492 g) ODOPM. The mixture was heated gradually to a temperature of 220° C. when the addition of ODOPM was completed. The substitution reaction was continued for 10 hours. The reaction product was dissolved in cyclohexanone, and washed with water several times before the solvent was evaporated under vacuum to obtain ODOPM-BPA-C (P-1-C ). Yield, 92%; softening temperature, 143-148° C. Phosphorus content: 9.06%.
Preparation Example 2 (P-2, DPOM-BPA)
To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 1 mole (228 g) bisphenol-A (BPA) was added, heated to 170° C. and then stirred to a molten state. 0.7 g (0.3 wt %) potassium acetate was mixed with the molten BPA followed by adding slowly 1 mole (264 g) diphenoxy phosphoryl methanol (DPOM). The mixture was heated gradually to a temperature of 220° C. when the addition of DPOM was completed. The substitution reaction was continued for 8 hours. The reaction product was dissolved in cyclohexanone, and washed with water several times before the solvent was evaporated under vacuum to obtain DPOM-BPA (P-2). Yield, 98%; softening temperature, 118-124° C. Phosphorus content: 6.54%.
Preparation Example 3 (P-3, ODOPM-DDM)
To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 1 mole (198 g) diaminodiphenylmethane (DDM) was added, heated to 170° C. and then stirred to a molten state. 0.7 g (0.3 wt %) potassium acetate was mixed with the molten DDM followed by adding slowly 1 mole (246 g) ODOPM. The mixture was heated gradually to a temperature of 220° C. when the addition of ODOPM was completed. The substitution reaction was continued for 8 hours. The reaction product was dissolved in cyclohexanone, and washed with water several times before the solvent was evaporated under vacuum to obtain ODOPM-DDM (P-3). Yield, 98%; softening temperature, 145-149° C. Phosphorus content: 6.57%.
Preparation Example 4 (P-4, DPOM-DDM)
To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 1 mole (198 g) diaminodiphenylmethane (DDM) was added, heated to 170° C. and then stirred to a molten state. 0.7 g (0.3 wt %) potassium acetate was mixed with the molten DDM followed by adding slowly 1 mole (264 g) DPOM. The mixture was heated gradually to a temperature of 220° C. when the addition of DPOM was completed. The substitution reaction was continued for 8 hours. The reaction product was dissolved in cyclohexanone, and washed with water several times before the solvent was evaporated under vacuum to obtain DPOM-DDM (P-4). Yield, 98%; softening temperature, 136-141° C. Phosphorus content: 6.31%.
Preparation Example 5 (P-5, ODOPM-DDS)
To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 1 mole (248 g) diaminodiphenyl sulfone (DDS) was added, heated to 180° C. and then stirred to a molten state. 0.7 g (0.3 wt %) potassium acetate was mixed with the molten DDS followed by adding slowly 1 mole (246 g) ODOPM. The mixture was heated gradually to a temperature of 220° C. when the addition of ODOPM was completed. The substitution reaction was continued for 8 hours. The reaction product was dissolved in cyclohexanone, and washed with water several times before the solvent was evaporated under vacuum to obtain ODOPM-DDS (P-5). Yield, 92%; softening temperature, 147-152° C. Phosphorus content: 5.88%.
Preparation Example 6 (P-6, DPOM-DDS)
To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 1 mole (248 g) diaminodiphenyl sulfone (DDS) was added, heated to 180° C. and then stirred to a molten state. 0.7 g (0.3 wt %) potassium acetate was mixed with the molten DDS followed by adding slowly 1 mole (264 g) DPOM. The mixture was heated gradually to a temperature of 220° C. when the addition of DPOM was completed. The substitution reaction was continued for 8 hours. The reaction product was dissolved in cyclohexanone, and washed with water several times before the solvent was evaporated under vacuum to obtain DPOM-DDS (P-6). Yield, 92%; softening temperature, 141-146° C. Phosphorus content: 6.28%.
Preparation Example 7 (P-7, ODOPM-MA)
To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 1 mole (126 g) Melamine (MA) and 500 ml N,N-dimethylacetamide (DMAc) were added, heated to 90° C. and then stirred until MA was dissolved completely. 0.63 g potassium acetate was mixed with the resulting solution followed by adding slowly 1 mole (246 g) ODOPM. The mixture was heated gradually to a temperature of 168° C. when the addition of ODOPM was completed. The substitution reaction was continued for 8 hours. The reaction mixture was cooled and filtered, and the resulting cake was dried to obtain ODOPM-MA (P-7). Yield, 98%; softening temperature, 129-134° C. Phosphorus content: 8.76%. Nitrogen content: 23.73%.
Preparation Example 8 (P-8, DPOM-MA)
To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 1 mole (126 g) Melamine (MA) and 500 ml N,N-dimethylacetamide (DMAc) were added, heated to 90° C. and then stirred until MA was dissolved completely. 0.63 g potassium acetate was mixed with the resulting solution followed by adding slowly 1 mole (264 g) DPOM. The mixture was heated gradually to a temperature of 168° C. when the addition of DPOM was completed. The substitution reaction was continued for 8 hours. The reaction mixture was cooled and filtered, and the resulting cake was dried to obtain DPOM-MA (P-8). Yield, 98%; softening temperature, 124-130° C. Phosphorus content: 8.33%. Nitrogen content: 22.58%.
Preparation Example 9 (P-9, ODOPM-DICY)
To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 1 mole (86 g) dicyandiamide (DICY) and 500 ml N,N-dimethylacetamide (DMAc) were added, heated to 90° C. and then stirred until DICY was dissolved completely. 0.6 g potassium acetate was mixed with the resulting solution followed by adding slowly 1 mole (246 g) ODOPM. The mixture was heated gradually to a temperature of 168° C. when the addition of ODOPM was completed. The substitution reaction was continued for 8 hours. The reaction mixture was cooled and filtered, and the resulting cake was dried to obtain ODOPM-DICY (P-9). Yield, 98%; softening temperature, 138-143° C. Phosphorus content: 9.87%. Nitrogen content: 17.83%.
Preparation Example 10 (P-10, DPOM-DICY)
To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 1 mole (86 g) dicyandiamide (DICY) and 500 ml N,N-dimethylacetamide (DMAc) were added, heated to 90° C. and then stirred until DICY was dissolved completely. 0.6 g potassium acetate was mixed with the resulting solution followed by adding slowly 1 mole (264 g) DPOM. The mixture was heated gradually to a temperature of 168° C. when the addition of DPOM was completed. The substitution reaction was continued for 8 hours. The reaction mixture was cooled and filtered, and the resulting cake was dried to obtain DPOM-DICY (P-10). Yield, 98%; softening temperature, 129-135° C. Phosphorus content: 9.34%. Nitrogen content: 16.87%.
ii). Dicyandiamide addition product type
Preparation Example 11 (P-11, DOPO-DICY)
To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 1 mole (86 g) dicyandiamide (DICY) was added, heated to 120° C. and then stirred to a molten state. 1 mole (216 g) 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) was added slowly to the molten DICY, and the resulting mixture was heated gradually to a temperature of 190° C. when the addition of DOPO was completed. The addition reaction was continued for 4 hours. The reaction mixture was cooled to obtain DOPO-DICY (P-11). Yield, 96%; softening temperature, 137-143° C. Phosphorus content: 10.26%. Nitrogen content: 18.54%.
Preparation Example 12 (P-12, DPP-DICY)
To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 1 mole (86 g) dicyandiamide (DICY) was added, heated to 120° C. and then stirred to a molten state. 1 mole (234 g) diphenyl phosphite (DPP) was added slowly to the molten DICY, and the resulting mixture was heated gradually to a temperature of 190° C. when the addition of DPP was completed. The addition reaction was continued for 4 hours. The reaction mixture was cooled to obtain DPP-DICY (P-12). Yield, 96%; softening temperature, 134-138° C. Phosphorus content: 9.68%. Nitrogen content: 17.50%.
iii). Substituted melamine and dicyandiamide types
Preparation Example 13 (P-13, ODOPC-MA)
To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 1 mole (126 g) Melamine (MA) and 500 ml N,N-dimethylacetamide (DAMc) were added, heated to 120° C. and then stirred until MA was dissolved completely. 1 mole (251 g) 2-(6-oxid-6H-dibenz<c,e><1,2>oxa-phosphorin-6-yl)chloride (ODOPC) was added slowly to the resulting solution. The mixture was heated gradually to a temperature of 170° C. when the addition of ODOPC was completed. The reaction was continued for 16 hours. The reaction mixture was cooled and filtered, and the resulting cake was dried to obtain ODOPC-MA (P-13). Yield, 94%; softening temperature, 137-142° C. Phosphorus content: 9.10%. Nitrogen content: 24.67%.
Preparation Example 14 (P-14, DPC-MA)
To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 1 mole (126 g) Melamine (MA) and 500 ml N,N-dimethylacetamide (DAMc) were added, heated to 120° C. and then stirred until MA was dissolved completely. 1 mole (253 g) diphenyl phosphoryl chloride (DPC) was added slowly to the resulting solution. The mixture was heated gradually to a temperature of 168° C. when the addition of DPC was completed. The reaction was continued for 10 hours. The reaction mixture was cooled and filtered, and the resulting cake was dried to obtain DPC-MA (P-14). Molecular weight: 558. Yield, 94%; softening temperature, 131-135° C. Phosphorus content: 9.05%. Nitrogen content: 24.53%.
Preparation Example 15 (P-15, ODOPC-DICY)
To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 1 mole (86 g) dicyandiamide (DICY) and 500 ml N,N-dimethylacetamide (DMAc) were added, heated to 120° C. and then stirred until DICY was dissolved completely. 1 mole (251 g) ODOPC was added slowly to the resulting solution. The mixture was heated gradually to a temperature of 170° C. when the addition of ODOPC was completed. The reaction was continued for 8 hours. The reaction mixture was cooled and filtered, and the resulting cake was dried to obtain ODOPC-DICY (P-15). Molecular weight: 515. Yield, 96%; softening temperature, 134-139° C. Phosphorus content: 10.32%. Nitrogen content: 18.64%.
Preparation Example 16 (P-16, DPC-DICY)
To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 1 mole (86 g) dicyandiamide (DICY) and 500 ml N,N-dimethylacetamide (DAMc) were added, heated to 120° C. and then stirred until DICY was dissolved completely. 1 mole (253 g) DPC was added slowly to the resulting solution. The mixture was heated gradually to a temperature of 170° C. when the addition of DPC was completed. The reaction was continued for 8 hours. The reaction mixture was cooled and filtered, and the resulting cake was dried to obtain DPC-DICY (P-16). Molecular weight: 519. Yield, 96%; softening temperature, 127-132° C. Phosphorus content: 10.25%. Nitrogen content: 18.51%.
Preparation of Phosphorus-containing Advanced Epoxy Resins and Cured Epoxy Resins
i). An advanced epoxy resin prepared from bisphenol A epoxy resin and ODOPM-BPA
Example A (P-A)
To a one liter reactor equipped with a temperature controller, a reflux condenser, a nitrogen feed, a vacuum system and a mechanical stirrer, 564 g diglycidyl ether of bisphenol A (BPA epoxy resin) having an epoxide equivalent weight (EEW) of 188 was added, and heated to 110° C. while stirring and vacuuming (<100 mmHg) for a period of 30 minutes to remove a trace amount of water contained in the epoxy resin. The vacuuming was stopped, and dried nitrogen was introduced into the reactor until the atmospheric pressure was reached. The temperature of the reactor was raised to 130° C., and 228 g ODOPM-BPA-A (P-1-A) was then added while stirring. After a molten mixture of ODOPM-BPA-A and BPA epoxy resin was formed, 500 ppm (based on total weight) ethyl triphenyl phosphonium chloride was added, and the temperature of the reaction mixture was increased to 160° C. and maintained at 160° C. for two hours. The equivalent ratio of epoxide group to hydroxyl group was 3.0:1 at the starting point of the reaction. The resultant advanced epoxy resin had an EEW of 396.
Example B (P-B)
The procedures of Example A were repeated except that ODOPM-BPA-A (P-1-A) was replaced by ODOPM-BPA-B (P-1-B). The equivalent ratio of epoxide group to hydroxyl group was 3.0:1 at the starting point of the reaction. The resultant solid advanced epoxy resin had an EEW of 424.
Example C (P-C)
The procedures of Example A were repeated except that ODOPM-BPA-A (P-1-A) was replaced by ODOPM-BPA-C (P-1-C). The equivalent ratio of epoxide group to hydroxyl group was 3.0:1 at the starting point of the reaction. The resultant solid advanced epoxy resin had an EEW of 453.
Control Example A
The procedures of Example A were repeated except that ODOPM-BPA-A (P-1-A) was replaced by bisphenol A. The equivalent ratio of epoxide group to hydroxyl group was 2.04:1 at the starting point of the reaction. The resultant solid advanced epoxy resin (designated as Control) had an EEW of 483.
Control Example B
The procedures of Example A were repeated except that ODOPM-BPA-A (P-1-A) was replaced by tetrabromobisphenol A. The equivalent ratio of epoxide group to hydroxyl group was 2.58:1 at the starting point of the reaction. The resultant solid advanced epoxy resin (designated as TBBA) had an EEW of 483.
Control Example C
The procedures of Example A were repeated except that ODOPM-BPA-A (P-1-A) was replaced by bis(3-hydroxyphenyl) phenyl phosphate (BHPP). The equivalent ratio of epoxide group to hydroxyl group was 2.04:1 at the starting point of the reaction. The resultant solid advanced epoxy resin (designated as BHPP) had an EEW of 483.
ii). Preparation of a cured epoxy resin from an advanced epoxy resin
Cured epoxy resins were prepared from the advanced epoxy resins prepared in Examples A-C and Control Examples A-C with a curing agent selected from phenol-formaldehyde novolac resin (PN), melamine-phenol-formaldehyde-novolac resin (MPN) and dicyandiamide (DICY).
The advanced epoxy resin was mixed with the curing agent (1:1 equivalent ratio) at 150° C. with stirring, and the well mixed molten mixture was poured into a hot aluminum mould, cured in an oven at 175° C. for one hour, and then postcured at 200° C. for two hours.
The thermogravimetric analysis data of the resulting cured epoxy resins are shown in Table 1. The flame-retardant properties of the resulting cured epoxy resins are shown in Table 2.
TABLE 1
TGA data
Rapid rate
Specimens
Temperature of
Temperature of
Tr (° C.)
Char yield at
Advanced
Content of
Tg
5 wt % loss, ° C.
10 wt % loss, ° C.
Step 1
Step 1
Step 2
Step 2
700° C., (%)
epoxy
Hardener
P (%)
(° C.)
Air
N 2
Air
N 2
Air
N 2
Air
N 2
Air
N 2
Control
PN
0
110
417
423
445
441
466
474
634
—
2
15
P-A
PN
1.54
131
387
387
417
413
455
452
674
—
17
24
P-B
PN
2.20
120
377
383
407
401
444
441
590
597
20
26
P-C
PN
2.96
115
367
367
397
393
452
438
622
614
22
27
Control
MPN
0
125
393
407
417
427
474
478
623
—
1
16
P-A
MPN
1.67
143
367
377
387
397
438
450
633
—
15
20
P-B
MPN
2.36
140
357
367
377
387
415
435
641
585
18
22
P-C
MPN
2.97
136
347
347
367
369
397
415
662
612
21
25
Control
DICY
0
132
393
393
417
417
478
481
628
658
2
6
P-A
DICY
1.86
150
367
377
387
387
433
441
627
676
12
16
P-B
DICY
2.61
140
357
363
377
387
429
419
621
692
15
19
P-C
DICY
3.26
137
347
353
363
367
390
407
614
674
17
21
BHPP
PN
4.27
105
345
347
361
361
380
376
532
530
35
37
TBBA
PN
17.72*
124
361
363
365
367
386
380
—
—
10
23
*Content of Br
—: Step 2 of rapid rate was not found
TABLE 2
Flame retardant properties (UL-94 test)
Content of flame-
Burning time
Specimens
retardant element (%)
(Sec)
Fume*
Drip
Classification
PN Control
P (0.00%)
89
—
Yes
V-2
P-A-PN
P (1.54%)
18
— —
No
V-1
P-B-PN
P (2.20%)
0
— —
No
V-0
P-C-PN
P (2.96%)
0
— —
No
V-0
MPN Conrol
P/N (0.00/3.11%)
36
+
No
V-2
P-A-MPN
P/N (1.67/3.93%)
2
— —
No
V-0
P-B-MPN
P/N (2.36/3.71%)
0
— —
No
V-0
P-C-MPN
P/N (2.97/3.11%)
0
— —
No
V-0
DICY Control
P/N (0.00/2.78%)
52
+
No
V-2
P-A-DICY
P/N (1.86/3.36%)
0
— —
No
V-0
P-B-DICY
P/N (2.61/3.14%)
0
— —
No
V-0
P-C-DICY
P/N (3.26/2.96%)
0
— —
No
V-0
TBBA/PN
Br (17.72%)
1
++
Yes
V-0
BHPP/PN
P (4.27%)
0
— —
No
V-0
*++: heavy;
+: slightly;
—: scarcely;
— —: no fume.
The data in Tables 1 and 2 show that the cured epoxy resins prepared from the ODOPM-BPA advanced epoxy resins of the present invention have excellent flame retardant properties in comparison with the conventional cured epoxy resins prepared from BPA advanced epoxy resins, especially no fume and dripping occur in the combustion test, and thus is very suitable for the printed circuit board applications.
Curing of Epoxy Resins with the Phosphorus-containing Hardeners and Nitrogen-phosphorus-containing Hardeners
i). Using P-1 to P-16 hardeners
Examples 1-16
Cured epoxy resins were prepared from a cresol formaldehyde novolac epoxy resin (CNE) with the hardeners P-1 to P-16 prepared in Examples 1 to 16 in an equivalent ratio of epoxide:active hydrogen=1:1 and with 0.2 wt % of triphenylphosphine as a curing accelerator. The mixture was grounded into fine powders to give thermosettable epoxy resin powders. The resin powders were cured in a mold at 150° C. and 50 kg/cm 2 for a period of one hour and then at 170° C. for two hours and further postcured at 200° C. for three hours to obtain cured specimens.
Control Example 1
The procedures of Example 1 were repeated except that ODOPM-BPA-A (P-1-A) used in Example 1 was replaced by phenol formaldehyde novolac resin (PN) to cure the cresol formaldehyde novolac epoxy resin (CNE) in the curing reaction.
Control Example 2
The procedures of Example 1 were repeated except that ODOPM-BPA-A (P-1-A) used in Example 1 was replaced by tetrabromobisphenol A (TBBA) to cure the cresol formaldehyde novolac epoxy resin (CNE) in the curing reaction.
Control Example 3
The procedures of Example 1 were repeated except that ODOPM-BPA-A (P-1-A) used in Example 1 was replaced by bis(3-hydroxyphenyl) phenyl phosphate (BHPP) to cure the cresol formaldehyde novolac epoxy resin (CNE) in the curing reaction.
Control Example 4
The procedures of Example 1 were repeated except that ODOPM-BPA-A (P-1-A) used in Example 1 was replaced by dicyandiamide (DICY) to cure the cresol formaldehyde novolac epoxy resin (CNE) in the curing reaction.
Control Example 5
The procedures of Example 1 were repeated except that ODOPM-BPA-A (P-1-A) used in Example 1 was replaced by melamine (MA) to cure the cresol formaldehyde novolac epoxy resin (CNE) in the curing reaction.
Control Example 6
The procedures of Example 1 were repeated except that ODOPM-BPA-A (P-1-A) used in Example 1 was replaced by bisphenol A (BPA) to cure the cresol formaldehyde novolac epoxy resin (CNE) in the curing reaction.
Control Example 7
The procedures of Example 1 were repeated except that ODOPM-BPA-A (P-1-A) used in Example 1 was replaced by diaminodiphenylmethane (DDM) to cure the cresol formaldehyde novolac epoxy resin (CNE) in the curing reaction.
Control Example 8
The procedures of Example 1 were repeated except that ODOPM-BPA-A (P-1-A) used in Example 1 was replaced by diaminodiphenyl sulfone (DDS) to cure the cresol formaldehyde novolac epoxy resin (CNE) in the curing reaction.
The dynamic mechanical analysis (DMA) properties of the resulting cured epoxy resins are shown in Table 3; the thermogravimetric analysis data thereof are shown in Table 4; and the flame-retardant properties thereof are shown in Table 5.
TABLE 3
dynamic mechanical analysis (DMA) properties
Glass transition
Flexural strength
temperature
at 50° C.
Specimens
Hardeners
(Tg, ° C.)
dyne/cm
Example 1
P-1
154
6.9
Example 2
P-2
142
7.3
Example 3
P-3
232
7.8
Example 4
P-4
186
7.1
Example 5
P-5
243
8.3
Example 6
P-6
202
7.4
Example 7
P-7
226
8.1
Example 8
P-8
178
7.2
Example 9
P-9
208
8.1
Example 10
P-10
186
7.1
Example 11
P-11
223
8.5
Example 12
P-12
189
7.8
Example 13
P-13
224
8.3
Example 14
P-14
181
7.2
Example 15
P-15
225
8.3
Example 16
P-16
187
7.5
Control Ex. 1
PN
176
7.2
Control Ex. 2
TBBA
120
6.1
Control Ex. 3
BHPP
125
6.8
Control Ex. 4
DICY
243
8.1
Control Ex. 5
MA
211
8.1
Control Ex. 6
BPA
150
6.8
Control Ex. 7
DDM
238
8.5
Control Ex. 8
DDS
242
8.7
TABLE 4
TGA data
Maximum
thermal
degradation
Hard-
Td 10%
temper-
Char yield (%)
Specimens
ener
° C.
ature ° C.
at 700° C.
Example 1
P-1
383
413
32
Example 2
P-2
471
405
31
Example 3
P-3
373
398
42
Example 4
P-4
371
395
39
Example 5
P-5
387
401
40
Example 6
P-6
381
401
38
Example 7
P-7
387
421
37
Example 8
P-8
385
413
34
Example 9
P-9
387
421
42
Example 10
P-10
381
403
40
Example 11
P-11
395
429
38
Example 12
P-12
389
403
36
Example 13
P-13
391
411
38
Example 14
P-14
385
403
35
Example 15
P-15
395
429
42
Example 16
P-16
383
413
39
Control Ex. 1
PN
427
473
29
Control Ex. 2
TBBA
387
407
34
Control Ex. 3
BHPP
393
409
37
Control Ex. 4
DICY
418
468
12
Control Ex. 5
MA
395
441
12
Control Ex. 6
BPA
417
446
15
Control Ex. 7
DDM
413
422
30
Control Ex. 8
DDS
417
438
28
TABLE 5
Flame retardant properties (UL-94 test)
Content of P, N
Burning time
Specimens
Hardener
or Br
(Sec)
Drip
Fume
Classification
Example 1
P-1
P (3.62)
0
No
No
V-0
Example 2
P-2
P (3.54)
0
No
No
V-0
Example 3
P-3
P/N (3.75/3.39)
0
No
No
V-0
Example 4
P-4
P/N (3.67/3.31)
0
No
No
V-0
Example 5
P-5
P/N (3.54/3.19)
0
No
No
V-0
Example 6
P-6
P/N (3.47/3.13)
0
No
No
V-0
Example 7
P-7
P/N (2.29/6.20)
0
No
No
V-0
Example 8
P-8
P/N (2.25/6.11)
0
No
No
V-0
Example 9
P-9
P/N (3.38/6.09)
0
No
Yes
V-0
Example 10
P-10
P/N (3.32/6.01)
0
No
No
V-0
Example 11
P-11
P/N (2.38/4.30)
0
No
No
V-0
Example 12
P-12
P/N (2.35/4.24)
0
No
No
V-0
Example 13
P-13
P/N (2.31/6.27)
0
No
No
V-0
Example 14
P-14
P/N (2.30/6.25)
0
No
No
V-0
Example 15
P-15
P/N (3.44/6.22)
0
No
No
V-0
Example 16
P-16
P/N (3.43/6.19)
0
No
No
V-0
Control Ex. 1
PN
0
86
Yes
No
V-2
Control Ex. 2
TBBA
Br (21.19)
0
Yes
Yes
V-0
Control Ex. 3
BHPP
P (4.20)
0
No
No
V-0
Control Ex. 4
DICY
N (6.32)
46
Yes
Yes
V-2
Control Ex. 5
MA
N (6.31)
32
No
Yes
V-2
Control Ex. 6
BPA
0
91
Yes
Yes
V-2
Control Ex. 7
DDM
N (2.81)
83
Yes
Yes
V-2
Control Ex. 8
DDS
N (2.67)
78
Yes
Yes
V-2
It can be seen from Table 3 that the cured epoxy resins of the present invention have glass transition temperatures (Tg) about 60° C. higher than that of the epoxy resin cured with the conventional flame-retardant TBBA hardener, The data in Table 4 show that the cured epoxy resins of the present invention have a better thermal stability and higher char yield than those of the conventional epoxy resin cured by flame-retardant TBBA. The data in Table 5 indicate that the cured epoxy resins of the present invention have excellent flame retardant properties, especially no fume and dripping occur in the combustion test, and thus is very suitable for use in the semiconductor encapsulation applications. The flame-retardant hardeners containing the phosphorus-containing rigid groups disclosed in the present invention can be used to prepare flame-retardant cured epoxy resins having improved thermal properties and flame-retardancy, as shown in Tables 3 to 5. The nitrogen and phosphorus elements contained in the hardeners of the present invention have a synergistic effect in flame-retardancy of the cured epoxy resin.
ii). Using phosphorus-containing BPA hardener (P-1-A) prepared in
Preparation Example 1-A
Various amounts of the hardener ODOPM-BPA-A (P-1-A) were separately mixed with bisphenol (BPA) to form a mixed curing agent for cresol formaldehyde novolac epoxy resin (CNE) to determine the flame-retardant effect of phosphorus. The mixed curing agents consisting of P-1-A/BPA in various weight ratios (0/100, 25/75, 50/50, 75/25, and 100/0) were prepared. Triphenyl phosphine (Ph 3 P) powder was used as a curing accelerator. The CNE was mixed with the above mixed curing agents and 0.2 wt % Ph 3 P in a mill at 25° C. to give thermosettable epoxy resin powders, wherein the equivalent ratio of epoxide group to hydroxyl group is 1:1. The resin powders were cured in a mould at 150° C. and 50 kg/cm 2 for a period of one hour and then at 170° C. for two hours and further postcured at 200° C. for three hours to obtain cured specimens.
For comparison, various weight ratios of tetrabromobisphenol A (TBBA) and PN (25/75, 75/25, 100/0) were also used as a curing agent to prepare the cured specimens as above.
The cured specimens were subjected to the thermogravimetric analysis and the UL-94 test. The results are shown in Table 6 and Table 7.
It can be seen from Table 6 that the Tg values of the phosphorus-containing cured epoxy resin specimens of the present invention (P-1-A/BPA) are about 30° C. higher than those of the conventional bromine-containing cured epoxy resin specimens. Furthermore, the phosphorus-containing cured epoxy resin specimens of the present invention exhibit significantly higher thermal degradation temperatures and higher char yields in comparison with the conventional bromine-containing cured epoxy resin specimens.
The data in Table 7 show that 1.13% phosphorus content of the phosphorus-containing cured epoxy resin of the present invention can produce substantially the same flame-retardant effect as 11.92% bromine content of the conventional bromine-containing cured epoxy resin. In addition, the phosphorus-containing cured epoxy resin specimens of the present invention generate much less fumes in the combustion test.
The results shown in Tables 6 and 7 indicate that the phosphorus-containing cured epoxy resin of the present invention is very suitable for semiconductor encapsulation applications.
TABLE 6
TGA data
Content of
Rapid rate
flame-
Temperature of
Temperature of
Tr (° C.)
Char yield at
retardant
5 wt % loss, ° C.
10 wt % loss, ° C.
Step 1
Step 1
Step 2
Step 2
700° C.,(%)
Specimens
element
Tg(° C.)
Air
N 2
Air
N 2
Air
N 2
Air
N 2
Air
N 2
P (%)
P-1-A/BPA (0/100)
0
150
407
397
421
417
436
446
—
—
4
15
P-1-A/BPA (25/75)
1.13
142
397
387
413
413
435
440
—
—
8
21
P-1-A/BPA (50/50)
2.08
146
383
381
405
401
425
435
620
—
15
24
P-1-A/BPA (75/25)
2.91
151
363
367
393
393
416
421
610
—
21
27
P-1-A/BPA (100/0)
3.62
154
357
353
393
383
412
413
561
567
28
32
Br (%)
TBBA/PN (25/75)
6.39
130
371
381
379
383
385
393
—
—
5
16
TBBA/PN (50/50)
11.92
127
369
377
379
387
385
395
—
—
7
17
TBBA/PN (75/25)
16.82
124
363
367
369
391
387
401
—
—
10
23
TBBA/PN (100/0)
21.29
121
367
369
371
395
391
407
—
—
12
25
—: Step 2 of rapid rate was not found
TABLE 7
Flame retardant properties (UL-94 test)
Burning
Specimens
time (Sec)
Fume*
Drip
Classification
P-1-A/BPA
P %
0/100
0
91
+
Yes
V-2
25/75
1.13
8
+
No
V-0
50/50
2.08
0
— —
No
V-0
75/25
2.91
0
— —
No
V-0
100/0
3.92
0
— —
No
V-0
TBBA/PN
Br %
25/75
6.39
20
++
Yes
V-1
50/50
11.92
6
++
Yes
V-0
75/25
16.82
0
+
No
V-0
100/0
21.19
0
—
No
V-0
*++: heavy;
+: slightly;
—: scarcely;
— —: no fume.
The phosphorus-containing compounds (A)-(I) of the present invention have an active hydrogen, and thus can be used as a staring material for the preparation of flame-retardant epoxy resins by reacting with epihalohydrin under alkaline condition as disclosed in U.S. Pat. No. 4,499,255. The details of this US patent are incorporated herein by reference. The flame-retardant epoxy resins so prepared will have one of the formulas (EP-A) to (EP-I) as follows:
wherein l, m, i, j, k, Z, X, Q and Q′ are defined as above; and L′ is hydrogen or
provided that at least two L′ are L.
Preferably, the flame-retardant epoxy resins (EP-A) to (EP-I) are prepared from the preferred phosphorus-containing compounds of the present invention.
Preferably, the flame retardant epoxy resin has the formula (EP-A).
Preferably, the flame retardant epoxy resin has the formula (EP-B).
The present invention further synthesizes a phosphorus-containing flame-retardant cured epoxy resin by curing the epoxy resin selected from (EP-A) to (EP-I) with the conventional curing agent for the epoxy resin, which preferably is selected from the group consisting of pherol-formaldehyde novolac resin, dicyandiamide and hexahydrophthalic anhydride. Preferably, the curing reaction is carried out at a temperature higher than 150° C. and with stoichiometric amount of the curing agent (hardener). More preferably, the curing reaction is carried out in the presence of a curing promoter such as triphenylphosphine, and in an amount of 0.01˜10.0 parts by weight of the curing promotor per 100 parts by weight of the epoxy resin. The phosphorus-containing flame-retardant cured epoxy resin of the present invention is suitable for use in making a flame-retardant printed circuit board as a matrix resin and in semiconductor encapsulations.
Preparation of Phosphorus-containing Epoxy Resins and Cured Epoxy Resins
i). Preparation of phosphorus-containing epoxy resins
Example 17 (P-D)
To a reaction vessel equipped with a temperature controller, a mechanical stirrer, a reflux condenser, a dean stark trap and a vacuum system was added 91.2 g (0.4 equivalent) of 2-(6-oxid-6H-dibenz<c,e><1,2>oxa-phosphorin-6-yl)methyl-bisphenol-A (ODOPM-BPA-A) (P-1-A), 185 g (2 equivalents) of epichlorohydrin (EPI), and 54 g of 1-methoxy-2-hydroxy propane as a solvent. After stirring at room temperature and atmospheric pressure to thoroughly mix the contents, the temperature was raised to 65° C. and the pressure was reduced to 160 mm Hg absolute. To the resultant solution was continuously added 32 g of 50% aqueous sodium hydroxide solution at a constant rate over a period of 1 hour. During the addition of the sodium hydroxide, the water was removed by codistilling with epichlorohydrin and solvent. The distillate was condensed and introduced into the dean stark trap, wherein two distinct phases, an aqueous phase (top) and an organic epichlorohydrin-solvent phase (bottom) were formed. The aqueous phase was removed continuously and disregarded. The organic phase was continuously returned to the reactor. After completion of the sodium hydroxide addition, the reaction mixture was maintained at a temperature of 65° C. and a pressure of about 160 mm Hg absolute for an additional 30 minutes. The reaction mixture was washed with deionized water two or three times to remove salt after cooling, and subsequently distilled to remove residual EPI resulting in a phosporus-containing epoxy resin (P-D) having an epoxide equivalent weight (EEW) of 298-301.
Example 18 (P-E)
The procedures of Example 17 were repeated except that 82.8 g (0.4 equivalent) 2-(6-oxid-6H-dibenz<c,e><1,2>oxa-phosphorin-6-yl)methyl-4,4′-biphenol-A (ODOPM-BP) was used to replace ODOPM-BPA-A (P-1-A). The resultant phosphorus-containing epoxy resin (P-E) had an EEW of 279-281.
Example 19 (P-F)
The procedures of Example 17 were repeated except that 95.6 g (0.4 equivalent) 2-(6-oxid-6H-dibenz<c,e><1,2>oxa-phosphorin-6-yl)methyl-4,4′-sulfonyl diphenol-A (ODOPM-SDP) was used to replace ODOPM-BPA-A (P-1-A). The resultant phosphorus-containing epoxy resin (P-F) had an EEW of 315-319.
Control Example 9 (BPA-9)
The procedures of Example 17 were repeated except that 45.6 g (0.4 equivalent) bisphenol-A (BPA) was used to replace ODOPM-BPA-A (P-1-A). The resultant phosphorus-containing epoxy resin (BPA-9) had an EEW of 181-185.
Control Example 10 (BP-10)
The procedures of Example 17 were repeated except that 37.2 g (0.4 equivalent) 4,4′-biphenol-A (BP) was used to replace ODOPM-BPA-A (P-1-A). The resultant phosphorus-containing epoxy resin (BP-10) had an EEW of 159-162.
Control Example 11 (SDP-11)
The procedures of Example 17 were repeated except that 50 g (0.4 equivalent) 4,4′-sulfonyl diphenol (SDP) was used to replace ODOPM-BPA-A (P-1-A). The resultant phosphorus-containing epoxy resin (SDP-11) had an EEW of 191-195.
Control Example 12 (TBBA-12)
The procedures of Example 17 were repeated except that 108.8 g (0.4 equivalent) tetrabromobisphenol A (TBBA) was used to replace ODOPM-BPA-A (P-1-A). The resultant phosphorus-containing epoxy resin (TBBA-12) had an EEW of 356-359.
Control Example 13 (BHPP-13)
The procedures of Example 17 were repeated except that 71.6 g (0.4 equivalent) bis(3-hydroxyphenyl) phenyl phosphate (BHPP) was used to replace ODOPM-BPA-A (P-1-A). The resultant phosphorus-containing epoxy resin (BHPP-13) had an EEW of 253-256.
ii). Preparation of a cured epoxy resin from a phosphorus-containing epoxy resin
Cured epoxy resins were prepared from the epoxy resins prepared in Examples 17-19 and Control Examples 9-13 with phenol-formaldehyde novolac resin (PN) as a curing agent.
The epoxy resin was mixed with the curing agent (1:1 equivalent ratio) at 150° C. with stirring, and the well mixed molten mixture was poured into a hot aluminum mould, cured in an oven at 170° C. for one hour, and then postcured at 200° C. for two hours.
The dynamic mechanical analysis (DMA) properties of the resulting cured epoxy resins are shown in Table 8; the thermogravimetric analysis data thereof are shown in Table 9; and the flame-retardant properties thereof are shown in Table 10.
TABLE 8
dynamic mechanical analysis (DMA) properties
Glass transition
Flexural strength
temperature
at 50° C.
Specimens
Epoxy resins
(Tg, ° C.)
dyne/cm
Example 17
P-D
132
6.5
Example 18
P-E
127
6.9
Example 19
P-F
189
8.1
Control Ex. 9
BPA-9
127
6.3
Control Ex. 10
BP-10
121
6.5
Control Ex. 11
SDP-11
187
8.3
Control Ex. 12
TBBA-12
117
6.3
Control Ex. 13
BHPP-13
105
6.9
TABLE 9
TGA data
Maximum
thermal
degradation
Char
Epoxy
Td 10%
temper-
yield (%)
Specimens
resins
° C.
ature ° C.
at 700° C.
Example 17
P-D
397
427
42
Example 18
P-E
401
441
44
Example 19
P-F
381
398
38
Control Ex. 9
BPA-9
417
442
26
Control Ex. 10
BP-10
425
456
24
Control Ex. 11
SDP-11
393
409
18
Control Ex. 12
TBBA-12
409
418
35
Control Ex. 13
BHPP-13
377
393
38
TABLE 10
Flame retardant properties (UL-94 test)
Burning
Epoxy
Content of
time
Classi-
Specimens
resins
P or Br
(Sec)
Drip
Fume
fication
Example 17
P-D
P (4.04)
0
No
No
V-0
Example 18
P-E
P (4.29)
0
No
No
V-0
Example 19
P-F
P (3.88)
0
No
No
V-0
Control Ex. 9
BPA-9
0
81
No
Slightly
V-2
Control Ex. 10
BP-10
0
93
No
Slightly
V-2
Control Ex. 11
SDP-11
0
72
Yes
Yes
V-2
Control Ex. 12
TBBA-12
Br (37.7)
0
No
No
V-0
Control Ex. 13
BHPP-13
P (4.64)
0
No
No
V-0
It can be seen from Table 8 that the cured epoxy resins of the present invention have glass transition temperatures (Tg) about higher than those of the conventional bisphenol-A cured epoxy resin and the conventional flame-retardant TBBA cured epoxy resin. The data in Table 9 show that the cured epoxy resins of the present invention have a better thermal stability and higher char yield than those of the conventional flame-retardant TBBA epoxy resin cured by phenol-formaldehyde novolac resin (PN). The data in Table 10 indicate that the cured epoxy resins of the present invention have excellent flame retardant properties, especially no fume and dripping occur in the combustion test, and thus is very suitable for use in the semiconductor encapsulation applications. The flame-retardant epoxy resins containing the phosphorus-containing rigid group (ODOPM) bonded to BPA, BP and SDP disclosed in the present invention can be used to prepare flame-retardant cured epoxy resins having improved thermal properties and flame-retardancy, as shown in Tables 8 to 10.
The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the appended claims rather than the foregoing description, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein. | The present invention discloses an active-hydrogen-containing phosphorus compound for cross-linking a resin and for imparting flame-retardancy to the cured resin, and in particular to a cured frame-retardant epoxy resin prepared by reacting the hardener with a di- or poly-functional epoxy resin via an addition reaction between the active hydrogen and the epoxide group. The present invention also discloses an epoxy resin made from the active-hydrogen-containing phosphorus compound and epihalohydrin. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit and priority of Korean Patent Application No. 10-2015-0043404, filed 27 Mar. 2015. The entire disclosure of the above applications is incorporated herein by references.
FIELD
[0002] The present disclosure relates to non-reducing end unsaturated mannuronic acid oligosaccharides and compositions containing the same as an active ingredient.
BACKGROUND
[0003] In the modern world, the functional food market is expanding with the increase in complex metabolic syndromes caused by obesity (based on the year 2014, 18% of OECD adults) and diabetes (based on the year 2011, 6.9%).
[0004] The metabolic syndrome refers to the complex occurrence of obesity, type 2 diabetes caused by insulin resistance, and various metabolic abnormalities. The metabolic syndromes rapidly increase due to the aging population and high-calorie diets habits, causing social costs, and thus the prevention of fundamental causes and the development of medical or food materials are urgent.
[0005] In the human intestinal ecosystem, microbes are present at birth to maintain the balance between beneficial bacteria and harmful bacteria. The microbes form intestinal microflora, coexist with humans, and have a direct or indirect effect on human health through interactions with humans. Recently, the National Institutes of Health (NIH) researched the relationships between intestinal microflora and diseases through the “Human Microbiome Project”, and raised the importance of the normalization of the intestinal flora since having unbalanced microbial flora causes the occurrence of inflammatory enteric diseases and the like. 1,2
[0006] According to the paper about the association between obesity and gut microbiome, which was published on the scientific journal “Nature” in 2006, slim people are different from obese people with respect to gut microbiome distribution, and it was confirmed through an experiment using mice that bacteria belonging to the Firmicutes show a relatively higher component percentage than bacteria belonging to the Bacteroidetes in obese mice. 3 Since then, the research about intestinal microbes and the human body has been conducted in various fields, and the development of intestinal microflora improving preparations is needed for the suppression of obesity and the treatment of diseases through the improvement in intestinal microflora.
[0007] Approximately 500,000 species of marine organisms, which correspond to about 80% of all species on Earth, are assumed to exist. However, of these, less than 1% of the marine organisms are being developed as useful living resources, and thus have a very high development potential. Alginic acid, which is a representative seaweed polysaccharide as a seaweed-derived functional material, is contained in 15-35% of brown algae, such as kelp or seaweed, and has polyuronide characteristics, in which two kinds of uronic acids, β-D-mannuronic acid (M) and α-L-guluronic acid (G), are connected via 1,4-glycosidic linkages at various ratios. Alginic acid-derived oligosaccharides may be classified into mannuro-oligosaccharide (MOS), guluro-oligosaccharide (GOS), and mannuronate and guluronate mixed oligosaccharide (alginate oligosaccharide, AOS), according to the component sugar, and may also be classified according to the double bond at the end of sugar.
[0008] Marine-derived polysaccharides have been used in human life for a long time, and the research about biological activities, such as anticancer activity, antioxidation, antihypertension, and antibiotic materials, which are derived from marine organisms, are being conducted actively and globally. The output of alginic acid sources produced globally is approximately 100,000 tons, of which about 30% are used as a food additive, but when the alginic acid sources are developed as high value-added medicinal sources, the values thereof can be doubled. The research of alginic acid-derived oligosaccharides achieves tangible results, such as being reported to have the biological activities of promoting the growth of roots of higher plants, promoting the growth of Bifidobacterium sp., anti-inflammation, antioxidation, and antibiotic activity, according to the structural feature, and thus alginic acid-derived oligosaccharides have widespread application fields.
[0009] Throughout the entire specification, many papers and patent documents are referenced and their citations are represented. The disclosure of the cited papers and patent documents are entirely incorporated by reference into the present specification and the level of the technical field within which the present invention falls, and the details of the present invention are explained more clearly.
SUMMARY
[0010] The present inventors endeavored to promote the use of alginic acid oligosaccharides for food and medicine. As a result, the present inventors investigated non-reducing end unsaturated mannuronic acid oligosaccharides, which are derived from alginic acid and have various biological activities, such as antiobesity and antidiabetic actions, an improvement in intestinal microflora, and estrogen efficacy, and then completed the present invention.
[0011] Therefore, an aspect of the present disclosure is to provide non-reducing end unsaturated mannuronic acid oligosaccharides.
[0012] Another aspect of the present disclosure is to provide compositions for alleviating, preventing, or treating obesity.
[0013] Still another aspect of the present disclosure is to provide compositions for alleviating, preventing, or treating diabetes.
[0014] Another aspect of the present disclosure is to provide probiotics for promoting intestinal beneficial bacteria.
[0015] Still another aspect of the present disclosure is to provide compositions for alleviating, preventing, or treating climacteric syndrome.
[0016] Other purposes and advantages of the present disclosure will become more obvious with the following detailed description of the invention, claims, and drawings.
[0017] In accordance with an aspect of the present invention, there is provided a non-reducing end unsaturated mannuronic acid oligosaccharide having a molecular weight of 100-3000 Da, which is obtained by lysing polymannuronate as a substrate with alginate lyase.
[0018] The present inventors endeavored to promote the use of alginic acid oligosaccharides for food and medicine. As a result, the present inventors investigated non-reducing end unsaturated mannuronic acid oligosaccharides, which are derived from alginic acid and have various biological activities, such as antiobesity and antidiabetic actions, an improvement in intestinal microflora, and estrogen efficacy.
[0019] As used herein, the term “non-reducing” refers to a feature of not having carbon of an anomer (a type of diastereomer in which a hydrogen atom and a hydroxyl group attached on one carbon atom are interchanged with each other in a cyclic reaction generating hemiacetals (forming a ring between C-1 and C-5) and hemiketals (forming a ring between C-2 and C-5) of monosaccharides)) in the oligosaccharide structure.
[0020] As used herein, the term “unsaturated” refers to a form in which a carbon chain with hydrogen atoms is unsaturated, and the term “saturated” refers to a form in which a carbon chain with hydrogen atoms is saturated.
[0021] The non-reducing end unsaturated mannuronic acid oligosaccharides of the present invention include all types of mannuronic acid oligosaccharides, which have no anomeric carbon and of which a carbon chain with hydrogen atoms is unsaturated.
[0022] The non-reducing end unsaturated mannuronic acid oligosaccharide has structural formula 1 shown in an example below (a mannuronic acid oligosaccharide having three linked sugars):
[0000]
[0023] The non-reducing end unsaturated mannuronic acid oligosaccharide has a Z-average molecular weight (m/z) of 175 for one sugar, 351 for two sugars, 527.4 for four sugars, 880 for five sugars, and 1056 for six sugars, and 1232 for seven sugars ( FIG. 2 )
[0024] As used herein, the term “non-reducing end saturated mannuronic acid oligosaccharide” refers to a saturated mannuronic acid oligosaccharide obtained by acid hydrolysis of polymannuronate.
[0025] The non-reducing end unsaturated mannuronic acid oligosaccharide is prepared by lysing polymannuronate as a substrate with alginate lyase.
[0026] According to an embodiment of the present invention, the alginate lyase refers to an enzyme that lyses alginate, which is composed of polyguluronate and polymannuronate, into low molecules.
[0027] According to a specific embodiment of the present invention, the alginate lyase is AlyDW11 (Korean Patent Registration No. 10-1277706) derived from an abalone intestinal strain.
[0028] The non-reducing end unsaturated mannuronic acid oligosaccharide of the present invention is composed of one or more sugars.
[0029] According to an embodiment of the present invention, the non-reducing end unsaturated mannuronic acid oligosaccharide includes one to ten mannuronic acids or guluronic acids. According to another embodiment of the present invention, the non-reducing end unsaturated mannuronic acid oligosaccharide includes one to nine mannuronic acids or guluronic acids. According to still another embodiment of the present invention, the non-reducing end unsaturated mannuronic acid oligosaccharide includes one to eight mannuronic acids or guluronic acids. According to a particular embodiment of the present invention, the non-reducing end unsaturated mannuronic acid oligosaccharide includes one to seven mannuronic acids or guluronic acids.
[0030] The non-reducing end unsaturated mannuronic acid oligosaccharide of the present invention has a deletion of a water molecule, and thus has a smaller mass value by approximately 18, which corresponds to a mass value of the water molecule, compared with the non-reducing end saturated mannuronic acid oligosaccharide ( FIG. 2 ).
[0031] The non-reducing end unsaturated mannuronic acid oligosaccharide of the present invention is composed of mannuronic acids and guluronic acids.
[0032] According to an embodiment of the present invention, the ratio of mannuronic acids : guluronic acids is 1.2-5.0:1 in the non-reducing end unsaturated mannuronic acid oligosaccharide. According to another embodiment of the present invention, the ratio is 1.2-4.5:1. According to still another embodiment of the present invention, the ratio is 1.8-4.0:1. According to a particular embodiment of the present invention, the ratio is 2.0-3.0:1.
[0033] That is, the non-reducing end unsaturated mannuronic acid oligosaccharide more predominantly contains mannuronic acids rather than guluronic acids by 1.2-5.0, 1.2-4.5, 1.8-4.0, or 2.0-3.0 times ( FIG. 4 ).
[0034] In accordance with another aspect of the present invention, there is provided a composition for alleviating, preventing, or treating obesity, the composition containing, as an active ingredient, the non-reducing end unsaturated mannuronic acid oligosaccharide.
[0035] As used herein, the term “obesity” refers to a condition in which adipose tissues are excessively accumulated in the body so as to cause health disorders.
[0036] The non-reducing end unsaturated mannuronic acid oligosaccharide of the present invention suppresses lipid accumulation.
[0037] According to an embodiment of the present invention, the non-reducing end unsaturated mannuronic acid oligosaccharide suppresses the accumulation of triglycerides by 20-60%, 25-50%, or 30-40%, and the non-reducing end saturated mannuronic acid oligosaccharide suppresses the accumulation of triglycerides by 10-30%, 10-25%, or 10-30%.
[0038] According to another embodiment of the present invention, the non-reducing end unsaturated mannuronic acid oligosaccharide suppresses the accumulation of triglycerides by at least two times, compared with the non-reducing end saturated mannuronic acid oligosaccharide.
[0039] The non-reducing end unsaturated mannuronic acid oligosaccharide controls intestinal microflora inducing obesity.
[0040] As used herein, the term “intestinal microflora or gut microflora” refers to microorganism complex community growing in animal guts. Each microorganism constituting intestinal microflora is beneficial or harmful to hosts due to material production or lytic ability, and for example, the intestinal microflora, as a whole, is involved in providing vitamins, preventing infection and helping gut functions (peristaltic movement and absorption), and therefore, the composition of the microflora is closely related to constipation and other intestine-related diseases (Mistuoka T. Bifidobacteria Microflora, 1(1): 3, 1982).
[0041] According to an embodiment of the present invention, the non-reducing end unsaturated mannuronic acid oligosaccharide reduces the growth of intestinal bacterial strains to control the intestinal microflora.
[0042] According to another embodiment of the present invention, the intestinal bacterial strains are selected from the group consisting of Roseburia sp. and Lactobacillus sp.
[0043] The non-reducing end unsaturated mannuronic acid oligosaccharide of the present invention inhibits the expression of adipocyte differentiation-related genes inducing obesity.
[0044] According to an embodiment of the present invention, the non-reducing end unsaturated mannuronic acid oligosaccharide inhibits the expression of adipocyte protein 2 (aP2), CAAT enhancer binding protein α (C/EBPα), and peroxisome proliferator-activated receptor γ (PPARγ).
[0045] According to another embodiment of the present invention, the non-reducing end unsaturated mannuronic acid oligosaccharide inhibits the expression of aP2, C/EBPα, and PPARγ by 15-35%, 50-70%, and 30-50%, respectively. This effect is superior to that of the non-reducing end saturated mannuronic acid oligosaccharide by 1.5-7.0 times.
[0046] The composition for alleviating, preventing, or treating obesity of the present invention may be prepared as a pharmaceutical composition for preventing or treating obesity, or a food composition or functional food composition for alleviating or preventing obesity.
[0047] In accordance with still another aspect of the present invention, there is provided a composition for alleviating, preventing, or treating obesity, the composition containing, as an active ingredient, the non-reducing end unsaturated mannuronic acid oligosaccharide.
[0048] As used herein, the term “diabetes” refers to a chronic disease characterized by a relative or absolute shortage in insulin, causing glucose-intolerance. The term “diabetes” includes all types of diabetes, for example, type 1 diabetes, type 2 diabetes, or hereditary diabetes. Type 1 diabetes is the insulin-dependent diabetes, and is mainly caused by β-cell disruption. Type 2 diabetes is the insulin-independent diabetes, and is caused by an insufficient secretion of insulin after eating or by insulin resistance.
[0049] According to an embodiment of the present invention, the non-reducing end unsaturated mannuronic acid oligosaccharide promotes glucose uptake.
[0050] These effects of the present invention result from only the non-reducing end unsaturated mannuronic acid oligosaccharide, but are not exhibited by the non-reducing end saturated mannuronic acid oligosaccharide.
[0051] According to another embodiment of the present invention, the non-reducing end unsaturated mannuronic acid oligosaccharide promotes glucose uptake via the AMP-activated protein kinase (AMPK) pathway.
[0052] The composition for alleviating, preventing, or treating diabetes of the present invention may be prepared as a pharmaceutical composition for preventing or treating diabetes, or a food composition or functional food composition for alleviating or preventing diabetes.
[0053] In accordance with still another aspect of the present invention, there is provided a probiotic for promoting intestinal beneficial bacteria, containing, as an active ingredient, the non-reducing end unsaturated mannuronic acid oligosaccharide.
[0054] The probiotic for promoting intestinal beneficial bacteria of the present invention promotes the growth of intestinal beneficial bacteria.
[0055] In an embodiment of the present invention, the intestinal beneficial bacteria are selected from the group consisting of Roseburia sp. and Lactobacillus sp.
[0056] As used herein, the term “probiotic” refers to a food supplement containing living bacteria, which helps for the health of a host organic body. The probiotic composition of the present invention may be prepared as a fermented milk product, but may be prepared in the form of a granule, a powder, or the like.
[0057] The administration method of the probiotic composition of the present invention is not particularly limited, but the probiotic composition may be orally administered in the form of a pill or a tablet, or may be administered by being added to food in the form of a powder or a granule. For example, when used as a medicine, the composition of the present invention per se may be used without formulating each component powder, but may be formulated in the dosage form of a powder, a granule, a fine granule, a tablet, a sugar-coated tablet, a capsule, a tablet, an enteric-coated preparation, or the like. An excipient, a binder, a disintegrant, or the like, which is used in general medicinal preparations, may be used as a diluent, and besides, a colorant, a stabilizer, a preserver, a lubricant, or the like may be added. When used as food, the food composition of the present invention per se may be used without formulating each component powder, but may be processed in a form that is suitable to uptake by adding a plant fiber, an oligosaccharide, a grain, a vitamin, and the like, or adding a flavoring, a colorant, a sweetening agent, and the like. In addition, the food composition, as a food additive, may be added and mixed with another food.
[0058] The probiotic for promoting intestinal beneficial bacteria of the present invention may be prepared into a pharmaceutical composition, a food composition, or a functional food composition.
[0059] In accordance with another aspect of the present invention, there is provided a composition for alleviating, preventing, or treating climacteric syndrome, the composition containing, as an active ingredient, the non-reducing end unsaturated mannuronic acid oligosaccharide.
[0060] As used herein, the term “climacteric syndrome” is a kind of female internal secretion syndrome, and refers to a transition period of the reduction or loss of physiological and sexual functions through general and gradual reductions of ovarian functions regardless of natural loss, loss of surgery, or chemically induced loss, and reaching the menopause, as one procedure during the climacteric period, which is a permanent stop of menstruation occurring after the ovarian functions are stopped. In the menopausal period, acute or chronic symptoms may occur depending on hormone changes, such as the reduction in estrogen production, the increases in follicle stimulating hormone and luteinizing hormone, etc. That is, vasomotor symptoms, such as hot flushes and night sweating, and psychological symptoms, such as anxiety, lack of concentration, and depression, may be shown as initial symptoms, and there may be urinary reproductive system and skin symptoms within a few years of menopause, and there may be osteoporosis, cardiovascular, and cerebrovascular diseases in few years after menopause.
[0061] The climacteric syndromes include a symptom selected from the group consisting of facial flushing, sweating, heart discomfort, sleep problems, depression, irritability, anxiety, physical fatigue, mental fatigue, sexual problems, urinary problems, vaginal dryness, joint discomfort, and muscle discomfort.
[0062] The composition containing the non-reducing end unsaturated mannuronic acid oligosaccharide as an active ingredient of the present invention increases the activity of estrogen.
[0063] The non-reducing end unsaturated mannuronic acid oligosaccharide activates estrogen through the expression of estrogen response element (ERE)-mediated underlying genes via an estrogen receptor pathway, in which estrogen acts as a ligand, and an estrogen-related receptor a pathway, which acts independently from estrogen.
[0064] According to an embodiment of the present invention, the non-reducing end unsaturated mannuronic acid oligosaccharide induces the expression of ERE via estrogen receptor α.
[0065] According to another embodiment of the present invention, the non-reducing end unsaturated mannuronic acid oligosaccharide induces the expression of ERE by expressing estrogen-related receptor α.
[0066] The activity of estrogen is increased through the expression of underlying estrogen genes due to the expression of ERE.
[0067] According to still another embodiment of the present invention, the non-reducing end unsaturated mannuronic acid oligosaccharide increases the mRNA expression of presenilin 2 (pS2), progesterone receptor (PR), and E2-mediated cathepsin D (CTSD).
[0068] According to another embodiment of the present invention, the non-reducing end unsaturated mannuronic acid oligosaccharide increases the mRNA expression of peroxisome proliferator-activated receptor gamma coactivator 1-α (PGC-1α), estrogen-related receptor α (ERRα), trans-acting T-cell-specific transcription factor (GATA3), and forkhead box protein A1 (FOXA1).
[0069] GATA3 and FOXA1 are important factors in mammary cell differentiation, and serve to inhibit the differentiation into cancer cells or malignant tumors.
[0070] The composition of the present invention further contains 17β-estradiol.
[0071] According to an embodiment of the present invention, the non-reducing end unsaturated mannuronic acid oligosaccharide shows a synergic effect together with 17β-estradiol.
[0072] The composition of the present invention may be prepared as a pharmaceutical composition for preventing or treating climacteric syndrome, or a food composition or functional food composition for alleviating or preventing climacteric syndrome.
[0073] Here, (a) the composition for alleviating, preventing, or treating obesity; (b) the composition for alleviating, preventing, or treating diabetes; (c) the probiotic for promoting intestinal beneficial bacteria; and (d) the composition for alleviating, preventing, or treating climacteric syndrome, of the present invention, may be prepared into a pharmaceutical composition.
[0074] According to a preferable embodiment of the present invention, the composition of the present invention contains: (a) a pharmaceutically effective amount of the above-described non-reducing end unsaturated mannuronic acid oligosaccharide of the present invention; and (b) a pharmaceutically acceptable carrier. As used herein, the term “pharmaceutically effective amount” refers to an amount that is sufficient to attain the efficacy or activity of the above-described non-reducing end unsaturated mannuronic acid oligosaccharide.
[0075] In cases where the composition of the present invention is prepared as a pharmaceutical composition, the pharmaceutical composition of the present invention contains a pharmaceutically acceptable carrier. The pharmaceutically acceptable carrier contained in the pharmaceutical composition of the present invention is conventionally used at the time of formulation, and examples thereof may include, but are not limited to, lactose, dextrose, sucrose, sorbitol, mannitol, starch, acacia gum, calcium phosphate, alginate, gelatin, calcium silicate, microcrystalline cellulose, polyvinylpyrrolidone, cellulose, water, syrup, methyl cellulose, methyl hydroxybenzoate, propyl hydroxybenzoate, talc, magnesium stearate, and mineral oil. The pharmaceutical composition of the present invention may further contain a lubricant, a wetting agent, a sweetening agent, a flavoring agent, an emulsifier, a suspending agent, a preservative, and the like, in addition to the above ingredients. Suitable pharmaceutically acceptable carriers and preparations are described in detail in Remington's Pharmaceutical Sciences (19th ed., 1995).
[0076] The pharmaceutical composition of the present invention may be administered orally or parenterally, and preferably, the oral administration manner is employed.
[0077] A suitable dose of the pharmaceutical composition of the present invention may vary depending on various factors, such as the method for formulation, manner of administration, the age, body weight, gender, and morbidity of the patient, diet, time of administration, excretion rate, and response sensitivity. A general dose of the pharmaceutical composition of the present invention is within the range of 0.001 μg/kg-100 mg/kg in adults.
[0078] The pharmaceutical composition of the present invention may be formulated into a unit or multiple dosages form using a pharmaceutically acceptable carrier and/or excipient according to the method easily conducted by a person having an ordinary skill in the art to which the present invention pertains. Here, the dosage form may be a solution in an oily or aqueous medium, a suspension, a syrup, or an emulsion, an extract, a powder, a granule, a tablet, or a capsule, and may further include a dispersant or a stabilizer.
[0079] As used herein, the term “containing, as an active ingredient” refers to the inclusion of an amount that is sufficient to attain the efficacy or activity of the above-described non-reducing end unsaturated mannuronic acid oligosaccharide. The quantitative upper limit of the above-described non-reducing end unsaturated mannuronic acid oligosaccharide contained in the composition of the present invention may be selected within an appropriate range by a person skilled in the art.
[0080] Here, (a) the composition for alleviating, preventing, or treating obesity; (b) the composition for alleviating, preventing, or treating diabetes; (c) the probiotic for promoting beneficial bacteria; and (d) the composition for alleviating, preventing, or treating climacteric syndromes, of the present invention, may be prepared into a food composition.
[0081] In cases where the composition containing, as an active ingredient, the non-reducing end unsaturated mannuronic acid oligosaccharide of the present invention, is prepared into a food composition, it contains components that are generally added at the time of food making, besides the non-reducing end unsaturated mannuronic acid oligosaccharide, and contains, for example, proteins, hydrocarbons, fats, nutrients, seasonings, and flavoring agents. Examples of the carbohydrate are monosaccharides, such as glucose and fructose; disaccharides, such as maltose, sucrose, and oligosaccharides; polysaccharides such as dextrin; typical sugars such as cyclodextrin; sugar alcohols, such as, xylitol, sorbitol, and erythritol. Examples of the flavoring agent may be natural flavoring agents (thaumatin, and stevia extract (e.g., rebaudioside A, glycyrrhizin, etc.)) and synthetic flavoring agents (saccharin, aspartame, etc.) For example, a drink, which is made from the food composition, may further contain citric acid, liquefied fructose, sugar, glucose, acetic acid, malic acid, fruit juice, an extract of Eucommia ulmoides, a jujube extract, and an licorice extract, in addition to the non-reducing end unsaturated mannuronic acid oligosaccharide of the present invention.
[0082] The composition of the present invention may be prepared as a functional food composition containing, as an active ingredient, the non-reducing end unsaturated mannuronic acid oligosaccharide of the present invention. The composition of the present invention, when prepared as a functional food composition, contains components that are normally added at the time of food making, for example, proteins, carbohydrates, fats, nutrients, seasoning, and flavoring agents. For example, the composition of the present invention, when used as a drink, may contain a flavoring agent or a natural hydrocarbon as an additive component, in addition to the non-reducing end unsaturated mannuronic acid oligosaccharide. Examples of the natural hydrocarbon include monosaccharides (e.g., glucose, fructose, etc.); disaccharides (e.g., maltose, sucrose, etc.); oligosaccharides; polysaccharides (e.g., dextrin, cyclodextrin, etc.); and sugar alcohols (e.g., xylitol, sorbitol, erythritol, etc.). As the flavoring agent, natural flavoring agents (e.g., thaumatin, stevia extract etc.) and synthetic flavoring agents (e.g., saccharin, aspartame, etc.,) may be used.
[0083] The non-reducing end unsaturated mannuronic acid oligosaccharide is an active ingredient for biological activity of alginate, which is known in the prior art, and exhibits an antiobesity effect, an antidiabetic effect, an effect of improving climacteric syndrome, and an effect of controlling intestinal microflora. These effects are remarkably superior compared with the non-reducing end saturated mannuronic acid oligosaccharide, and this means that the double bond at the end sugar of the non-reducing end saturated mannuronic acid oligosaccharide and the unsaturated form thereof are important factors.
[0084] Features and advantages of the present invention are summarized as follows:
[0085] (a) The present invention provides non-reducing end unsaturated mannuronic acid oligosaccharides, and pharmaceutical compositions for alleviating, preventing, or treating obesity, diabetes, and climacteric syndrome, and probiotics for promoting intestinal beneficial bacteria, the pharmaceutical compositions and the probiotics contain the non-reducing end unsaturated mannuronic acid oligosaccharide as an active ingredient.
[0086] (b) The present invention leads to a production of non-reducing end unsaturated mannuronic acid oligosaccharides, which are active materials of alginate, and thus provides its excellent antiobesity effect, antidiabetic effect, estrogen activity, and an intestinal microflora controlling effect.
[0087] (c) These effects are remarkably excellent compared with mannuronic acid oligosaccharides having a non-reducing end saturated mannuronic acid oligosaccharide of the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0088] The above and other objects, features, and advantages of the present invention will be more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0089] FIG. 1 shows thin-layer chromatography results of non-reducing end unsaturated mannuronic acid oligosaccharides;
[0090] FIG. 2 shows mass analysis results of non-reducing end unsaturated mannuronic acid oligosaccharides and non-reducing end saturated mannuronic acid oligosaccharides;
[0091] FIG. 3 shows a double bond ratio of non-reducing end unsaturated mannuronic acid oligosaccharide (USMOS) and non-reducing end saturated mannuronic acid oligosaccharide (SMOS);
[0092] FIG. 4 shows circular dichroism (CD) confirmation results of the sugar composition of non-reducing end unsaturated mannuronic acid oligosaccharide (USMOS) and non-reducing end saturated mannuronic acid oligosaccharide (SMOS);
[0093] FIGS. 5 a and 5 b show results of inhibiting lipid accumulation and inhibiting the expression of obesity-related genes aP2, C/EBPα, and PPARγ using real-time PCR, by the treatment with non-reducing end unsaturated mannuronic acid oligosaccharide (USMOS);
[0094] FIGS. 6 a to 6 c show glucose uptake promotion results and expression levels of related proteins, p-PAK, p-Akt, and p-AS160, by the treatment with non-reducing end unsaturated mannuronic acid oligosaccharide (USMOS);
[0095] FIGS. 7 a and 7 b show intestinal microflora analysis results of obesity-induced rats by intraperitoneal administration of non-reducing end unsaturated mannuronic acid oligosaccharide (USMOS);
[0096] FIG. 8 shows principal coordinate (POC) analysis results of intestinal microflora of old mice by the uptake of a non-reducing end unsaturated mannuronic acid oligosaccharide (USMOS);
[0097] FIG. 9 shows phylum-level comparative analysis results of the intestinal microflora change of old mice by the uptake of non-reducing end unsaturated mannuronic acid oligosaccharide (USMOS);
[0098] FIGS. 10 a and 10 b show mRNA expression levels of pS2, PR, and CTSD by the treatment with non-reducing end unsaturated mannuronic acid oligosaccharide (USMOS);
[0099] FIG. 11 shows mRNA expression levels of PGC-1α, ERRα, GATA3, and FOXA1 by the treatment with a non-reducing end unsaturated mannuronic acid oligosaccharide (USMOS);
[0100] FIG. 12 shows a mechanism of non-reducing end unsaturated mannuronic acid oligosaccharide (USMOS); and
[0101] FIG. 13 shows various biological activity effects of non-reducing end unsaturated mannuronic acid oligosaccharide (USMOS).
DETAILED DESCRIPTION
[0102] Hereinafter, embodiments of the present invention will be described below in detail with reference to the accompanying drawings, so that those of ordinary skill in the art may easily work the embodiments. However, the present invention may be realized in various different forms, and therefore is not limited to embodiments to be described herein.
EXAMPLE 1
Preparation of Alginic Acid Oligosaccharide
[0103] For the preparation of poly-mannuronate (poly M), 1 g of sodium alginate (Wako, Osaka Japan) and 100 ml of 0.3 M HCl were placed together, and heated at 100° C. for 2 hours. The heated sodium alginate-HCl solution was centrifuged at 500 g for 5 min, and the separated precipitate was dissolved in distilled water. After NaCl was added such that the precipitate dissolved in the distilled water has 0.1 M, the solution was adjusted to pH of 2.8-3.0, and then centrifuged at 500 g for 5 min to separate supernatant and precipitate. The separated precipitate and supernatant were subjected to alcohol precipitation and drying, to prepare poly M from the supernatant and poly G from the precipitate, which were used as substrates for preparing mannuronic acid oligosaccharides using alginate lyase (Haug, A et al. A study of the constitution of alginic acid by partial acid hydrolysis. Acta Chemica Scandinavica, 1966, 20(1): 183-190., and Joo, D. S. et al. Preparation of oligosaccharides from alginic acid by enzymatic hydrolysis. Korean Society of Food Science and Technology, 1996, 28(1): 146-151).
[0104] For the preparation of non-reducing end unsaturated mannuronic acid oligosaccharides, a transgenic strain was used, wherein the transgenic strain was produced by recombining a gene corresponding to ORF11, which was selected from metagenomic library of intestine DNA of abalone inhabiting the sea near Yeosu, Korea in February 2009, and has an excellent mannuronic acid lysing ability, in pMAL-c2x expression vector, and then cloning it in the BL21(DE3) strain (Korean Patent No 10-1277706).
[0105] 500 ml of the transgenic strain was inoculated in Luria-Bertani (LB) supplemented with 40 L of ampicillin (100 μg/ml), and cultured at 37° C. When the absorbance at 600 nm reached 0.4-0.5, isopropyl-β-D-thiogalactopyranoside (IPTG) was added to the culture to a final concentration of 0.3 mM, followed by culturing for 12 hours. On the completion of the culturing, the culture was centrifuged at 9,000 g for 15 min to precipitate cells. After the precipitated cells were suspended in 10 mM phosphate buffer (pH 7.0), sonication was performed for cell membrane disruption, and centrifugation at 9,000 g for 15 min was performed for coenzyme isolation. After the centrifugation, the separated supernatant was used as a coenzyme. 0.3% poly-mannuronate (poly M) was dissolved in 1 L of 10 mM phosphate buffer (pH 7.0), and AgNO 3 was added to a final concentration of 1 mM. A substrate lysis reaction was conducted at 45° C. for 48 h using a 2.5 L-fermentor (KBT KB-250, Japan). After the reaction, the resultant material was filtered through an ultrafiltration membrane system (Vivaflow 50, Sartorius, Ag, Germany) to obtain a mixture of oligosaccharides with a molecular weight of 3,000 Da or less, followed by lyophilization, to prepare non-reducing end unsaturated mannuronic acid oligosaccharides.
[0106] Thin-layer chromatography was performed to investigate the production of oligosaccharides, and the method thereof was as follows. The non-reducing end unsaturated mannuronic acid oligosaccharides were dissolved in water to a concentration of 0.1 mg/μl, and then 3 μl of the solution was spotted on silica gel plate (Merck KGaA, Germany). The non-reducing end unsaturated mannuronic acid oligosaccharides were sorted by the size thereof using a development solvent (1-butanol:formic acid:water=4:6:1), and then the presence of oligosaccharides was confirmed using a color developing reagent (anise aldehyde 0.5 ml, acetic acid 10 ml, MeOH 85 ml, H 2 SO 4 5 ml) added with sulfuric acid.
EXAMPLE 2
Composition and Structural Characterization of Non-Reducing End Unsaturated Mannuronic Acid Oligosaccharides
[0107] In the present example, poly mannuronate was lysed with AlyDW11 alginate lyase to secure a mixture of the non-reducing end unsaturated mannuronic acid oligosaccharides, from which fractions with a molecular weight of 3000 Da or less were then secured using an ultrafiltration membrane system (VivaFlow 50, Sartorius). In order to analyze component sugars of the non-reducing end unsaturated mannuronic acid oligosaccharides, the prepared sample was purified using an ion exchange resin column (Hitrap DEAE Sepharose FF, GE Healthcare), followed by lyophilization. The purified non-reducing end unsaturated mannuronic acid oligosaccharides were dissolved in water, and then the solution was injected into UPLC/MS system to analyze component sugars thereof.
[0108] For setting ultra performance liquid chromatography (UPLC, Waters), ACQUITY UPLC BEH C18 column (1.7 μm 1.0×100 mm, Waters) was used, and the linear gradient of solvent A (15 mM amylamine and 25 mM hexafluoroisopropanol (HFIP)) and solvent B (15 mM amylamine and 25 mM HFIP in acetonitrile) was controlled at 0.4 ml/min for 12 min. The eluate separated from C 18 -UPLC was analyzed using a mass spectrometer (Quadrupole-Time of Flight, Q-TOF, Waters). Q-TOF analysis was carried out in the ESI negative mode, and the conditions were: capillary and cone voltages were 3 kV and 40 V, respectively; desolvation flow rate was 600 L/h; temperature was 300° C.; and source temperature was 120° C. TOF MS data was analyzed at a scan time of 0.5 s in the range m/z 100-1300. For accurate analysis, 2 ng/μl leucine enkephalin (554.2619 Da in ESI negative mode) was used as a lock spray for all analysis.
[0109] As can be seen in FIG. 2 , as a result of mass analysis results of the non-reducing end unsaturated mannuronic acid oligosaccharides, the non-reducing end unsaturated mannuronic acid oligosaccharides are composed of one to seven sugars, and especially, peaks having mass values, which are smaller than the previously reported mass values of mannuronic acid oligosaccharides by 18, were observed, and thus it can be seen that non-reducing end saturated mannuronic acid oligosaccharides are formed through the removal of a water molecule, and are more dominant than non-reducing end saturated mannuronic acid oligosaccharides (SMOS).
[0110] The results showing the ratios of non-reducing end unsaturated mannuronic acid oligosaccharide (USMOS) to non-reducing end saturated mannuronic acid oligosaccharide (SMOS) were present in FIG. 3 . As shown in FIG. 3 , it was verified that the non-reducing end unsaturated mannuronic acid oligosaccharides had, on average, two times or more monosaccharides than the non-reducing end saturated mannuronic acid oligosaccahrides. The molecular weights of the non-reducing end saturated mannuronic acid oligosaccharides are as follows: 1 sugar (m/z 193), 2 sugars (m/z 369), 3 sugars (m/z 545), 4 sugars (m/z 722), 5 sugars (m/z 898) 6 sugars (m/z 1074), 7 sugars (m/z 1250).
[0111] In order to measure the percentage of mannuronic acids in the non-reducing end unsaturated mannuronic acid oligosaccharides, a circular dichroism (CD) spectroscopy signal was measured using circular dichroism spectroscopy (CD, J-715 spectropolarimeter, JASCO). CD signals were measured in the region of 190-250 nm using a cuvette (1 cm) at room temperature, and in order to obtain consistent CD signals, the non-reducing end unsaturated mannuronic acid oligosaccharides were used at 1 mg/ml. In order to investigate the composition ratio of mannuronic acid:guluronic acid, the ratio of mannuronic acid and guluronic acid was calculated by measuring a peak (an absorbance value at 200 nm) and a trough (an absorbance value at 215 nm). The calculation is as follows:
[0000] peak/trough<1, mannuronic acid/guluronic acid=2.0 (peak/trough) (1)
[0000] peak/trough>1, mannuronic acid/guluronic acid=27 (peak/trough)+40 (2)
[0112] As can be seen from FIG. 4 , it was confirmed that the non-reducing end unsaturated mannuronic acid oligosaccharides had a mannuronic acid/guluronic acid ratio of 2.12 (peak=6.66, trough=6.42).
EXAMPLE 3
Suppression of Non-Reducing End Unsaturated Mannuronic Acid Oligosaccharides on Adipocyte Lipid Accumulation
[0113] When 3T3-L1 preadiocytes were cultured in DMEM medium to reach confluence, the cells were treated with 0.5 mM isobutylmethylxanthine (IBMX), 1 mM dexamethasone, and 1 μg/ml insulin (MDI) for 2 days, and then the medium was exchanged with DMEM+serum medium supplemented with 1 μg/ml insulin at an interval of 48 hours, to induce the differentiation into adipocytes for 7 days. At the time of the exchange of medium, the cells were treated with the non-reducing end unsaturated mannuronic acid oligosaccharides at 0.2 mg/ml. After 7 days, the adipocyte lipid accumulation and the degree of suppression of differentiation were observed by Oil red O staining and RNA extraction, and the results were depicted in FIG. 5 a.
[0114] As can be seen from FIG. 5 a , as a result of observing triglycerides, which were stained with Oil red O, using an optical microscope, the treatment with non-reducing end unsaturated mannuronic acid oligosaccharides at 0.2 mg/ml resulted in a significantly weaker Oil red O staining intensity in the adipocytes, compared with a control. Further, as a quantitative result of triglycerides, which were stained with Oil red O, through pigment extraction, USMOS having a double bond at the non-reducing end suppressed triglyceride accumulation by about 40%, compared with the control, and non-reducing end saturated mannuronic acid oligosaccharides suppressed the lipid accumulation by about 15%, compared with the control. Hence, it was verified that the formation of a double bond is an important factor in the antiobesity effect.
[0115] 3T3-L1 preadiocytes were differentiated into adipocytes by the same method. The cells were treated with non-reducing end unsaturated mannuronic acid oligosaccharides at 0.2 mg/ml, and then RNA extraction was conducted by the GeneJET RNA purification kit, and thereafter, the results of the inhibition of the expression of aP2, adipose differentiation-related gene CAAT enhancer binding protein α (C/EBPα), and peroxisome proliferator-activated receptor γ (PPARγ), which are adipose differentiation markers, were depicted in FIG. 5 b.
[0116] As shown in FIG. 5 b , it was verified that the treatment with non-reducing end unsaturated mannuronic acid oligosaccharides reduced the expression levels of aP2, C/EBPα, and PPARγ by 25%, 60%, and 40%, respectively, compared with the control. In addition, it was verified that the non-reducing end unsaturated mannuronic acid oligosaccharides had an excellent antiobesity effect, compared with the non-reducing end saturated mannuronic acid oligosaccharides.
EXAMPLE 4
Verification on Control of Glucose Uptake by Non-Reducing End Unsaturated Mannuronic Acid Oligosaccharides
[0117] L6 muscle cells were cultured in DMEM medium containing 10% serum, and the L6 cells were completely differentiated while the medium was exchanged with 2% serum medium. The culture medium containing the completely differentiated L6 muscle cells was exchanged with serum-free DMEM medium, and the cells were treated with non-reducing end unsaturated mannuronic acid oligosaccharides at 0.2 mg/ml for 1 hour. After that, the medium treated with non-reducing end unsaturated mannuronic acid oligosaccharides was discarded, followed by washing two times with previously warmed Krebs-Ringer Hepes buffer (KRH buffer) at 37° C., thereby removing glucose in the medium. After the treatment with 0.04 mM [ 3 H]-2-deoxyglucose for 15 min, the KRH buffer, which contained [ 3 H]-2-deoxyglucose, was promptly discarded, and then ice-cooled PBS was added to stop the reaction. The cells were disrupted using a cell lysis buffer, and then the radioactivity measurement was conducted using a scintillation counter to investigate a glucose transport ability increasing effect by alginic acid oligosaccharide treatment.
[0118] As shown in FIG. 6 a , it was verified that the treatment with non-reducing end unsaturated mannuronic acid oligosaccharides promoted the intracellular glucose uptake to a similar degree, compared with insulin (0.2 μM) as a positive control. It was verified that, as the treatment with non-reducing saturated mannuronic acid saccharide at 0.2 mg/ml did not lead to glucose uptake, the formation of a double bond at the non-reducing end was important in the promotion of glucose uptake. In addition, it was verified that, as the co-treatment with non-reducing end unsaturated mannuronic acid oligosaccharides and 1 μM compound C (C. C), which is an inhibitor of AMP-activated protein kinase (AMPK) as an important protein in glucose uptake, suppressed glucose uptake, the non-reducing end unsaturated mannuronic acid oligosaccharides promoted the glucose uptake via AMPK pathway ( FIG. 6 b ).
[0119] In order to investigate an increase in phosphorylation of PAK, Akt, and AS160, which influence the expression of transporters related to the promotion of glucose uptake, by the treatment with non-reducing end unsaturated mannuronic acid oligosaccharides, the muscle cells were treated with different concentrations of non-reducing end unsaturated mannuronic acid oligosaccharides, followed by protein extraction and western blotting. As a result, as shown in FIG. 6 c , it was verified that the phosphorylation was increased in a dose-dependent manner of the non-reducing end unsaturated mannuronic acid oligosaccharides. Therefore, it was anticipated that the non-reducing unsaturated mannuronic acid oligosaccharides would promote the AMPK pathway and the phosphorylation of PAK, Akt, and AS160, for the promotion of glucose uptake, to influence the expression of glucose transporter 4 (GLUT4).
EXAMPLE 5
Verification on Intestinal Microflora Controlling Efficacy by Non-Reducing End Unsaturated Mannuronic Acid Oligosaccharides
[0120] In order to investigate the intestinal microflora improvement efficacy of non-reducing end unsaturated mannuronic acid oligosaccharides, rats were used as obese animal models and mice were used as aged animal models. 3-week aged male SD rats, as obesity-induced rats, were purchased from Central Lab. Animal Inc, and then acclimatized for 3 days. The feeding environment was as follows: temperature was 20±2° C., relative humidity was 50±10%, light/dark cycle was 12 hours per day, and a high-fat diet was induced for 10 weeks. An experiment was carried out while non-reducing end unsaturated mannuronic acid oligosaccharides (0.25 mg/kg) were intraperitoneally administered to experiment groups at an interval of 48 hours. 1-month and 17-month aged male C57BL/6J mice, as old mice, were purchased from Korea Basic Science Institute. The feeding environment was as follows: temperature was 20±2° C., relative humidity was 50±10%, light/dark cycle was 12 hours per day, and an experiment was carried out for 10 weeks. For experiment groups, non-reducing end unsaturated mannuronic acid oligosaccharides (0.2 mg/kg) were supplied to water. After the completion of the experiment, intestine contents of the experimental animals were collected, and 200 mg thereof were taken to secure pure DNA using Fast DNA™SPIN Kit for Soil kit on the basis of the method suggested in the kit. The concentration and purity of the extracted DNA were measured using a Nanodrop, and then the DNA concentration and purity were investigated on the basis of DNA band results extracted through agarose gel electrophoresis. For the amplification of bacterial 16S rRNA gene in isolated DNA, amplification PCR was performed using 27F forward primer (GAGTTTGATCMTGGCTCAG) containing V1-V3 hypervariable region and 518R reverse primer (WTTACCGCGGCTGCTGG) under conditions of initial denaturation at 94° C. for 5 min and 30 cycles of 30 seconds at 94° C., 45 seconds at 55° C., and 1 minute and 30 seconds at 72° C. PCR products purified through QIAquick gel extraction kit (Qiagen, Germany) were pyrosequenced using GS Junior Titanium system (Roche, Germany) as a DNA sequencer. Methods and reactions necessary for the pyrosequencing were carried out by ChunLab (Korea) according to the manufacturer's manuals.
[0121] As shown in FIGS. 7 a and 7 b , in the intestinal microflora of obese rats receiving non-reducing end unsaturated mannuronic acid oligosaccharides, Roseburia sp. and Lactobacillus sp., which belong to gram positive bacteria (Firmicutes), were increased by about 4% and 2%, respectively, compared with the control (obesity-induced rats, high-fat diet (HFD)), resulting in the microflora change, and Clostridium sp. and Ruminococcus sp., which belong to gram negative bacteria (Bacteroidetes), were increased by about 1%, respectively. 4,5
[0122] As shown in FIG. 8 , it was verified through PCO analysis that, in the old mice drinking non-reducing end unsaturated mannuronic acid oligosaccharides, the intestinal microflora thereof was similar to that of 1-month aged mice, but were different from that of 17-month aged mice. In addition, it was verified that the above old mice formed similar intestinal microflora to 1-month aged mice taking non-reducing end unsaturated mannuronic acid oligosaccharides.
[0123] As can be seen from FIG. 9 , it was verified that, in the 17-month old mice taking non-reducing end unsaturated mannuronic acid oligosaccharides, gram positive bacteria (Bacteroidetes) were increased by about 22%, and relatively, gram negative bacteria (Firmicutes) were decreased by about 22%, compared with a control (17-month aged mice), and these results were similar to the intestinal microflora of the 1-month aged mice.
EXAMPLE 6
Verification on Estrogen Sensitizer Function of Non-Reducing Unsaturated Mannuronic Acid Oligosaccharides
[0124] 17β-estradiol used in the present study was purchased from Sigma (St. Louis, Mo., USA), and Dulbecco's modified Eagle's medium/F12 (DMEM/F12), fetal bovine serum, Opti-MEM medium, and penicillin-streptomycin were purchased from Gibco (NY, USA). PBS, cell count kit (CCK-8), RNeasy small kit, bovine insulin, and FuGENE HD were purchased from WeIGENE (Daegu, Korea), Dojindo Molecular Technologies (Tokyo, Japan), QIAGEN (Hiden, Germany), Cell Applications (San Diego, USA), and Promega (Madison, Wis., USA), respectively.
[0125] MCF-7 cells were cultured at 37° C. in DMEM/F12 medium supplemented with 10% bovine fetal serum, penicillin-streptomycine (100 U/ml), and 1% bovine insulin, and in order to measure estrogen sensitizer activity, the estrogen response element (ERE)-luciferase activity and the expression levels of pS2, PR, CTSD, PGC-1α, ERR, GATA3, and FOXO1 were investigated.
[0126] The cells were treated with non-reducing end unsaturated mannuronic acid oligosaccharides (0.1 mg/ml) for 48 hours, and then, in order to investigate ERE-luciferase activity, luciferase analysis was carried out by transfecting the MCF-7 cells with pEGFP-C1-ERα, 3× ERE TATA luc, and pRL-SV40 using FuGENE HD reagent, followed by dissolving. RNA extraction was carried out by GeneJET RNA purification kit method, and then the expression levels of pS2, PR, CTSD, PGC-1α, ERR, GATA3, and FOXO1 were investigated through real-time PCR.
[0127] As shown in FIGS. 10 a and 10 b , it was verified that, unlike the non-reducing end saturated mannuronic acid oligosaccharides, the treatment with non-reducing end unsaturated mannuronic acid oligosaccharides increased the expression of pS2, which is an estrogen signal underlying gene, by about five times, compared with the control, and the co-treatment with estrogen (E2 and 17β-estradiol) and the non-reducing end unsaturated mannuronic acid oligosaccharides increased ERE luciferase activity and the expression of pS2 and PR, through estrogen receptor α (ERα), and reduced the expression of CTSD, and thus the non-reducing end unsaturated mannuronic acid oligosaccharides selectively regulated the expression of estrogen receptor α underlying signal genes.
[0128] As shown in FIG. 11 , the treatment with non-reducing end unsaturated mannuronic acid oligosaccharides increased the expression of peroxisome proliferator-activated receptor c coactivator-1a (PGC-1α) and its transcription partner, estrogen related receptor α (ERRα), thereby increasing mRNA expression of GATA binding protein 3 (GATA3) and forkhead box protein A1 (FOXO1) together with ERα pathway, and thus the non-reducing end unsaturated mannuronic acid oligosaccharides had an estrogen sensitizer efficacy.
EXAMPLE 7
Mechanism Diagram of Antiobesity, Anti-Diabetic, and Estrogen Sensitivity-Increasing Actions of Non-Reducing end Unsaturated Mannuronic Acid Oligosaccharides
[0129] The overall diagram of mechanisms of antiobesity, anti-diabetic, and estrogen sensitivity-increasing actions of the non-reducing end unsaturated mannuronic acid oligosaccharides was presented in FIG. 12 .
[0130] As shown in FIG. 12 , as a result of summarizing the mechanisms of antiobesity, anti-diabetic, and estrogen sensitivity-increasing actions by the treatment with non-reducing end unsaturated mannuronic acid oligosaccharides, it was verified that the treatment with non-reducing end unsaturated mannuronic acid oligosaccharides increased the expression of PGC-1α through AMPK activation, and activated estrogen-related receptor α, β, γ (ERRs), which are transcription partners of PGC-1α, thereby promoting fatty acid β oxidation, and thus the non-reducing end unsaturated mannuronic acid oligosaccharides had an antiobesity effect. In addition, as intramuscular AMPK has been reported to promote the fatty acid β oxidation metabolism, by mediating the fatty acid synthesis and degradation, and to increase the expression of mitochondria-related genes through PGC-1 expression, the non-reducing end unsaturated mannuronic acid oligosaccharides were anticipated to increase the expression and number of mitochondrial genes through AMPK activation and by increasing the expression of PCG-1α, and thus the non-reducing end unsaturated mannuronic acid oligosaccharides had an efficacy of improving insulin resistance.
[0131] It was verified that, the non-reducing end unsaturated mannuronic acid oligosaccharides, as an estrogen sensitizer, when used together with estrogen, increased the mRNA expression of GATA3 and FOXO1 through the estrogen receptor α (ERα) pathway, and increased the expression of ERRα and PGC-1α, and thus the non-reducing end unsaturated mannuronic acid oligosaccharide had an estrogen sensitizer function by activating ERE through the ERα pathway dependent on PGC-1α.
[0132] In addition, it was verified that the non-reducing end unsaturated mannuronic acid oligosaccharides improved the intestinal microflora in the body, and thus increased antiobesity indicator strains ( Roseburia sp. and Lactobacillus sp.) and decreased obesity indicator strains ( Clostridium sp. and Ruminococcus sp.), and thus the non-reducing end unsaturated mannuronic acid oligosaccharides had antiobesity, anti-diabetic, intestinal microflora-improving, and estrogen sensitivity-increasing efficacies in combination.
REFERENCES
[0133] 1. Qin J1 et al. A human gut microbial gene catalogue established by metagenomic sequencing. nature. 2010. 59-65
[0134] 2. Human Microbiome Project Consortium. Structure, function and diversity of the healthy human microbiome. nature. 2012. 207-214
[0135] 3. Turnbaugh P J et al. An obesity-associated gut microbiome with increased capacity for energy harvest. nature. 2006. 1027-31
[0136] 4. Nadal I et al. is in clostridia, bacteroides and immunoglobulin-coating fecal bacteria associated with weight loss in obese adolescents. Int J Obes (Lond). 2009. 758-767
[0137] 5. Neyrinck A M et al. Prebiotic Effects of Wheat Arabinoxylan Related to the Increase in Bifidobacteria, Roseburia and Bacteroides/Prevotella in Diet-Induced Obese Mice. PLoS One. 2011. e20944
[0138] Although the present invention has been described in detail with reference to the specific features, it will be apparent to those skilled in the art that this description is only for a preferred embodiment and does not limit the scope of the present invention. Thus, the substantial scope of the present invention will be defined by the appended claims and equivalents thereof. | Disclosed is a non-reducing end unsaturated mannuronic acid oligosaccharide having a molecular weight of 100-3000 Da, which is obtained by lysing polymannuronate as a substrate with alginate lyase, and provided are: a non-reducing end unsaturated mannuronic acid oligosaccharide; and pharmaceutical compositions for alleviating, preventing, or treating obesity, diabetes, and climacteric syndrome, and probiotics for promoting intestinal beneficial bacteria, the compositions and probiotics containing, as an active ingredient, the non-reducing end unsaturated mannuronic acid oligosaccharide, so that the antiobesity and antidiabetic effects, estrogen activity, and intestinal microflora controlling effect of the non-reducing end unsaturated mannuronic acid oligosaccharides are remarkably excellent as compared with non-reducing end saturated mannuronic acid oligosaccharides. | 0 |
This application is a continuation-in-part of U.S. patent application Ser. No. 08/004,404 filed Jan. 14, 1993, now abandoned. It is in turn a continuation-in-part of U.S. patent application Ser. No. 07/965,817, filed Oct. 23, 1992now abandoned, which is a continuation-in-part of U.S. patent application Ser. No. 07/880,379, filed May 8, 1992, now abandoned, a continuation of which was filed Sept. 24, 1993 and assigned Ser. No. 08/126,024.
FIELD OF THE INVENTION
The present invention relates to a non-invasive method for determining hemoglobin concentration in tissue and to an in-vitro method for determining hemoglobin concentration in blood.
BACKGROUND
Methods and devices for non-invasively determining the percentage of hemoglobin which is carrying oxygen are generally known in the medical field. This percentage is referred to as hemoglobin saturation. The type of hemoglobin which carries oxygen is called oxyhemoglobin, while the type of hemoglobin which is devoid of oxygen is called deoxyhemoglobin. Hemoglobin saturation is of interest since it indicates the degree of oxygenation of the blood in the tissues.
A device which can perform a non-invasive measurement of hemoglobin saturation is generally referred to as a pulse oximeter. With this device, light is transmitted through a monitoring site which is usually the finger, ear or toe. The pulse oximeter measures absorbances in the visible and near-infrared ranges of the electromagnetic spectrum, in order to measure hemoglobin saturation. It is well known that oxyhemoglobin is redder than deoxyhemoglobin. As such, deoxyhemoglobin nominally absorbs light at 603 nm more intensely than oxyhemoglobin. There is another difference in absorption characteristics of these two species which is not visible: oxyhemoglobin nominally absorbs light at 940 nm more intensely than deoxyhemoglobin. The quantity of light absorbed at these two wavelengths is characteristic of a particular mix of oxy and deoxyhemoglobin. Hemoglobin saturation is calculated using absorbance data and a prediction curve which is generated by a large population study which correlates pulse oximetric data with traditional hemoglobin saturation measurements.
Tissue contains absorbing substances other than the species of hemoglobins. However, generally a pulse oximeter can isolate the absorbances of the hemoglobin species of interest from the absorbances of potentially interfering species. It does so by determining the difference between the absorbance of light by tissue before an arterial pulse and the absorbance of light by tissue at the peak of an arterial pulse. The difference in absorbance is attributed to arterial blood at the site of the measurement. In summary, the absorbance prior to a pulse is subtracted from the absorbance at the peak of a pulse to determine the percentage oxygen saturation of arterial blood hemoglobin.
U.S. Pat. No. 4,819,752, the disclosure of which is incorporated herein by reference, discloses a pulse oximeter type device which measures hemoglobin saturation using these principles. The device disclosed in this patent differs from prior an methods in the way in which it processes signals, in relation to isolating the pulsatile component, determining the size of the pulsatile component and in determining the size of the non-pulsatile component.
Similarly, U.S. Pat. No. 4,805,623, the disclosure of which is incorporated herein by reference, describes a spectrophotometric method of measuring the concentration of a dilute component such as hemoglobin in a light- or other radiation scattering environment. The disclosed crux of the invention involves simultaneous measurement of the absorbed/reflected light of the dilute and of the reference components. Essential features of the method employed in U.S. Pat. No. 4,805,623 include, determination of path-length and an extinction coefficient of the analyte in the light-scattering environment, along with use of complex theoretical formulas.
As is generally known to those of ordinary skill in the art, in-vivo spectrophotometric measurements are complicated by scattering losses, difficulties in path-length measurement and spectroscopic interference from species other than those of interest. Spectrophotometric analysis is typically based on a model that assumes pure collimated light is reduced in intensity only by absorbing species. The intensity is reduced by an exponential process known as "Beer's law", wherein absorbance is proportional to concentration. A classical Beer's law approach to analyte measurement in tissue, using a path-length and extinction coefficient determination however, generally gives clinically unacceptable results due at least in part to the complications referred to above.
The method of the present invention differs fundamentally from that of U.S. Pat. No. 4,805,623 ("the '623 patent") in that it does not require a light path-length or an extinction coefficient determination. Furthermore, in a preferred embodiment the method of the present invention employs a pulse based measurement by using a pulse oximeter which has been modified to make measurements at the appropriate wavelengths for hemoglobin concentration.
Spectrophotometric methods have also been utilized to measure hemoglobin concentration in-vitro. These methods are generally referred to using the terminology "in-vitro hemoglobinometry". In the most commonly used method of in-vitro hemoglobinometry, a blood sample is diluted, lysed and treated with potassium cyanide. An absorbance reading is taken at 540 nm and compared with that of a standard solution. This method is described in Clinical Diagnosis & Management By Laboratory Methods, Henry, John B. (W. B. Saunders Company, Philadelphia, 181h Ed. 1991).
SUMMARY OF THE INVENTION
The method of the present invention comprises scanning tissue, in-vive, or a blood sample, in-vitro, with a plurality of wavelengths of light in the visible and near-infrared region including analyte wavelengths and reference wavelengths. The absorbance data is combined in ratio form which minimizes and preferably eliminates the need to calculate a path-length and an extinction coefficient and the need to estimate unpredictable scattering losses.
In the in-vive setting, a pulse oximeter, which has been appropriately modified include wavelengths for hemoglobin concentration, may be employed in order to isolate the absorbance of blood from the absorbance due to tissue other than blood. Specifically, multiple light emitting diodes are used which are of the appropriate wavelengths for hemoglobin concentration measurement. Hemoglobin concentration is obtained by comparing spectral data to prediction table data which have been obtained with correlation studies.
In particular embodiments of the present invention, multiple light emitting diodes may be utilized to emit light at a sufficient number of wavelengths to generate derivative spectral data or, alternatively, to emit light at multiple wavelengths which provide a hemoglobin concentration using ordinary absorbance dam. In either case, the light emitting diodes would preferably be utilized with a modified pulse oximeter to obtain a pulse based measurement.
Alteratively, hemoglobin measurements could be made in the in-vive and in the in-vitro settings using derivative (with respect to wavelength) spectroscopy without the need for a pulse oximeter. For example, using second derivative spectroscopy, hemoglobin measurements can be made using ratios of derivative data with a conventional spectrometer.
The present invention advantageously provides a method for non-invasive hemoglobin measurement. This method has a variety of potential uses. For example, prior to accepting blood donations, blood collection centers must immediately determine that a potential donor is not anemic. Currently, this determination is done by pricking a donor's finger and extracting a drop of blood. Pediatric clinics also frequently use the finger stick method for rapid hemoglobin concentration. This method disadvantageously exposes the potential donor to minor pain and results in the possibility of blood-borne infection patient and technical personnel. It would be desirable to offer a painless non-invasive measurement in the above settings.
In addition it has become state of the an in intensive care units and in operating rooms to monitor hemoglobin saturation with the pulse oximeter. The present invention could be incorporated in the current pulse oximeter with relative ease and would offer additional clinically relevant information.
The present invention also advantageously provides a method for in-vitro hemoglobin measurement, which may be performed on a whole blood sample and minimizes, or eliminates, the need for reagents or for lysis of the blood. In addition, there is no release of harmful reagents such as cyanide into the environment. The in-vitro method of the present invention comprises scanning a blood sample, in-vitro, with a plurality of wavelengths of light in the visible and near-infrared region including analyte wavelengths and reference wavelengths. Preferably, a vertical light path is used in scanning. The absorbance data is combined in ratio form which minimizes and preferably eliminates the need to calculate a path-length and an extinction coefficient and the need to estimate unpredictable scattering losses. The in-vitro method of hemoglobin measurement of the present invention could be incorporated into large laboratory based hematology analysers or into hand held devices for hemoglobin concentration measurement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a visible light spectrum of oxyhemoglobin.
FIG. 2 is a visible light spectrum of deoxyhemoglobin.
FIG. 3 is a visible light spectrum of a finger of the inventor using the reflectance mode.
FIG. 4 is a near-infrared spectrum of water.
FIG. 5 is a near-infrared spectrum of a finger of the inventor using the reflectance mode.
FIG. 6 is a near-infrared spectrum of cadaveric skin using the transmittance mode.
FIG. 7 is a correlation plot of the near-infrared spectroscopic measurement using ratios of derivative absorbance data versus the Coulter STKS monitor hemoglobin measurement.
FIG. 8 depicts a hypothethical reference curve.
FIG. 9 depicts a second derivative spectrum of unlysed blood.
DETAILED DESCRIPTION
While performing spectroscopic studies on human tissue, it was noted that capillary bed tissue has a visible light spectrum which resembles that of hemoglobin. It was also noted that this same tissue has a near-infrared spectrum which is similar to that of water This observation forms the basis of a hemoglobin concentration measurement.
The essence of any concentration measurement is comparison of at least two components. In the usual in-vitro hemoglobin measurement, the absorbance of a blood sample of unknown concentration is compared to a reference curve which is generated using samples of known concentration. In tissue, similar information can be obtained by using a reference which is the absorbance of the tissue at a wavelength other than the hemoglobin absorption band which is referred to as the analyte wavelength. This reference absorbance provides a guage by which one can measure the size of the hemoglobin absorption band, i.e., the hemoglobin concentration.
FIGS. 1 and 2 are visible light spectra of the species of hemoglobin. As seen in these spectra, the absorbance of both species of hemoglobin reaches the highest amplitude in the region from 400 to 450 nm. The similarity to the visible light spectrum in FIG. 3 should be noted. The visible light spectrum of capillary bed tissue of the finger is similar to a combination spectrum of the two species of hemoglobin.
FIG. 4 shows the near-infrared spectrum of water. Absorption bands are seen at approximately 940 nm, 1140 nm and 1460 nm. There is a trough at approximately 1370 nm. FIGS. 5 and 6 show near-infrared spectra of human tissue in the reflectance and transmittance modes, respectively. Likewise, there is a similarity between the near-infrared spectrum of water and of tissue. In tissue, absorption bands are also seen at approximately 940 nm, 1140 nm and 1470 nm and a trough is seen at approximately 1370 nm. This similarity makes sense when one considers the fact that capillary bed tissue is approximately 80 to 90% water.
In the earliest work done by this inventor, a single term ratio of two absorbances in the near-infrared region was used to measure hemoglobin concentration in unlysed blood samples. An analyte wavelength of 816 nm, which is an isobestic point in the spectra of the major hemoglobin species, i.e., oxy and deoxyhemoglobin, and a reference wavelength of 1370 nm were used. A weak correlation with the traditional hemoglobin concentration was observed using this approach. Improved results were obtained when using single-term ratios of derivative (with respect to wavelength) spectral data to measure hemoglobin concentration in unlysed blood samples. For example, using a single-term ratio of second derivative log (1/T) data at 1740 and 1346 nm, hemoglobin concentration could measured with a standard error of 0.43 g/dL and an R 2 of 0.986. In fact, there are numerous areas in the near-infrared region in which accurate measurement of hemoglobin is possible using single-term ratios of derivative absorbance data. A more detailed description of my earlier work in hemoglobin measurement is found in my earlier patent applications, Ser. No. 07/965,817, filed Oct. 23, 1992 and Ser. No. 7/880,379, filed May 8, 1992. The disclosure of each of these applications is hereby incorporated herein by reference.
A summary of representative regions from which analyte/reference wavelength combinations can be selected and of a few particularly suitable wavelength combinations appears below. This list is by no means exhaustive.
______________________________________Analyte Wavelength Reference Wavelength Derivative______________________________________1735-1749 nm 1669-1679 nm second1744 nm 1674 nm second1740 nm 1346 nm second2203-2213 nm 2177-2187 nm first2208 nm 2182 nm first.______________________________________ In the second derivative spectrum of hemoglobin, other analyte regions useful for hemoglobin measurement include the bands which are centered at 1694 nm, 20.54 nm and nm.
While one may accurately measure hemoglobin concentration in unlysed blood samples using derivative spectroscopy, there are other methods of measurement which may also be useful in an in vivo and/or in vitro setting.
For this reason, an additional approach was devised which uses absorbance data at multiple wavelengths combined in a ratio which eliminates the need for a path-length measurement and compensates for unpredictable scattering losses. A device using either derivative or ordinary absorbance data could use light emitting diodes at the appropriate wavelengths and could be used with a modified pulse oximeter which is operated in either the transmittance or the reflectance mode. In this fashion, it is anticipated that absorbance due to hemoglobin can be isolated from the absorbance due to tissue proteins. In order to determine hemoglobin concentration a microprocessor is programmed to receive the absorbance data and to calculate the hemoglobin concentration according to a previously generated prediction table formed with correlation studies.
It was found that the above approach using absorbance data at multiple wavelengths combined in a ratio which eliminates the need for a path-length measurement and compensates for unpredictable scattering losses could be used to measure the hemoglobin content of unlysed blood samples. The results for the calibration set were a standard error of 0.386 g/dL and an R of 0.9931, and for the prediction set were a standard error of 0.384 g/dL and an R of 0.9911. The calibration equation with which this data was obtained had the form:
H=b.sub.0 +b.sub.1 X.sub.1 (W.sub.1)+b.sub.x X.sub.2 (W.sub.2) +b.sub.3 X.sub.3 (W.sub.3)+. . .
where:
H is the hemoglobin concentration,
the subscripted b's are weighting factors, and
the subscripted X(W)'s are the absorbance data at wavelength W.
The set of wavelengths and weighting factors which yielded the above prediction characteristics is summarized below. As a means to normalize the data, this calibration divides the absorbance at each of the following wavelengths by the absorbance at 1450 nm. However, this set of wavelengths and weighting factors is not the only set which will predict hemoglobin content accurately, and the method of the present invention is not limited to use with these wavelengths.
______________________________________Wavelength (nm) b______________________________________b.sub.o -25.71 676 29.621116 1291.711132 -1307.162100 25.091450 normalization factor used as a divisor.______________________________________
As will be recognized by those of ordinary skill in the art, the methods of the present invention may also be utilized to measure the concentration of other substances in the blood including, but not limited to, urea, glucose and cholesterol. For example, in order to measure the concentration of cholesterol in the blood a ratio may be formed by scanning tissue, in-vivo, or a blood sample, in-vitro, with a plurality of wavelengths of light and dividing a sum of ordinary absorbances of cholesterol at a plurality of near-infrared and/or mid-infrared wavelengths, by absorbance at a reference wavelength. An appropriately modified pulse oximeter may be utilized to perform these measurements. Thus, the method of the present invention includes a non-invasive method for measuring a substance in blood selected from the group consisting of urea, glucose and cholesterol using a measurement comprising a ratio formed by dividing a sum of ordinary absorbance at a plurality of near-infrared wavelengths, or a sum of ordinary absorbance at a plurality of mid-infrared wavelengths, by the absorbance at a reference wavelength.
Further details and advantages of the present invention will become apparent from the following examples.
EXAMPLE 1
A spectroscopic measurement of hemoglobin concentration in a large population of unlysed blood samples was sought. Visible and near-infrared transmittance (T) spectra of unlysed blood samples were obtained with an NIRSystems Model 6500 Spectrophotometer modified for an open cell and a vertical light path. The path length and temperature of the samples were not rigidly controlled. Hemoglobin content could be measured using a single-term ratio of second derivative (with respect to wavelength) log (1/T) data at 1740 nm and 1346 nm with a standard error of 0.43 g/dL and an R 2 of 0.986. Calibration was done on a set of 104 samples (2 spectra of blood from 52 patients) having hemoglobin levels of 6.1 to 19.2 g/dL. Validation was done on an independent set of 56 samples (2 spectra of blood from 28 patients) having hemoglobin levels of 7.2 to 19.0 g/dL. The reproducibility of the measurement, tested by computing the coefficient of variability of the 28 duplicated results, was 0.63%. Evidence that other near-infrared regions can be used for hemoglobin measurement as well was obtained. As shown in FIG. 7, an R 2 of 0.9:88 was obtained when the wavelength pair used for the measurement was 1744 nm and 1674 nm.
EXAMPLE 2
This example illustrates the use of one of the in-vitro methods of the present invention to determine a patient's hemoglobin level. Using the procedure set forth in Example 1, a reference curve can be generated by graphing a ratio of derivative absorbance data for each patient versus the hemoglobin concentration by a reference method such as the Coulter STKS Monitor. A hypothetical reference curve is shown in FIG. 8.
An infrared spectrophotometer is used to shine light vertically through an unlysed blood sample. A derivative transformation (with respect to wavelength) of the spectral data is carded out and an appropriate single-term ratio of derivative absorbance data is used the measurement.
FIG. 9 depicts the resulting second derivative absorbance spectrum of a representative unlysed blood sample. From inspection, the second derivative of absorbance at an analyte wavelength of 1744 nm divided by the second derivative of absorbance at a reference wavelength of 1674 nm is yA/yR=3 mm/13 mm=0.23. From inspection of FIG. 8, which is the reference curve, when the ratio of second derivative absorbance data is 0.23, the patient's hemoglobin concentration is 6.6 g/dL. Using the measurement which consists of multiple wavelengths of absorbance data combined in ratio form, a similar process is used to obtain a patient's hemoglobin concentration.
As will be realized by those of ordinary skill in the art from the foregoing description, the method of the present invention presents a simple procedure for in-vitro and in-vivo determination of a patient's hemoglobin concentration. | A non-invasive and an in-vitro method for determining a person's hemoglobin concentration are described. The methods employ substantially simultaneous measurements of absorbance of near-infrared and long wavelength visible light. The measurement consists of a combination of ordinary absorbance data at multiple wavelengths in the form of a ratio or of a ratio of derivative absorbance data. The method minimizes the need for path-length measurement or extinction coefficient determination or estimation of scattering losses. In the in-vitro setting, the method minimizes the need for cell lysis or for reagents. | 6 |
RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Application Ser. No. 60/850,544 filed Oct. 10, 2006 the disclosure of which is incorporated herein.
FIELD OF THE INVENTION
[0002] This disclosure relates generally to a novelty beverage holder and more particularly to a beverage holder with an implanted device capable of producing sounds when triggered by a user.
BACKGROUND OF THE INVENTION
[0003] Beverage containers and insulated holders, wraps and coolers are widely varied and are formed from any number of insulating materials. Beverage holders are generally configured to frictionally engage and removably secure a can or bottle of chilled liquid. These devices often provide the dual benefit of maintaining temperature of the beverage being consumed and providing a convenient and relatively inexpensive media for the display of messages, advertisements and the like. For the most part, known beverage holders are simple unitary devices molded or manufactured from a single piece of material and have no accoutrements to enhance their utility or amusement.
SUMMARY OF INVENTION
[0004] According to the practice of this invention, a thermally insulated beverage holder is fashioned from a material, such as foam, Styrofoam or polyethylene. The beverage holder is generally configured with a substantially closed bottom and a generally open top. The overall form of the beverage holder is generally cylindrical. Further, the beverage holder may include removable insulating liners and be configured to house beverage cans, bottles, or glassware of any variety of shapes and sizes.
[0005] The beverage holder is provided with a compartment which houses a device capable of emitting sounds. Several types of devices are generally known, including small electronic relays with a microprocessor and chip capable of electronically retaining a recorded sound and then transmitting, upon operation, the sound via a small audio speaker. Such devices can easily be manufactured approximately the size of a U.S. minted quarter, or less than one inch in diameter. Further, such devices are relatively thin, often less than one-quarter (¼) inch thick. The device includes a triggering mechanism integral thereto although it may be provided with a remote switch. It is preferred that the remote switch be present and positioned and mounted proximate the periphery of the beverage holder. It is understood that the mounting position and orientation of the remote switch can be anywhere on the beverage holder, although, it is preferably mounted substantially adjacent the sound emitting device which is generally placed near the bottom surface of the beverage holder.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a plan view of one embodiment of the invention.
[0007] FIG. 2 is a bottom view of one embodiment of the invention with a bottom mounted switch.
[0008] FIG. 3 is a plan view of a second embodiment of the invention.
[0009] FIG. 4 is a plan view showing an internally positioned switch.
[0010] FIG. 5 is a plan view showing a side mounted switch.
DESCRIPTION OF THE INVENTION
[0011] Referring now generally to the drawings, an insulated beverage holder is provided. The beverage holder 102 , in the preferred embodiment, has a substantially cylindrical sidewall 104 with a partially closed bottom 106 and an open top 108 . It is understood that the beverage holder 102 can be configured in any shape and size configured to retain beverage cans, bottles, glassware, and the like without departing from the spirit and scope of this invention.
[0012] It is also understood that the beverage holder 102 can be manufactured from any variety of insulating materials, including foam, plastics, polyethylenes or similar materials. It is preferable that the material from which the beverage holder is manufactured is substantially resistant to liquids and provides insulating properties.
[0013] The diameter of the top opening 108 , which is adjacent the upper-most edge or rim 110 of the beverage holder 102 is preferably slightly larger than the diameter of the beverage container which is to be inserted into the holder. The beverage holder 102 height should be sufficient to encase at least fifty percent (50%) of the beverage container.
[0014] As is known within the industry, the beverage holder 102 may also be configured to accept an insulating liner which further insulates the beverage being retained in the holder.
[0015] The bottom 106 of the holder will generally be manufactured of the same material as the holder sidewall 104 . As shown in FIG. 2 , it is preferable to provide at least one hole 112 completely through the bottom surface 106 to prevent suction or vapor-locking which may occur between the beverage container itself and the holder 102 . It is often difficult to remove the beverage from the holder without the presence of such a hole 112 . Moreover, the hole 112 allows condensation on the beverage container, or spilled liquid, to readily escape the holder. This promotes the longevity of the device and specifically the electrical components of the inventive device.
[0016] The bottom 106 portion of the beverage holder is also provided with a compartment 114 for housing a sound emitting device 116 . The sound emitting device 116 is capable of electronically retaining and then audibly transmitting a predetermined sound. Such devices 116 are generally available and can take any variety of configuration. The preferred device 116 is relatively small having dimensions of approximately one inch in diameter with less than one-quarter (¼) inch in height. The device 116 includes a small speaker, a power supply such as a battery, a small timer, and a processor or memory unit capable of storing electronic data, specifically sounds and music. The device 116 is provided with a switch 118 that allows a user to selectively activate the device 116 whereupon a sound or music or combination thereof is emitted for a predetermined period of time, said time period controlled by the timer of the device 116 . The switch 118 may be fabricated integral the device 116 or may be remotely connected thereto via electrical wiring 126 .
[0017] The device 116 is mounted in the compartment 114 substantially adjacent the bottom surface 106 of the beverage container. If the device 116 is provided with an integral switch 118 , the switch 118 is positioned substantially adjacent the outer periphery 122 of the cylindrical sidewall 104 of the container. The switch 118 may also be oriented generally downward so that it is accessible through the bottom 106 . This orientation allows the device 116 to be triggered and activated either when the beverage holder 102 is placed on a surface, or picked up from a surface. It is preferable, however, that a remote switch 118 be provided to the device 116 which could be mounted substantially adjacent the outer periphery 122 of the cylindrical sidewall 104 as shown in FIGS. 1, 3 and 5 . This allows ease of user access, and is more convenient than positioning the switch 116 on the bottom surface 106 where it may be inadvertently triggered when the beverage container 102 is placed on a surface.
[0018] As shown in FIG. 4 , another position for the switch would be on the inner wall 120 or on the upper surface (not shown) of the bottom piece so that the switch 118 would be actuated each time a beverage container is placed into the holder 102 . When the container is removed from the holder 102 the switch is released thereby resetting the switch 118 so that it will activate the device 116 when another container is positioned within the holder 102 .
[0019] The compartment 114 of the bottom surface 104 can take any readily ascertainable configuration, although it is preferable to use a simple two piece bottom portion to the container sandwiching the device 116 therebetween. The compartment may also be manufactured by cutting or placing a slit in the bottom 104 and inserting the device 116 therein as shown in FIG. 2 . Depending on the type of device 116 used, it may be necessary to implant the device 116 in the cylindrical sidewall 104 of the holder 102 to limit exposure to moisture, condensation or liquid from the beverage. Modern sound emitting devices may be relatively flexible, such as those found in greeting cards, and accordingly can be flexed into an arc to contour to the shape of the sidewall 104 of the beverage holder.
[0020] The device 116 is provided with a timer that can be programmed so that the sound emission expires randomly or after a predetermined period of time. The timer can also be programmed to cause emission of the recorded sound more than one time (looped). The device 116 may be configured to allow a user to record their own music or message to be replayed.
[0021] It is understood that it is desirable to provide a sound byte, music or other audible emission in the device 116 which is substantially compatible to a theme or advertisement displayed or present on the outer surface of the insulated beverage holder. As shown in FIGS. 1, 3 , 4 and 5 , the beverage holder surface 124 will be compatible to printed words or graphic images or a combination thereof by screen printing, overlay, adhesive sticker, or other methods known in the industry. If, for example, the insulated beverage holder 102 displays a logo or graphic image of a race car, the device 116 may emit the sound of a race car engine or cheering fans. For a logo used by a beverage manufacturing company on the surface of the insulated beverage holder, the device 116 may emit the jingle or music associated with the beverage. It should be understood that any combination of advertising images and sounds, including music, can be configured in the insulated beverage holder 102 . The novelty device provides a desirable marketing and advertising tool which is relatively inexpensive and easy to manufacture from components which are generally available in the marketplace.
[0022] Generally, the user places their desired beverage in the top opening 108 of the insulated beverage container 102 and then, as desired, actuates the switch 118 thereby triggering the device 116 to emit the provided sound. It is understood that a variety of switch locations and methods for activation can be used to change to allow selective operation of the device as more particularly described herein.
[0023] Accordingly, while one embodiment of the present invention has been shown and described, it is understood that many changes and modifications may be made thereto without departing from the spirit and scope of the invention as defined in the appended claims. | An insulated beverage container with an integrated sound producing device wherein the sounds emitted from the sound producing device are compatible with images, advertisements or other materials displayed on the surface of the insulated beverage container. The sound emitting device is configured to store and then emit, upon actuation by a user, predetermined sounds over a specific length of time. While the sound emitting insulated beverage container is intended as a novelty device, it can be used for advertisements and in marketing by associating specific sounds with advertisement displayed on the outer surface of the container. | 0 |
The present invention relates to a cylinder head structure for a dual or double overhead camshaft engine.
BACKGROUND OF THE INVENTION
1. Field of the Invention
Typically, a double overhead camshaft engine (referred to hereinafter as a DOHC engine) is provided with a pair of overhead camshafts for a row of cylinders. Such a pair of overhead camshafts usually includes an intake camshaft and an exhaust camshaft, which are arranged parallel to a crankshaft of the engine. One of the overhead camshafts, called a drive camshaft, is connected or coupled to the crankshaft by a belt which transmits the engine output to drive the drive camshaft The other of the overhead camshafts, called driven camshaft, is connected or coupled to the drive camshaft by transmission means, such as meshing camshaft gears secured to the drive and driven camshafts, respectively The transmission means transmits the rotation of the drive camshaft to drive the driven camshaft. To operate, or drive, valves with the overhead camshaft, a valve drive mechanism or valve train, including cams having cam lobes, is provided. Each cam lobe drives one valve.
2. Description of Related Art
A valve train such as that referred to above is known from, for instance, Japanese Unexamined Utility Model Publication No. 61- 171,807. Each valve drive mechanism of this publication cooperates with a hydraulic valve lash adjuster, which supports and urges a rocker arm disposed between a cam lobe of the overhead camshaft and a valve stem so as to maintain zero valve stem to rocker clearance. Such a hydraulic valve lash adjuster is described in, for example, Japanese Unexamined Utility Model Publication No. 55- 144803.
The drive overhead camshafts of the DOHC engine are supported for rotation by supporting means provided on a cylinder head. Camshaft supporting means of this kind typically comprise two bearing parts for supporting, for rotation, the camshafts therebetween. Such supporting means may include cam carrier means, provided separately from the cylinder head and bolted, or otherwise secured, to the cylinder head, and cap means, formed integrally with a cylinder head cover.
Since a camshaft drive mechanism as described above narrows a space between the drive and driven camshafts, a DOHC engine of this kind can be provided with a reduced width. On the other hand, the camshaft supporting means can be formed from a reduced number of parts and, consequently, allow the DOHC engine to be simple in structure.
In recent years, DOHC engines have typically been provided with a plurality of intake valves and a plurality of exhaust valves for each cylinder in order to increase intake charging efficiency and develop an increase in output power. Some DOHC engines of this kind have a different number of intake and exhaust valves for each cylinder.
The provision of a plurality of intake valves and a plurality of exhaust valves for each cylinder, and of an individual hydraulic valve lash adjuster for each valve, somewhat conflicts with a fundamental demand in car design for DOHC engines which are small in size. In particular, the cylinder head of a small DOHC engine must be formed with a plurality of bores and holes for installing the valves and valve trains, including the hydraulic valve lash adjusters, which unavoidably causes a decrease in structural rigidity of the DOHC engine body.
Oil, which lubricates the camshafts and valves and operates the hydraulic valve lash adjusters, scatters over a cylinder head during engine operation and produces oil mist. With an increase in the number of intake and exhaust valves and hydraulic valve lash adjusters, the quantity of oil mist on the cylinder head increases. Accordingly, blow-by gas, which is introduced into an oil separator, contains an increased quantity of oil mist, so that it is necessary to provide an oil separator of large capacity in order to process the blow-by gas efficiently. A large capacity oil separator necessarily occupies a large space, even though the DOHC engine is designed to be small in size.
In-mesh camshaft gears, for operationally coupling the drive and driven camshafts, are covered by a gear cover so as to prevent both foreign articles from being caught between the camshaft gears and lubrication oil from being scattered from the camshaft gears. In addition, the gear cover, if it is secured to the DOHC engine with the cam carrier means, is typically rigidly connected to the cam carrier means. For easy connection between the gear cover and cam carrier means, the gear cover is usually constructed as two parts which are separable in a direction parallel to the axis of the crankshaft. That is, the gear cover comprises a front cover section and a rear cover section formed integrally with the cam carrier means and bolted at several points around the peripheries of the camshaft gears or otherwise secured to each other, so as to enclose marginal portions of the camshaft gears.
To improve the rigidity of the camshaft supporting means and, in particular, parts of the camshafts near the camshaft gears, the cam carrier means is formed by radial bearing means and thrust bearing means. Since the camshaft gear has a diameter larger than diameters of the related camshaft and cam lobes, the camshaft gear projects downward on a side of the cylinder head. In order to eliminate an interference between the camshaft gear and an upper end of the cylinder head, the cylinder head is formed in an upper end portion with a recess for receiving lower parts of the in-mesh camshaft gears. That is, the in-mesh camshaft gears are accommodated in a space defined between the gear cover and the end recess.
Since it opens downward, the gear cover, or cover member, is low in rigidity. In addition, since the cover member is integral with the camshaft supporting means, it receives external loads from the camshafts, and is apt to cause a large, three dimensional deformation, owing to a change of torque of the camshafts, abnormal operations of the valve means, such as jumping and bouncing, or changes in angles of torsion of the camshafts, for example.
SUMMARY OF THE INVENTION
The primary object of the present invention is to provide a cylinder head structure for a double overhead camshaft engine, having a plurality of intake valves and a plurality of exhaust valves for each cylinder, which has a high structural rigidity.
Another object of the present invention is to provide a cylinder head structure for a double overhead camshaft engine, provided with a plurality of intake valves and a plurality of exhaust valves for each cylinder, with a bearing means which is free from deformation and potential seizing.
According to the present invention, the cylinder head structure for a double overhead camshaft engine, provided with a plurality of intake valves and a plurality of exhaust valves for each cylinder, includes a cylinder head block and a cylinder head cover mounted on the cylinder head block so as to support, for rotation, the intake and exhaust camshafts on the cylinder head block. The cylinder head block and cylinder head cover form therebetween a hermetically sealed chamber, creating an oil jacket. The cylinder head block is integrally formed with partition means, such as a lengthwise extending wall, for dividing the hermetically sealed chamber into two chambers enclosing major portions of the intake and exhaust camshafts, respectively. The chambers are in communication with each other near first ends of the chambers.
Outlet means, such as a hole, is formed in the cylinder head cover so as to permit blow-by gas to flow out the chamber enclosing the one of the intake and exhaust camshafts which drives either the intake valve, or valves, or the exhaust valve, or valves. The camshaft which is enclosed by the cylinder head cover including the outlet means is that one which drives the smallest number of valves per cylinder.
The outlet means is desirably located closer to a second end of the chamber in which it is formed than to a position at which the chambers are in communication with each other.
A cover means is bolted or otherwise secured to one end of camshaft carrier means, formed as the cylinder head cover, at a plurality of points around a gear train. Such a gear train may include a pair of gears in mesh with each other, coupled to first ends of the intake and exhaust camshafts so as to turn the intake and exhaust camshafts in opposite directions. The cover means has bearing means integrally formed inside thereof so as to support the intake and exhaust camshafts, thereby restricting movement of end portions of the intake and exhaust camshafts. The cover means further has reinforcing means, which may include a plurality of bosses for receiving bolts for fixing the cover means to the cylinder head, integrally formed outside thereof and extending along almost the whole vertical length of the cover means, for providing an increase in rigidity of the cover means.
The cylinder head is integrally formed with a boss which extends below the bearing means along the whole width of the cylinder head block and is formed with an oil passage.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and features of the present invention will be apparent to those skilled in the art from the following detailed description of preferred embodiments thereof when considered in conjunction with the accompanying drawings, wherein similar reference numerals have been used to designate the same or similar elements throughout the drawings, and in which:
FIG. 1 is a plan view of a double overhead camshaft engine;
FIG. 2 is a plan view of a cylinder head structure in accordance with a preferred embodiment of the present invention which is disassembled from the double overhead camshaft engine of FIG. 1;
FIG. 3 is a bottom view of a cylinder head cover formed as camshaft carrier means;
FIG. 4 is an enlarged cross-sectional view along line IV--IV of FIG. 2;
FIG. 5 is an enlarged cross-sectional view along line V--V of FIG. 2;
FIG. 6 is an enlarged cross-sectional view along line VI--VI of FIG. 5;
FIG. 7 is a front view of the double overhead camshaft engine of FIG. 1;
FIG. 8 is a cross-sectional view along line VI--VI of FIG. 7;
FIG. 9 is an enlarged plan view of a front part of the cylinder head cover shown in FIG. 3;
FIG. 10 is a cross-sectional view along line X--X of FIG. 9;
FIG. 11 is a front view showing a variant of camshaft supporting means of the double overhead camshaft engine of FIG. 1; and
FIG. 12 is a front view showing another variant of camshaft supporting means of the double overhead camshaft engine of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings in detail and, in particular, to FIGS. 1 and 2, one of two cylinder heads 1 in accordance with a preferred embodiment of the present invention is shown. Each cylinder head 1 is mounted on one of left and right cylinder blocks (only one of which is shown), and is arranged in a V-formation, such that a predetermined relative angle, for example, a relative angle of 60 degrees, is formed between the heads. The cylinder heads and blocks form part of an overhead camshaft (DOHC) engine A, such as a V-6 DOHC engine, of the type having three intake ports and two exhaust ports for each cylinder (not shown). The cylinder head 1 is formed with various bores, such as three intake valve guide bores 5, two exhaust valve guide bores 6, one plug installation bore 7, three hydraulic valve lash adjuster installation bores 8a and two hydraulic valve lash adjuster installation bores 8b for each cylinder.
An intake camshaft 3, which is provided with one intake camshaft lobe 3a for each intake valve means, is supported on the cylinder head 1 for rotation by means of camshaft carrier means 2 and camshaft cover means 44, which will be described in detail later. Similarly, an exhaust camshaft 4, which is provided with one exhaust camshaft lobe 4a for each exhaust valve means, is supported on the cylinder head 1 for rotation by means of the camshaft carrier means 2 and camshaft cover means 44.
Camshaft carrier means 2, constructed to serve as a cylinder head cover and cam cap, is mounted on the cylinder head 1. In an oil jacket, which is a space formed between the cylinder head 1 and cam carrier means 2 and will be described later, intake and exhaust overhead camshafts 3 and 4 are disposed so as to drive intake valves 18 and exhaust valves 19 (see FIG. 5). To support the overhead camshafts 3 and 4 for rotation, the camshaft carrier means 2 is integrally formed with bearing means. That is, the camshaft carrier means 2 is integrally formed with bosses 9 in alignment with the plug installation bores 7, respectively, which are in a row parallel to the row of the cylinders and extend upward from the upper surface thereof. As is shown in FIG. 3, the camshaft carrier means 2 is further integrally formed with a plurality of journal bearings 10 and 11, which are arranged in rows on opposite sides of the row of the bosses 9 inside the camshaft carrier means 2, so as to support, for rotation, the intake and exhaust overhead camshafts 3 and 4, respectively.
As is well known, the intake camshaft 3 is formed with a cam lobe for one intake valve 1B and is provided with a camshaft gear 12 secured to one end of the intake camshaft 3. The exhaust camshaft 4 is formed with a cam lobe for one exhaust valve 19 and is provided with a camshaft gear 13 secured to one end of the exhaust camshaft 4. These camshaft gears 12 and 13 are in mesh with each other in a gear chamber 27, formed at one end of the cylinder head 1. One of the camshafts 3 or 4 projects outside of the cylinder head 1 and is provided with a camshaft pulley (not shown), which is connected or coupled by a belt (not shown) to a crankshaft (not shown) of the engine A so as to transmit the engine output to the camshaft 3 or 4, thereby driving the camshafts 3 and 4 in opposite directions.
Referring to FIG. 5, the cylinder head 1 is provided with a combustion chamber 15 formed in each cylinder at a lower part of the cylinder head 1. The combustion chamber 15 is provided with three intake ports 16 for each cylinder, with openings which extend to one side of the cylinder head 1. Further, the combustion chamber 7 is provided with two exhaust ports 17 for each cylinder, with openings which extend to the opposite side of the cylinder head 1, remote from the intake ports 16. Each intake port 16, opening into the combustion chamber 15, is opened and shut at a predetermined timing by intake valve means 18. Each exhaust port 17, opening into the combustion chamber 15, is opened and shut at a predetermined timing by exhaust valve means 19.
Fuel mixture is introduced into the cylinder through the intake ports 16 while opened by the intake valve means 18, respectively. Then, after squeezing, or compressing, the fuel mixture in the cylinder, a spark plug 26 provides a spark inside the combustion chamber 15 so that the fuel mixture explodes. Thereafter, burned gases are blown out of the cylinder through the exhaust ports 17 while they are opened by the exhaust valve means 19.
Intake valve means 18, comprising a valve stem 18a and an intake valve 18b formed integrally with the intake valve stem 18a, is driven by a valve train. The valve train includes a valve spring 21 for urging the intake valve 18b in a direction such that the intake valve 18b opens the intake port 16, an intake valve guide sleeve 5a in the guide bore 5 for supporting the valve stem 18a for sliding movement, a rocker arm 23 with a roller 25 which is operated by an intake camshaft lobe 3a rubbing on, i.e., engaging, the roller 25 of the rocker arm 23, and a hydraulic valve lash adjuster 22. The hydraulic valve lash adjuster 22, which may be of any known type, is provided with a pivot 24, brought into contact with one end of the rocker arm 23 by hydraulic oil delivered through an oil passage 36 formed in the cylinder head 1, so as to maintain zero valve stem to rocker clearance. The intake valve means 1 is provided with a valve spring retainer 20 secured to an upper end portion of the valve stem 18a.
Similarly, the exhaust valve means 19, comprising a valve stem 19a and an intake valve 19b formed integrally with the intake valve stem 19a, is driven by a valve train which is the same in structure as the valve train of the intake valve.
As is apparent from the arrangement of the bores 5 and 8a shown in FIG. 2, the intake valve means 18 for each cylinder are located at points or vertices of a triangle so that two of the three intake valve means 18 are in a straight line extending in a lengthwise direction of the engine body A. The three hydraulic valve lash adjusters 22 of the intake valve means 18 for each cylinder are arranged in a triangular pattern surrounding the center intake valve means 18. Similarly, as is apparent from the arrangement of the bores 6 and 8b shown in FIG. 2, the exhaust valve means 19 are arranged in a row in a lengthwise direction of the engine body A, and the hydraulic lash valve adjusters 22 of the exhaust valve means 19 for the cylinders are arranged in a row parallel to the row of the exhaust valve means 19.
The difference in number between the intake and exhaust valve means 18 and 19 for each cylinder provides an available space between each adjacent cylinders which is smaller on a side of the intake valve means 18 than on a side of the exhaust valve means 19 Accordingly, a distance between adjacent journal bearings 10 for the intake camshaft 3 is smaller than a distance between adjacent journal bearings 11 for the exhaust camshaft 4
The cylinder head 1 is integrally formed with an elongated partition wall 28 between the row of the intake valve guide bores 5 and the row of the plug installation bores 7. The partition wall 28 is located in the transverse direction of the cylinder head 1 closer to the row of the intake valve guide bores 5 than to the row of the exhaust valve guide bores 6, and extends in the lengthwise direction of the cylinder head 1 from the gear chamber 27 to the rear end of a peripheral connecting wall 29. On the other hand, the camshaft carrier means 2 is integrally formed with an elongated partition wall 30, extending vertically downward, which abuts against an upper surface of the partition wall 28 of the cylinder head 1.
When assembling the camshaft carrier means 2 to the cylinder head 1 by bolts 39, the oil jacket P, defined between the cylinder head 1 and camshaft carrier means 2, is divided into two oil chambers 31 and 32 by means of the elongated partition walls 28 and 30 abutting against each other. Since the elongated partition wall 28 of the cylinder head 1 does not extend inside the gear chamber 27, the two oil chambers 31 and 32 communicate with each other through the gear chamber 27 as is shown by an arrow X in FIG. 2 In other words, the oil jacket P is formed as a U-shaped space between the cylinder head 1 and camshaft carrier means 2.
As is shown in FIG. 1, the camshaft carrier means 2 is formed with a rib 33, forming a space S therein, to which an oil separator 34 is bolted. A plurality of buffer ribs 34a are formed in the space S so as to provide a zigzag path for blow-by gas. Blow-by gas is introduced into the oil separator 34 from the oil jacket P through a blow-by gas inlet 35 formed in the camshaft carrier means 2. It is desired to locate the blow-by gas inlet 35 so as to open into the oil chamber 32 under the exhaust camshaft 4, which has a lower number of valves than the intake camshaft 3, and so as to be far away from the gear chamber 27 of the cylinder head 1 in the lengthwise direction. First to third oil passages 36, 37 and 38 for supplying oil to the hydraulic valve lash adjusters 22 are formed in the elongated partition wall 28 and side ribs 1a of the cylinder head 1, respectively.
Referring to FIG. 6, the intake camshaft 3 extends in a lengthwise direction of the cylinder head 1 (from the right or front to the left or rear in FIG. 6) so as to be parallel with the crankshaft of the engine and is supported for rotation by a radial bearing portion 46 formed integrally with the camshaft carrier means 2 and a radial bearing portion 47 formed integrally with the camshaft cover means 44. Similarly, the exhaust camshaft 4 extends in the lengthwise direction so as to be parallel with the crankshaft and, hence, the intake camshaft 3, and is supported for rotation by a radial bearing portion 48 formed integrally with the camshaft carrier means 2 and a radial bearing portion 49 formed integrally with the camshaft cover means 44.
The front end of the intake camshaft 3 is provided with a timing pulley 52 secured thereto by a bolts 51. This pulley 52 is connected or coupled to the crankshaft by a belt (not shown) which transmits the engine output to drive the pulley 52 at a speed of one-half that of the crankshaft. The pulley 52 is protected by a pulley cover 53. The intake camshaft gear 12 of the intake camshaft 3, located slightly rearward of the pulley 52, and the exhaust camshaft gear 13, provided near the front end of the exhaust camshaft 4, are in mesh with each other so as to rotate at the same speed but in the opposite directions. In order to eliminate backlash of the exhaust camshaft gear 13, a gear 61 is provided so as to mesh with the intake camshaft gear 12 and be displaceable with respect to the exhaust camshaft gear 13. These camshaft gears 12 and 13 are enclosed within the gear chamber 27 defined between the cylinder head 1 and camshaft carrier means 2 and, particularly, by the camshaft cover means 44, a gear casing portion 57 formed as a front end portion of the camshaft carrier means 2 and a groove 58 (see FIG. 7) formed in a front upper portion of the cylinder head 1.
The intake camshaft 3 has a front journal 62A which supports the intake camshaft gear 12 in the gear chamber 27 having a diameter larger than that of the front end portion of the intake camshaft 3. A front surface of the front journal 62A slidably abuts against a rear thrust surface 63 of the boss of the camshaft cover means 44, which serves as a part of a thrust bearing means. The intake camshaft 3 is provided behind the front journal 62A of the intake camshaft 3 with a thrust collar 64 having a diameter larger than that of the front journal 62A of the intake camshaft 3. The thrust collar 64 slidably abuts against a front thrust surface 65 of the boss of the camshaft carrier means 2 which serves as another part of the thrust bearing means. The thrust bearing means, comprising the front and rear thrust surfaces 63 and 65, supports the intake camshaft 3 so as to prevent a thrust movement of the intake camshaft 3. The intake camshaft 3 is further formed behind the thrust collar 64 with a rear journal 62B having a diameter between those of the front journal 62A and the thrust collar 64. A peripheral surface of the rear journal 62B is surrounded by an inner surface of a bore 46, serving as radial bearing means, formed in the boss of the camshaft carrier means 2.
Exhaust camshaft 4 is provided with a lock nut 66, secured thereto behind the exhaust camshaft gear 13. The lock nut 66 slidably abuts against a rear thrust surface of a front thrust metal insert or washer 67, embedded in the camshaft cover means 44, which serves as a part of the thrust bearing means. The exhaust camshaft 4 is further provided behind the exhaust camshaft gear 13 with a thrust collar 68, slidably abutting against a front thrust surface 69 of the boss of the camshaft carrier means 2, which serves as another part of the thrust bearing means. The thrust bearing means, comprising the front thrust metal insert 67 and the thrust collar 68, supports the exhaust camshaft 4 so as to prevent a thrust movement of the exhaust camshaft 4. The camshaft cover means 44 has a front end boss 71 formed with a bore 70 having an internal thread. A plug 72 is screwed into the bore 70.
The cylinder head 1 is further formed in its upper portion with the first to third oil passages 36, 37 and 38 for delivering hydraulic oil to the hydraulic valve lash adjuster 22. In more detail, the first oil passage 36 initially extends in the lengthwise direction so as to be in communication with the hydraulic valve lash adjusters 22 for the intake valve means 18 and then turns upwards just before the groove 58 so as to open to the upper surface of the cylinder head 1. The second oil passage 37 initially extends parallel with the first oil passage 36 in the lengthwise direction so as to be in communication with the hydraulic valve lash adjuster 22 for the center intake valve means 18 and then turns upwards just before the groove 58 so as to open to the upper surface of the cylinder head 1. The third oil passage 38 initially extends parallel with the first and second oil passages 36 and 38 in the lengthwise direction so as to be in communication with the hydraulic valve lash adjusters 22 for the exhaust valve means 19 and then turns upwards just before the groove 58 so as to open to the upper surface of the cylinder head 1.
Referring to FIGS. 1, 7 and 8, the camshaft carrier means 2, formed with the radial bearing means 46 and 48 for the intake and exhaust camshafts 3 and 4, respectively, and the gear casing portion 57, is mounted and bolted by a plurality of bolts 89 onto the cylinder head 1. The camshaft cover means 44 is attached and bolted at several points around the peripheries of the camshaft gears 12 and 14 to the upper front end of the camshaft carrier means 2 by a plurality of bolts 90 so as to support the front ends of the intake and exhaust camshafts 3 and 4 and cover the intake and exhaust camshaft gears 12 and 13. The rear end portion of the camshaft cover means 44 is shaped to conform to the gear casing portion 57 of the camshaft carrier means 2. As was previously described, the camshaft cover means 44, gear casing portion 57 of the camshaft carrier means 2 and the groove 58 form therebetween the gear chamber 27 for receiving therein the intake and exhaust camshaft gears 12 and 13.
The camshaft cover means 44 is formed on its front end with vertically extending bosses 92 having an internal thread. Bolts 91 are threaded in these internally threaded bosses 92 to secure the camshaft cover means 44 to the cylinder head 1. The vertically extending bosses 92 increase the rigidity of the camshaft cover means 44.
Referring to FIGS. 9 and 10, the camshaft carrier means 2 is formed with an oil passage 93 extending transversely behind the gear casing portion 57 and below the radial bearing means 46 and 48 for the intake and exhaust camshafts 3 and 4 so as to be in communication with the radial bearing means 46 and 48. The oil passage 93 is formed in a transverse boss 94 extending along the whole width of the gear casing portion 57 of the camshaft carrier means 2. The transverse boss 94 thus formed functions as a beam to provide an increase in the rigidity of the radial bearing means 46 and 48 for the intake and exhaust camshafts 3 and 4, so that the radial bearing means 46 and 48 are free from deformation due to thrust loads This structure, which causes no deformation of the radial bearing means 46 and 48, prevents an increase in resistance to sliding movement of the radial bearing means 46 and 48 and the occurrence of seizing in the radial bearing means 46 and 48. Furthermore, since the camshaft carrier means 2 is improved in rigidity at, in particular, the front end portion, the camshaft cover means 44, connected to the camshaft carrier means 2, is improved in rigidity.
Lubrication oil is delivered into the oil passage 93 from an oil gallery P provided between the cylinder head 1 and camshaft carrier means 2 through a main oil passage 95. A part of the lubrication oil in the oil passage 93 is introduced toward the radial bearing means 46 and 48 and then toward camshaft journal bearings 10 and 11 through axial oil passages 74 and 82 formed in the intake and exhaust camshafts 3 and 4, respectively. The oil passage 93 is formed with first to third branch oil passages 96, 97 and 98, branching off downward therefrom, which are brought into communication with the first to third oil passages 36, 37 and 38, respectively, when the camshaft carrier means 2 is bolted to the cylinder head 1. A part of the oil in the oil passage 93 is supplied downward to the hydraulic valve lash adjusters 22 through the branch oil passages 96, 97 and 98 and the first to third oil passages 36, 37 and 38.
Referring again to FIG. 6, a branch oil passage 75, branching off from the intake camshaft oil passage 74, extends to a radial bearing 47. A part of the oil passed through the branch oil passage 75 is delivered to the front thrust surface 63 and the other is discharged into an annular space 77 formed between the camshaft cover means 44 and an oil seal ring 76. A return oil passage 78 is formed in the camshaft cover means 44 so as to axially extend from the space 77 and return the oil in the space 77 to the front thrust surface 63. The provision of these oil passages 75 and 78 sufficiently lubricates the front thrust surface 63.
The intake camshaft 3 is further formed with a radial oil passage 79 extending from the axial oil passage 74 and opening to the outer surface of the rear journal 62B. The radial oil passage 79 is axially located in a position closer to the front end of the rear journal 62B than to the rear end of the rear journal 62B. A part of the oil passing in the axial oil passage 74 is delivered to the radial bearing means 46 through the radial oil passage 79. The radial oil passage 79, located closer to the front end of the rear journal 62B, allows the major part of lubrication oil passed throughout the radial oil passage 79 to flow towards the rear thrust surface 65, so as to lubricate sufficiently the rear thrust surface 65. After the lubrication of the rear thrust surface 65, the oil is returned through a groove 81 formed in the thrust collar 64.
Similarly, a branch oil passage 83, branching off from the exhaust camshaft oil passage 82, extends to a radial bearing 49, so as to lubricate the radial bearing portion 49. A part of the oil passed through the branch oil passage 83 enters into an undercut groove 84 formed inside the internal thread bore 70, and then is returned through a return oil passage 85 so as to lubricate the front thrust metal insert 67 and the friction gear 61. The exhaust camshaft 4 is further formed with a radial oil passage 86 extending from the axial oil passage 82 and opening to the outer surface of the rear journal 48. A part of oil passing in the axial oil passage 82 is delivered to the radial bearing means 48 through the radial oil passage 86. After the lubrication of the rear radial bearing means 48, the oil is forced towards the front thrust surface 69, so as to lubricate sufficiently the front thrust surface 69.
Referring to FIG. 11, showing a variant of the cylinder head structure of the preferred embodiment of the invention, the bosses 92 located on opposite sides of the exhaust camshaft 4 may be formed integrally with the front end boss 71 having a bore 70 of the camshaft cover means 44. This provides an increase in rigidity of that part surrounding the exhaust camshaft 4 of the camshaft cover means 44.
Referring to FIG. 12, showing another variant of the cylinder head structure of the preferred embodiment of the invention, the camshaft cover means 44 is provided with two connecting bolts 90 on each side of the cylinder head. This provides an increase in rigidity of both sides of the camshaft cover means 44.
As is apparent from the above description, although the cylinder head 1 has a large number of bores and holes formed therein, the provision of the elongated partition wall 28 between the rows of bores 5 and 8a and the rows of bores 6 and 8b provides an increase in structural rigidity, torsional strength and bending strength of the cylinder head 1. Accordingly, even though the cylinder head is made small in size, a lack of rigidity is not caused.
While the engine A is in operation, blow-by gas, which escapes from the combustion chambers 15 into the oil jacket P above the cylinder head 1, is introduced into the oil separator 34 through the blow-by gas inlet 35 formed in the camshaft carrier 2. The blow-by gas flows in the oil separator 34 through the zigzag path in the space S and is discharged into an intake manifold (not shown) through a blow-by gas outlet 34b of the oil separator 34 after the elimination of oil mist by the buffer ribs 34a.
It is generally understood that as the number of valves and hydraulic valve lash adjusters for each cylinder becomes larger, the quantity of lubrication oil and working oil for the valve trains and hydraulic valve lash adjusters which is scattered and sprayed over the upper surface of the cylinder head 1 increases.
However, with a cylinder head 1 constructed as described above, since the U-shaped space P is formed between the cylinder head 1 and the camshaft carrier means 2 and is communicated with the zigzag path of the oil separator 34 by the blow-by gas inlet 35 at a location far away from the gear chamber 27, blow-by gas travels a long distance to the oil separator 34. Accordingly, if there is a large quantity of oil mist on the upper surface of the cylinder head 1, the oil mist conveyed by blow-by gas adheres to surfaces of the cylinder head I and the camshaft carrier means 2 while the blow-by gas travels through the U-shaped path, so that removal of oil mist is fostered and the blow-by gas, with a low content of oil mist, flows into the oil separator 34.
More oil mist is produced in the oil chamber 31 on the same side as the intake valves, which are provided in a number larger than the number of the exhaust valves, than in the oil chamber 32 on the same side as the exhaust valves. However, since the blow-by gas inlet 35 is located on the same side as the oil chamber 32, in which less oil mist is produced, blow-by gas in the oil chamber flows in a long path, from the oil chamber 31 to the blow-by gas inlet 35 through the oil chamber 32, until it enters the oil separator 34, so as to remove oil mist effectively. This makes it possible to install a low capacity oil separator in the engine A to process sufficiently the blow-by gas.
The vertically extending bosses 92 of the camshaft cover means 44 serve as reinforcement beams. Two of the vertically extending bosses 92 and an oil sealing boss 96 are connected by puller fitting bosses 95. Accordingly, the camshaft cover means 44 is greatly strengthened in rigidity, so that if the ends of the intake and exhaust camshafts 3 and 4 receive an external load, the camshaft cover means 44 is free from deformations in axial and transverse directions. A great increase in rigidity of the whole structure of the camshaft cover means 44 allows the use of not only smaller but also fewer bolts for firmly, liquid-tightly connecting the camshaft cover means 44 and the gear casing portion 57 of the camshaft carrier means 2.
Because the bosses 92 are located on opposite sides of the bearings 47 and 63 for the intake camshaft 3 and the bearings 49 and 67 for the exhaust camshaft 4, the gear casing portion 57 of the camshaft carrier means 2 is reinforced in structural rigidity by the camshaft cover means 44. Accordingly, the intake and exhaust camshafts 3 and 4 are firmly supported for rotation by the bearings 47, 49, 63 and 67, so as to be prevented from producing vibration and noise.
Since the oil passage boss 94, extending in the transverse direction of the cam carrier means below the intake and exhaust camshaft bearing means 46 and 48, serves as a transverse beam, an increase in structural rigidity of the end portion, including the camshaft bearing means 46 and 48 of the camshaft carrier means 2, is provided. Accordingly, if the ends of the intake and exhaust camshafts 3 and 4 receive an external load, an end portion, including the camshaft bearing means 46 and 48 of the camshaft carrier means 2, is free from deformations in axial and transverse directions, and an increase in friction and seizing in the camshafts bearing means 46 and 48 is prevented.
Since oil is delivered into the first to third oil passages 36, 37 and 38, branching off from the oil passage 93 and located above the cylinder head 1, the first to third oil passages 36, 37 and 38 are always filled with oil. Accordingly, even if an oil pump (not shown) does not operate immediately after the start of the engine, the hydraulic valve lash adjusters 22 are supplied with oil. Further, even if air mixes into the oil in the first to third oil passages 36, 37 and 38 during the operation of engine, the air bubbles rise quickly into the oil passage 93, and air is prevented from entering into the hydraulic valve lash adjusters 22. | A cylinder head for a double overhead camshaft engine, with a plurality of intake valves and a plurality of exhaust valves for each cylinder, is covered by a cylinder head cover to support, for rotation, intake and exhaust camshafts. A hermetically sealed chamber, formed between the cylinder head and head cover as an oil jacket, is divided into two chambers, enclosing major parts of the intake and exhaust camshafts, respectively, which are in communication with each other near first ends of the chambers. An outlet hole is formed in the cylinder head cover so as to permit blow-by gas to flow out of the chamber. A cover, covering a gear train for operationally coupling the intake and exhaust camshafts, is bolted to one end of the head cover at several points around the gear train and to the cylinder head. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This non-provisional application claims priority under 35 U.S.C. §119(a) on Patent Application No. 2009-156463 filed in Japan on Jul. 1, 2009, the entire contents of which are hereby incorporated by reference.
TECHNICAL FIELD
[0002] This invention relates to a melamine-functional organosilicon compound and a method for preparing the same. More particularly, it relates to a multi-functional silyl compound having a melamine skeleton in the molecule which has high water solubility and is able to form a film upon hydrolytic condensation because of the melamine skeleton combined with the siloxane structure.
BACKGROUND ART
[0003] One typical group of organosilicon compounds is silane coupling agents. The silane coupling agents have two or more different functional radicals in their molecule, and serve as a chemical bridge to bond an organic material and an inorganic material that would otherwise be difficult to bond. In the silane coupling agent, one functional radical is a hydrolyzable silyl radical which forms a silanol radical in the presence of water. This silanol radical, in turn, reacts with a hydroxyl radical on the surface of inorganic material to form a chemical bond to the inorganic material surface. The other functional radicals include vinyl, epoxy, amino, (meth)acrylic, mercapto and similar radicals which form a chemical bond with organic materials such as various synthetic resins, as well as ureido, isocyanurate and other polar radicals which do not form a chemical bond, but hydrogen bond or otherwise interact due to their polarity. By virtue of these attributes, the silane coupling agents are widely used as modifiers, adhesive aids, and various other additives in organic and inorganic resins.
[0004] Among others, those silane coupling agents having non-bonding functional radicals such as ureido and isocyanurate are used as resin modifiers and paint additives. Generally isocyanurate silane coupling agents are advantageous in that their hydrolytic condensates have a film forming ability since they are of tris(silyl) type, and that they are compatible with resins because of inclusion of polar radicals. However, these silane coupling agents find limited use in aqueous applications because of a lack of water solubility.
[0005] Heterocyclic structures similar to isocyanurate include triazine structures. Mono(silyl) silane coupling agents having triazine structure are disclosed in JP-A 2006-213677 and JP-A 2007-131556. These patent documents relate to only organosilicon compounds of triazine structure having a thiol radical(s) introduced therein. With such teaching, a melamine skeleton as disclosed herein cannot be formed. On account of the thiol radical being introduced, a tris(silyl) structure as disclosed herein cannot be formed.
[0006] JP-A H07-026242 discloses an adhesive composition comprising a silicone-modified melamine resin. Since a melamine resin derivative is tied with silicone by condensation of hydroxyl with silanol, undesirably the modified resin is prone to untying in the presence of water or alcohol. Silane coupling agents are nowhere described. JP-A H11-100237 discloses a composition for use as a glass fiber sizing agent, comprising a melamine resin and a reactive silane coupling agent. Since this material is a blend of components, it is impossible to isolate the material as a compound and identify the structure thereof.
CITATION LIST
[0007] Patent Document 1: JP-A 2006-213677
[0008] Patent Document 2: JP-A 2007-131556
[0009] Patent Document 3: JP-A H07-026242
[0010] Patent Document 4: JP-A H11-100237
SUMMARY OF INVENTION
[0011] An object of the invention is to provide an organosilicon compound of triazine structure, specifically melamine structure, having a film forming ability, water solubility and compatibility with resins, and a method for preparing the organosilicon compound.
[0012] The inventor has found that an organosilicon compound having the desired properties is obtainable from reaction of cyanuric chloride with a primary and/or secondary amino-containing organosilicon compound having the general formula (3) shown below.
[0013] In one aspect, the invention provides a melamine skeleton-bearing organosilicon compound having the general formula (1).
[0000]
[0000] Herein R 0 is independently hydrogen or a substituted or unsubstituted monovalent hydrocarbon radical which may be separated by carbonyl carbon or a heteroatom selected from the group consisting of oxygen, sulfur and nitrogen, and at least one of R 0 is the following structure (A):
[0000]
[0000] wherein the broken line designates a valence bond, X is a substituted or unsubstituted divalent hydrocarbon radical which may be separated by carbonyl carbon or a heteroatom selected from the group consisting of oxygen, sulfur and nitrogen, the divalent hydrocarbon radical bonding to the nitrogen atom via a carbon atom at one end and bonding to the silicon atom via a carbon atom at the other end, R 1 is independently hydrogen or a substituted or unsubstituted C 1 -C 4 alkyl radical, R 2 is independently a substituted or unsubstituted C 1 -C 4 alkyl radical, and n is an integer of 1 to 3.
[0014] In a preferred embodiment, the organosilicon compound has the general formula (2):
[0000]
[0000] wherein X, R 1 , R 2 , and n are as defined above, R 3 is independently hydrogen or a substituted or unsubstituted monovalent hydrocarbon radical which may be separated by carbonyl carbon or a heteroatom selected from the group consisting of oxygen, sulfur and nitrogen.
[0015] In another aspect, the invention provides a method for preparing the organosilicon compound comprising the steps of reacting cyanuric chloride with a primary and/or secondary amine compound and neutralizing with a base, the primary and/or secondary amine compound comprising an organosilicon compound having the general formula (3).
[0000]
[0000] Herein X, R 1 , R 2 , R 3 , and n are as defined above.
[0016] In a preferred embodiment, the reaction uses at least 4 moles of the organosilicon compound having formula (3) per mole of cyanuric chloride and occurs at a temperature of 25 to 150° C. The base is typically ethylenediamine.
ADVANTAGEOUS EFFECTS OF INVENTION
[0017] The organosilicon compound of the invention is useful as a silane coupling agent since it is fully compatible with resins due to a polar structure or melamine structure and highly water soluble due to amine functionality. It is also useful as an additive to aqueous paints since a hydrolytic condensate thereof has a film forming ability particularly when it is a multifunctional silyl melamine.
BRIEF DESCRIPTION OF DRAWINGS
[0018] FIGS. 1 , 2 , and 3 show 1 H-NMR, 13 C-NMR, and 29 Si-NMR spectra of the reaction product in Example 1, respectively.
DESCRIPTION OF EMBODIMENTS
[0019] The singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. The notation (C n -C m ) means a radical containing from n to m carbon atoms per radical. As used herein, the term “silane coupling agent” is encompassed by “organosilicon compound”.
Organosilicon Compound
[0020] The organosilicon compound of the invention has a structure of the following general formula (1).
[0000]
[0000] Herein R 0 is each independently hydrogen or a substituted or unsubstituted monovalent hydrocarbon radical which may be separated by carbonyl carbon or a heteroatom selected from the group consisting of oxygen, sulfur and nitrogen. At least one R 0 is the following structure (A):
[0000]
[0000] wherein the broken line designates a valence bond, X is a substituted or unsubstituted divalent hydrocarbon radical which may be separated by carbonyl carbon or a heteroatom selected from the group consisting of oxygen, sulfur and nitrogen, the divalent hydrocarbon radical bonding to the nitrogen atom via a carbon atom at one end and bonding to the silicon atom via a carbon atom at the other end, R 1 is each independently hydrogen or a substituted or unsubstituted C 1 -C 4 alkyl radical, R 2 is each independently a substituted or unsubstituted C 1 -C 4 alkyl radical, and n is an integer of 1 to 3.
[0021] Preferably the compound has the general formula (2).
[0000]
[0000] Herein X, R 1 , R 2 and n are as defined above. R 3 is each independently hydrogen or a substituted or unsubstituted monovalent hydrocarbon radical which may be separated by carbonyl carbon or a heteroatom selected from the group consisting of oxygen, sulfur and nitrogen, preferably hydrogen or alkyl, and most preferably hydrogen.
[0022] In formulae (1) and (2), R 0 and R 3 are optionally substituted monovalent hydrocarbon radicals which may be separated by carbonyl carbon or a heteroatom selected from oxygen, sulfur and nitrogen, examples of which include alkyl radicals such as methyl, ethyl, propyl, isopropyl, butyl, isobutyl, tert-butyl, pentyl, neopentyl, hexyl, cyclohexyl, octyl, nonyl and decyl, aryl radicals such as phenyl, tolyl, xylyl and naphthyl, aralkyl radicals such as benzyl, phenylethyl and phenylpropyl, alkenyl radicals such as vinyl, allyl, propenyl, isopropenyl, butenyl, hexenyl, cyclohexenyl and octenyl, and the following.
[0000]
[0000] Herein A is a monovalent hydrocarbon radical, examples of which include alkyl radicals such as methyl, ethyl, propyl, isopropyl, butyl, isobutyl, and tert-butyl. B is a divalent hydrocarbon radical, examples of which include alkylene radicals such as methylene, ethylene and propylene.
[0023] It is to be noted that the substituent on the foregoing structures is a radical selected from the group consisting of alkyl, aryl, perfluoroalkyl, polyether, perfluoropolyether and hydrolyzable silyl radicals. Of these, alkyl and aryl radicals are preferred. The substituent may be attached to a polysiloxane structure as mentioned above, typically silicone oil and silicone resin, or an organic polymer structure.
[0024] In formulae (1) and (2), R 1 and R 2 are optionally substituted C 1 -C 4 alkyl radicals, examples of which include methyl, ethyl, propyl, isopropyl, n-butyl, isobutyl, tert-butyl, and substituted forms of the foregoing radicals in which some or all hydrogen atoms are substituted by halogen atoms, such as chloromethyl and 3,3,3-trifluoropropyl. Preferably R 1 and R 2 each are methyl or ethyl.
[0025] In formulae (1) and (2), X is an optionally substituted divalent hydrocarbon radical which may be separated by carbonyl carbon or a heteroatom selected from oxygen, sulfur and nitrogen, the divalent hydrocarbon radical bonding to the nitrogen atom via a carbon atom at one end and bonding to the silicon atom via a carbon atom at the other end. Examples of the divalent hydrocarbon radical include, but are not limited to, methylene, ethylene, propylene, 1-methylpropylene, 2-methylpropylene, 3-methylpropylene and butylene. The subscript n is an integer of 1 to 3, preferably 2 or 3, and most preferably 3.
[0026] Examples of the melamine-functional organosilicon compound include those of structural formulae (4) to (7) below. Herein Me stands for methyl and Et for ethyl.
[0000]
Method
[0027] The organosilicon compound of the invention may be prepared by reacting cyanuric chloride with a primary and/or secondary amine compound and neutralizing the reaction product with a base. The primary and/or secondary amine compound used herein contains, as an essential component, an organosilicon compound having both a primary and/or secondary amino radical and a hydrolyzable silyl radical, represented by the following general formula (3):
[0000]
[0000] wherein X, R 1 , R 2 , R 3 and n are as defined above. To distinguish the organosilicon compound of the invention and the starting organosilicon compound containing a primary and/or secondary amino radical and a hydrolyzable silyl radical, the former is referred to as the target organosilicon compound and the latter is referred to as the organosilicon reactant, hereinafter.
[0028] The essential reactants used in the reaction are cyanuric chloride and an organosilicon reactant having both a primary and/or secondary amino radical and a hydrolyzable silyl radical. Besides, reactants having a primary and/or secondary amino radical such as hydrocarbons having a primary and/or secondary amino radical and polysiloxanes having a primary and/or secondary amino radical may be used along with the essential reactants, and then the target organosilicon compound having a melamine skeleton in the molecule can still be prepared.
[0029] Non-limiting examples of the primary and/or secondary amine compound include organosilicon compounds having both a primary and/or secondary amino radical and a hydrolyzable silyl radical such as α-aminomethyltrimethoxysilane,
α-aminomethylmethyldimethoxysilane, α-aminomethyldimethylmethoxysilane, α-aminomethyltriethoxysilane, α-aminomethylmethyldiethoxysilane, α-aminomethyldimethylethoxysilane, γ-aminopropyltrimethoxysilane, γ-aminopropylmethyldimethoxysilane, γ-aminopropyldimethylmethoxysilane, γ-aminopropyltriethoxysilane, γ-aminopropylmethyldiethoxysilane, γ-aminopropyldimethylethoxysilane, N-(2-aminoethyl)-α-aminomethyltrimethoxysilane, N-(2-aminoethyl)-α-aminomethylmethyldimethoxysilane, N-(2-aminoethyl)-α-aminomethyldimethylmethoxysilane, N-(2-aminoethyl)-α-aminomethyltriethoxysilane, N-(2-aminoethyl)-α-aminomethylmethyldiethoxysilane, N-(2-aminoethyl)-α-aminomethyldimethylethoxysilane, N-(2-aminoethyl)-γ-aminopropyltrimethoxysilane, N-(2-aminoethyl)-γ-aminopropylmethyldimethoxysilane, N-(2-aminoethyl)-γ-aminopropyldimethylmethoxysilane, N-(2-aminoethyl)-γ-aminopropyltriethoxysilane, N-(2-aminoethyl)-γ-aminopropylmethyldiethoxysilane, N-(2-aminoethyl)-γ-aminopropyldimethylethoxysilane, bis(trimethoxysilylpropyl)amine, bis(methyldimethoxysilylpropyl)amine, bis(dimethylmethoxysilylpropyl)amine, bis(triethoxysilylpropyl)amine, bis(methyldiethoxysilylpropyl)amine, bis(dimethylethoxysilylpropyl)amine, N-phenyl-γ-aminopropyltrimethoxysilane, N-phenyl-γ-aminopropylmethyldimethoxysilane, N-phenyl-γ-aminopropyldimethylmethoxysilane, N-phenyl-γ-aminopropyltriethoxysilane, N-phenyl-γ-aminopropylmethyldiethoxysilane, N-phenyl-γ-aminopropyldimethylethoxysilane, N-phenyl-α-aminomethyltrimethoxysilane, N-phenyl-α-aminomethylmethyldimethoxysilane, N-phenyl-α-aminomethyldimethylmethoxysilane, N-phenyl-α-aminomethyltriethoxysilane, N-phenyl-α-aminomethylmethyldiethoxysilane, and N-phenyl-α-aminomethyldimethylethoxysilane; and
organosilicon compounds having a primary and/or secondary amino radical such as similar alkoxysilane oligomers having a primary and/or secondary amino radical.
[0071] In the production of the target organosilicon compound, cyanuric chloride and the organosilicon reactant having both a primary and/or secondary amino radical and a hydrolyzable silyl radical may be combined at any desired ratio. It is preferred from the aspects of reactivity and productivity to use 4 to 20 moles and more preferably 4.5 to 10 moles of the organosilicon reactant per mole of cyanuric chloride. This is true particularly when a tris(trialkoxysilyl) melamine compound is to be produced. If the amount of the organosilicon reactant is too small, hydrogen chloride generated during the reaction may form a salt with an amino radical to detract from the reactivity, resulting in a decline of productivity. Besides the unreacted reactants may be entrained as impurities to reduce the purity of the tris(trialkoxysilyl) compound. Too much amounts of the organosilicon reactant may simply add to the cost of production because the reaction may be saturated.
[0072] When another reactant having a primary and/or secondary amino radical is used in the reaction with cyanuric chloride, the total amount of the organosilicon reactant having both a primary and/or secondary amino radical and a hydrolyzable silyl radical and the other reactant having a primary and/or secondary amino radical is preferably 4 to 20 moles and more preferably 4.5 to 10 moles per mole of cyanuric chloride. The organosilicon reactant is preferably blended with the other reactant in such a molar ratio as to meet 0<(other reactant)/(organosilicon reactant)≦2 and more preferably 0.5≦(other reactant)/(organosilicon reactant)≦2.
[0073] A solvent may be used in the production of the target organosilicon compound, if desired. The solvent used is not particularly limited as long as it is nonreactive with the reactants, cyanuric chloride and primary and/or secondary amine compounds. Examples include aliphatic hydrocarbon solvents such as pentane, hexane, heptane and decane, ether solvents such as diethyl ether, tetrahydrofuran and 1,4-dioxane, and aromatic hydrocarbon solvents such as benzene, toluene and xylene.
[0074] The reaction to produce the target organosilicon compound is exothermic. Since side reactions can occur at unnecessarily high temperatures, the reaction temperature is preferably controlled in a range of 25° C. to 150° C., more preferably 35° C. to 120° C., and most preferably 50° C. to 120° C. Below 25° C., the reaction rate may be retarded to invite a decline of productivity and side reactions may concomitantly occur to reduce the purity. A temperature of higher than 150° C. may cause pyrolysis, leading to a low purity.
[0075] The reaction time required to produce the target organosilicon compound is not particularly limited as long as the above-mentioned temperature management during exothermic reaction is possible and the exothermic reaction is brought to completion. The reaction time is preferably about 10 minutes to about 24 hours and more preferably about 1 hour to about 20 hours.
[0076] The method for the production of the target organosilicon compound should involve a neutralization step after the reaction since hydrochloric acid generates during the reaction. The base used for neutralization is not particularly limited as long as it forms with hydrogen chloride a salt in insoluble solid or liquid form which can be separated. Suitable bases include trialkylamines, ethylenediamine, urea, metal alkoxides and the like. Of these, ethylenediamine is preferred because it effectively forms a hydrochloride salt in liquid form which can be readily separated.
[0077] In the production of the target organosilicon compound, the amount of the base added for neutralization is 1 to 3 moles, and preferably 1.2 to 2 moles per mole of hydrogen chloride generated on a stoichiometric basis. If the amount of the base added is too small, only a fraction of hydrochloric acid may be trapped, resulting in the target compound having an increased chloride ion content. Too much amounts of the base may simply add to the cost of production because the neutralization reaction is saturated.
[0078] The temperature of the neutralization step is preferably controlled in a range of 25° C. to 150° C., more preferably 35° C. to 120° C., and most preferably 50° C. to 120° C. Below 25° C., the reaction rate may be retarded, resulting in a decline of productivity. A temperature of higher than 150° C. may cause pyrolysis, leading to a low purity. The neutralization time is preferably about 10 minutes to about 24 hours and more preferably about 1 hour to about 20 hours.
EXAMPLE
[0079] Examples of the invention are given below by way of illustration and not by way of limitation. In Examples, the viscosity is measured at 25° C. by a capillary viscometer. The specific gravity and refractive index are also measured at 25° C. Nuclear magnetic resonance spectroscopy is abbreviated as NMR. Me stands for methyl and Et for ethyl.
Example 1
Preparation of N,N,N-tris(trimethoxysilylpropyl)melamine
[0080] A 1-L separable flask equipped with a stirrer, reflux condenser, dropping funnel and thermometer was charged with 55.3 g (0.3 mol) of cyanuric chloride and 300 g of toluene, which were stirred while heating to an internal temperature of 50° C. To the flask 403.3 g (2.2 mol) of γ-aminopropyltrimethoxysilane (KBM-903, Shin-Etsu Chemical Co., Ltd.) was added dropwise. The reaction was exothermic and the internal temperature rose to 80° C. Stirring was continued for 8 hours while heating to an internal temperature of 110° C. After the reaction, the temperature was adjusted to 80° C. To the flask 81 g (1.3 mol) of ethylenediamine was added dropwise for neutralization over 4 hours. The reaction solution separated into two layers. The upper layer was taken out, from which the solvent and unreacted substances were distilled off under vacuum. The reaction product was left as a pale yellow liquid having a viscosity of 1,690 mm 2 /s, a specific gravity of 1.15 and a refractive index of 1.489. On NMR spectroscopy, the reaction product was identified to be a single compound having the following chemical structural formula (4). FIGS. 1 , 2 and 3 show 1 H-NMR, 13 C-NMR and 29 Si-NMR spectra of the compound, respectively.
[0000]
Example 2
Preparation of N,N,N-tris(triethoxysilylpropyl)melamine
[0081] A 1-L separable flask equipped with a stirrer, reflux condenser, dropping funnel and thermometer was charged with 55.3 g (0.3 mol) of cyanuric chloride and 300 g of toluene, which were stirred while heating to an internal temperature of 50° C. To the flask 486.9 g (2.2 mol) of γ-aminopropyltriethoxysilane (KBE-903, Shin-Etsu Chemical Co., Ltd.) was added dropwise. The reaction was exothermic and the internal temperature rose to 80° C. Stirring was continued for 8 hours while heating to an internal temperature of 110° C. After the reaction, the temperature was adjusted to 80° C. To the flask 81 g (1.3 mol) of ethylenediamine was added dropwise for neutralization over 4 hours. The reaction solution separated into two layers. The upper layer was taken out, from which the solvent and unreacted substances were distilled off under vacuum. The reaction product was left as a pale yellow liquid having a viscosity of 1,730 mm 2 /s, a specific gravity of 1.08 and a refractive index of 1.485. On NMR spectroscopy, the reaction product was identified to be a single compound having the following chemical structural formula (5). NMR spectroscopy data of the compound are shown below.
[0082] 1 H-NMR (300 MHz, CDCl 3 , δ (ppm)): 0.58 (t, 6H), 0.82 (t, 27H), 1.63 (quint, 6H), 3.30 (t, 6H), 3.45 (q, 18H), 4.88 (s, 3H)
[0083] 13 C-NMR (75 MHz, CDCl 3 , δ (ppm)): 6.2, 18.1, 23.3, 43.5, 50.9, 166.8
[0084] 29 Si-NMR (60 MHz, CDCl 3 , δ (ppm)): −41.8
[0000]
Example 3
Preparation of N,N-bis(trimethoxysilylpropyl)-N-phenyl-melamine
[0085] A 1-L separable flask equipped with a stirrer, reflux condenser, dropping funnel and thermometer was charged with 55.3 g (0.3 mol) of cyanuric chloride and 300 g of toluene, which were stirred while heating to an internal temperature of 50° C. To the flask a mixture of 179.3 g (1.4 mol) of γ-aminopropyltrimethoxysilane (KBM-903, Shin-Etsu Chemical Co., Ltd.) and 65.1 g (0.7 mol) of aniline was added dropwise. The reaction was exothermic and the internal temperature rose to 80° C. Stirring was continued for 8 hours while heating to an internal temperature of 110° C. After the reaction, the temperature was adjusted to 80° C. To the flask 81 g (1.3 mol) of ethylenediamine was added dropwise for neutralization over 4 hours. The reaction solution separated into two layers. The upper layer was taken out, from which the solvent and unreacted substances were distilled off under vacuum. The reaction product was left as a pale yellow liquid having a viscosity of 2,210 mm 2 /s, a specific gravity of 1.05 and a refractive index of 1.493. On NMR spectroscopy, the reaction product was identified to be a compound of the following chemical structural formula (6) having alkoxysilyl and phenyl radicals in a ratio of 2:1. 1 H-NMR spectroscopy data of the compound are shown below.
[0086] 1 H-NMR (300 MHz, CDCl 3 , δ (ppm)): 0.61 (t, 4H), 1.69 (quint, 4H), 3.22 (t, 4H), 3.56 (s, 18H), 4.91-5.04 (s, 3H), 6.64-7.11 (m, 5H)
[0000]
Example 4
Preparation of N,N-bis(trimethoxysilylpropyl)-N-butyl-melamine
[0087] A 1-L separable flask equipped with a stirrer, reflux condenser, dropping funnel and thermometer was charged with 55.3 g (0.3 mol) of cyanuric chloride and 300 g of toluene, which were stirred while heating to an internal temperature of 50° C. To the flask a mixture of 179.3 g (1.4 mol) of γ-aminopropyltrimethoxysilane (KBM-903, Shin-Etsu Chemical Co., Ltd.) and 51.1 g (0.7 mol) of n-butylamine was added dropwise. The reaction was exothermic and the internal temperature rose to 80° C. Stirring was continued for 8 hours while heating to an internal temperature of 110° C. After the reaction, the temperature was adjusted to 80° C. To the flask 81 g (1.3 mol) of ethylenediamine was added dropwise for neutralization over 4 hours. The reaction solution separated into two layers. The upper layer was taken out, from which the solvent and unreacted substances were distilled off under vacuum. The reaction product was left as a pale yellow liquid having a viscosity of 1,450 mm 2 /s, a specific gravity of 1.12 and a refractive index of 1.454. On NMR spectroscopy, the reaction product was identified to be a compound of the following chemical structural formula (7) having alkoxysilyl and butyl radicals in a ratio of 2:1. 1 H-NMR spectroscopy data of the compound are shown below.
[0088] 1 H-NMR (300 MHz, CDCl 3 , δ (ppm)): 0.63 (t, 4H), 0.83 (t, 3H), 1.60-1.69 (m, 8H), 3.22-3.31 (m, 6H), 3.61 (s, 18H), 4.88-5.01 (s, 3H)
[0000]
Example 5
Preparation of N,N-bis(trimethoxysilylpropyl)-N-(polydimethylsiloxypropyl)melamine
[0089] A 1-L separable flask equipped with a stirrer, reflux condenser, dropping funnel and thermometer was charged with 55.3 g (0.3 mol) of cyanuric chloride and 300 g of toluene, which were stirred while heating to an internal temperature of 50° C. To the flask a mixture of 179.3 g (1.4 mol) of γ-aminopropyltrimethoxysilane (KBM-903, Shin-Etsu Chemical Co., Ltd.) and 135 g (0.3 mol as amino) of a primary amino-terminated polydimethylsiloxane (KF-8010, Shin-Etsu Chemical Co., Ltd.) was added dropwise. The reaction was exothermic and the internal temperature rose to 80° C. Stirring was continued for 8 hours while heating to an internal temperature of 110° C. After the reaction, the temperature was adjusted to 80° C. To the flask 81 g (1.3 mol) of ethylenediamine was added dropwise for neutralization over 4 hours. The reaction solution separated into two layers. The upper layer was taken out, from which the solvent and unreacted substances were distilled off under vacuum. The reaction product was left as a pale yellow liquid having a viscosity of 1,930 mm 2 /s, a specific gravity of 1.05 and a refractive index of 1.433. On NMR spectroscopy, the reaction product was identified to be a compound having functional radicals, alkoxysilyl and polydimethylsiloxane radicals in an average ratio of 2:1. 1 H-NMR spectroscopy data of the compound are shown below.
[0090] 1 H-NMR (300 MHz, CDCl 3 , δ (ppm)): 0.02-0.11 (m, 53H), 0.61-0.64 (m, 4H), 1.63-1.68 (m, 6H), 3.20-3.25 (m, 6H), 3.58-3.64 (m, 18H), 4.88-5.01 (s, 3H)
[0091] Japanese Patent Application No. 2009-156463 is incorporated herein by reference.
[0092] Although some preferred embodiments have been described, many modifications and variations may be made thereto in light of the above teachings. It is therefore to be understood that the invention may be practiced otherwise than as specifically described without departing from the scope of the appended claims. | A melamine skeleton-bearing organosilicon compound has a film forming ability, water solubility and compatibility with resins. It is prepared by reacting cyanuric chloride with a primary and/or secondary amine compound and neutralizing with a base. | 2 |
BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates to electronic device enclosures, more particularly to an electronic device enclosure with a cover.
[0003] 2. Description of Related Art
[0004] A server system may include a plurality of data storage devices. The storage devices are installed together on a chassis. Any voids created by the removal or absence of one or more of the storage devices can adversely effect heat dissipation of the server system.
[0005] Therefore, there is room for improvement within the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Many aspects of the embodiments can be better understood with references to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the embodiments. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0007] FIG. 1 is an exploded, isometric view of an embodiment of an electronic device enclosure and data storage devices.
[0008] FIG. 2 is an exploded view of a cover of FIG. 1 .
[0009] FIG. 3 is an enlarged view of a circled portion III of FIG. 1 .
[0010] FIG. 4 is an assembled view of the electronic device enclosure and storage devices of FIG. 1 .
[0011] FIG. 5 is a cross-sectional, cutaway view, taken along line V-V of FIG. 4 .
DETAILED DESCRIPTION
[0012] The disclosure is illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and such references mean at least one.
[0013] FIG. 1 illustrates an electronic device enclosure in accordance with an embodiment. The electronic device enclosure includes a chassis 10 and a plurality of covers 50 . In one embodiment, the electronic device is a server system.
[0014] The chassis 10 includes a bottom plate 11 and two side plates 13 . The two side plates 13 extend from opposite sides of the bottom plate 11 . The two side plates 13 are substantially parallel to each other and perpendicular to the bottom plate 11 . Two dividing plates 15 are extend from the bottom plate 11 to provide receiving areas for data storage devices. The two dividing plates 15 are in a same plane. The plane is substantially parallel to the two side plates 13 and perpendicular to the bottom plate 11 . The two dividing plates 15 , each of the side plates 13 , and the bottom plate 11 cooperatively define a receiving space 113 . The receiving space 113 can receive a storage device 20 . The storage device 20 may be a hard disk drive, compact disk read-only memory (CD-ROM) drive, digital video disc (DVD) drive, floppy disk drive, for example. Two fixing posts 131 protrude from each of the two side plates 13 and each of the two dividing plates 15 corresponding to the receiving space 113 .
[0015] Referring to FIG. 2 , each of the plurality of covers 50 includes a top wall 51 , two sidewalls 53 , a front wall 55 , and a back wall. The top wall 51 defines an opening 511 . Users can conveniently lift up each of the covers 50 via the opening 511 . The two sidewalls 53 extend upwards from opposite edges of the top wall 51 . The two sidewalls 53 are substantially parallel to each other and perpendicular to the top wall 51 . The front wall 55 and the back wall extend upwards from other opposite edges of the top wall 51 . Each of the two sidewalls 53 defines two cutouts 531 . Two clipping arms 533 are formed on each of the two cutouts 531 and cooperatively define a latching hole 535 corresponding to each of the two fixing posts 131 . In one embodiment, the two clipping arms 533 substantially form a U-shape. The latching hole 535 includes a wide portion 5353 and a narrow portion 5351 communicating with the wide portion 5353 . A width of the wide portion 5353 is greater than a width of the narrow portion 5351 .
[0016] When none of the storage device 20 is received in the receiving space 113 , one of the covers 50 is put in the empty receiving space 113 . This is done by aligning the latching holes 535 with the corresponding fixing posts 131 and pushing down on each of the covers 50 to deform the two clipping arms 533 until the fixing posts 131 extend through the wide portions 5353 to be engaged into the narrow portions 5351 . After the fixing posts 131 are engaged, the clipping arms 533 rebound to clip the fixing posts 131 . Each of the covers 50 is thereby secured to the chassis 10 .
[0017] To install the storage device 20 in the receiving space 113 of the chassis 10 , an acting force is applied to each of the covers 50 to move each of the covers 50 away from the bottom plate 11 causing the fixing posts 131 to be removed from the narrow portions 5351 to the wide portions 5353 . Each of the covers 50 is thereby detached from the chassis 10 .
[0018] It is to be understood, however, that even though numerous characteristics and advantages have been set forth in the foregoing description of embodiments, together with details of the structures and functions of the embodiments, the disclosure is illustrative only and changes may be made in detail, especially in the matters of shape, size, and arrangement of parts within the principles of the disclosure to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | An electronic device enclosure includes a chassis and a cover. The chassis includes a fixing post and defines a receiving space configured to receive a storage device. The cover defines a latching hole. The fixing post is engaged in the latching hole to engage the cover with the chassis and cover the receiving space when no storage device is in the receiving space. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/823,225, filed on Aug. 22, 2006, and entitled, “Antifreeze Foam Injection System,” which is incorporated herein by reference in its entirety for all purposes.
TECHNICAL FIELD
[0002] Embodiments of the present invention are related generally to safe, economical, reliable, and environmentally responsible systems and methods for keeping pipelines (also referred to as conduits, lines, hoses, manifolds, etc.), and more importantly the liquid therein, from freezing; and more specifically to systems and methods for injecting antifreeze foam into pipelines.
BACKGROUND
[0003] Existing methods for keeping lines unfrozen may include the use of heat tape, recirculating lines, heated lines, weep systems (in which water is run continuously or intermittently through lines), air purge, and/or liquid antifreeze injection. Such methods may serve to prevent freezing of lines, but often suffer from high operating costs, wastefulness, high-energy demand, dangerousness, unreliability, and/or high expense for the related equipment. There exists a need in the art for improved systems and methods for antifreeze foam injection.
SUMMARY
[0004] Systems for antifreeze foam injection according to embodiments of the present invention include an antifreeze manifold carrying a pressurized antifreeze liquid, the pressurized antifreeze liquid having a foam surfactant, an air manifold carrying pressurized air; a junction of the antifreeze manifold and the air manifold, the junction configured to combine the pressurized antifreeze liquid and the pressurized air to form antifreeze foam; a foam generator in fluid communication with the junction, the foam generator configured to enhance bubble formation of the antifreeze foam, and an outlet conduit configured to receive the antifreeze foam. Such embodiments of systems may further include a container of the antifreeze liquid, an air compressor configured to create the pressurized air, a diaphragm pump actuated by the pressurized air of the air compressor, the diaphragm pump operable to pump from the container to create the pressurized antifreeze liquid, first air pressure regulator upstream of the diaphragm pump, the first regulator configured to regulate the pressurized antifreeze liquid to a first pressure, and a second air pressure regulator downstream from the air compressor, the second air pressure regulator configured to regulate the pressurized air to a second pressure.
[0005] According to some embodiments, the system may further include a first solenoid valve configured to control flow of the pressurized antifreeze liquid to the antifreeze manifold, and a second solenoid valve configured to control flow of the pressurized air to the air manifold. In some cases, the liquid pressure is higher than the gas pressure. The outlet may include a low pressure outlet and a high pressure outlet; the low pressure outlet may be, for example, a solenoid dump valve. According to some embodiments, the outlet conduit includes a dump gun with a trigger, and activation of the trigger dispenses fluid through the high pressure outlet, and non-activation of the trigger opens the low pressure outlet to facilitate antifreeze foam injection through the conduit. The foam generator may be made by forming a Teflon® mesh within a plastic pipe, for example.
[0006] Methods for antifreeze foam injection according to embodiments of the present invention include storing an antifreeze liquid having a foam surfactant, pressurizing the antifreeze liquid to a first pressure, pressurizing a gas to a second pressure, wherein the second pressure is different from the first pressure, combining the antifreeze liquid at the first pressure with the gas at the second pressure to form an antifreeze foam, and injecting the antifreeze foam into a conduit to displace freezable fluid in the conduit. In some cases, the second pressure is less than the first pressure. According to some embodiments, the gas is air, the first pressure is approximately fifty pounds per square inch, and the second pressure is approximately forty pounds per square inch. In addition, a foam generator may be used to combine the antifreeze liquid with the gas to enhance bubble protection. In some embodiments, the antifreeze liquid is approximately six hundred forty parts water, one hundred twenty-eight parts methanol, and one part foam surfactant.
[0007] An electronic control unit may be employed to monitor an ambient temperature near the conduit, and then initiate injection of the antifreeze foam into the conduit when the ambient temperature reaches a temperature at which the freezable fluid in the conduit freezes. In other embodiments, the electronic control unit monitors whether the conduit is being used to dispense the freezable fluid, and then initiates injection of the antifreeze foam into the conduit when the conduit is no longer being used to dispense the freezable fluid.
[0008] Methods for antifreeze foam injection in an automatic or self-service car wash bay according to embodiments of the present invention may include storing an antifreeze liquid having a foam surfactant, pressurizing the antifreeze liquid to a first pressure, pressurizing air to a second pressure, wherein the second pressure is smaller than the first pressure, combining the antifreeze liquid at the first pressure with the air at the second pressure to form an antifreeze foam mixture, directing the antifreeze foam mixture through a foam generator to enhance bubble production, opening a low pressure outlet in a carwash bay conduit, and injecting the antifreeze foam mixture into the carwash bay conduit. According to some embodiments of the present invention, injecting the antifreeze foam mixture into the carwash bay conduit includes displacing freezable fluid in the conduit with the antifreeze foam mixture. The carwash bay conduit may terminate at a dump gun, such that opening the low pressure outlet includes releasing a trigger of the dump gun. Alternatively, the carwash bay conduit may terminate at an automatic carwash panel, such that opening the low pressure outlet includes opening a dump solenoid valve.
[0009] While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 illustrates an antifreeze foam injection system according to embodiments of the present invention.
[0011] FIG. 2 depicts a solenoid valve assembly for use with an antifreeze foam injection system according to embodiments of the present invention.
[0012] FIG. 3 depicts an exemplary dual-outlet dump gun, according to embodiments of the present invention.
[0013] FIG. 4 depicts an example of a low-pressure foam/fluid applicator wand and a high-pressure fluid discharge wand, according to embodiments of the present invention.
[0014] While the invention is amenable to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and are described in detail below. The intention, however, is not to limit the invention to the particular embodiments described. On the contrary, the invention is intended to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION
[0015] Embodiments of the present invention may be employed with nearly any existing system where pipes are exposed to freezing conditions. For example, embodiments of the present invention may be used to freeze protect pipelines used in the car washing industry (self-service or automated type). Car washes typically have hoses in the bays that feed pressure guns (or wands), foam brushes, applicator guns, tire brushes, automatic car wash equipment, and so forth. Of course, in the event of freezing temperatures, the lines will freeze, causing shut downs, and often time-consuming and expensive repairs.
[0016] Embodiments of the present invention, in most basic terms, constitute an antifreeze foam injection system. Embodiments of such a system purge freezable liquid from the line by displacing the liquid with a pressurized timed output of antifreeze bubbles. FIG. 1 visually displays how an embodiment of such a system works. The following is a step-by-step description referencing the antifreeze foam injection system 100 of FIG. 1 .
[0017] To begin with, the antifreeze foam (AFF) does not start out as foam, according to embodiments of the present invention. An antifreeze mixture (for example: 640 parts water, 128 parts methanol, 1 part foam additive surfactant designed to be miscible with methanol) is either purchased as is or can be blended on-site using conventional methods well known in the art. Alternatively, a mixture of polypropylene glycol may be formulated to create a foam which does not use flammable materials; other chemical formulas may also serve to create a foam with freeze-resistant properties or a lower freezing temperature. This mixture may be stored in a holding tank 1 for future use.
[0018] When the temperature drops below freezing, an electronic control unit 2 (“ECU”), using a temperature sensor, may begin operation. The ECU 2 will wait a preset amount of time before initiating line purge. Once the preset amount of time has been reached, the ECU 2 may begin to systematically (depending on quantity and size of lines) purge the lines of freezable liquids by deploying AFF through the lines. The ECU 2 may be programmed to recognize that a line is currently in use, and to wait to purge that particular line until the line is no longer being used. Whenever a line is being used (i.e. a customer is washing a car), the ECU 2 notes which of the lines is being used and, after a preset amount of time after a line is no longer being used, may proceed to purge with AFF only the line or lines that were previously being used during the automatic and/or systematic purging. Whenever a facility is used (i.e. a customer is washing a car), the ECU 2 notes which lines are being used, waits a preset amount of time after a line is used, then proceeds to purge with AFF only the line or lines that were being used, according to embodiments of the present invention. The ECU 2 may also be programmed to remember whether a line is filled with AFF even if the temperature goes above freezing and back below again, such that the ECU 2 is programmed to refrain from purging a line that already contains AFF.
[0019] In order to fill the lines with a pressurized and timed output of AFF, the ECU 2 may open both a liquid solenoid valve 3 and an air solenoid valve 4 . The liquid solenoid valve 3 is fed by a pressurized manifold 5 (which may be pressurized by an air operated diaphragm pump 6 ) and employs a regulated and adjustable pressure setting 7 (which, for example, may be set at 50 psi—depending on many site specific factors). Air solenoid valve 4 may be fed by a pressurized manifold 8 (which may be connected to an air compressor tank 9 ), which may also employ a regulated and adjustable pressure setting 10 (typically set at 40 psi, but also may depend on many site specific factors). Site specific factors which may influence the desired pressure settings for pressure setting 7 and/or pressure setting 10 may include, but are not limited to, the type of equipment being purged, orifice (tip) size, service tubing size, chemical makeup of AFF ingredients, whether a foam generator 16 is used, cracking pressure of check valves used, and/or the hardness of water on site. Beneficial settings for pressure settings 7 , 10 may be located during a test activation as part of initial installation and/or periodic maintenance. During such testing, both pressure regulators 7 , 10 may be adjusted to maximize beneficial foaming properties, similar to the way in which standard car wash equipment is installed and/or tested. A pressure setting of 50 psi for regulator 7 and a pressure setting of 40 psi for regulator 10 have been found to work effectively to create AFF for a particular installed car wash system.
[0020] Antifreeze foam may be made effectively by using a surfactant that lowers the surface tension of the antifreeze/water mixture to a point at which the final chemical will “bubble” effectively by mixing together with pressurized air. Injecting air into a stream of “soapy” (high in surfactant) water causes bubbles to form, according to embodiments of the present invention. Although foam generator 16 is not necessary for the creation of antifreeze foam according to embodiments of the present invention, the foam generator 16 enhances the bubbling effect and bubble sizing so as to reduce the amount of chemical required and to maximize the amount of displacement capability of the antifreeze foam. According to embodiments of the present invention, foam generator 16 may be constructed of a twelve-inch length of one and one-half inch Schedule 80 PVC pipe housing with reducing bushings on either end for the housing. Inside the PVC pipe, a portion of a Teflon® (for chemical stability) scouring pad (e.g. those available at a local grocery store) may be formed and/or mounted therein. A crossbar may be employed at the end of the generator 16 to prevent unwanted shards of the Teflon material from passing downstream, according to embodiments of the present invention.
[0021] The outlets of solenoid valves 3 , 4 may be plumbed to manifolds 12 , 11 respectively; manifolds 11 , 12 , may ideally be placed as close as possible to where the exposed freezing line is protected from outside elements (typically inside a heated equipment room, or preferably in a freeze-protected trough 13 designed to house feed lines along the roof/ceiling and terminating above the bays). At this point, both the pressurized liquid and air combine in a “T” junction. Both lines 11 , 12 should be connected to check valves 14 , 15 to prevent unwanted backflow, according to embodiments of the present invention. When the air and liquid mixes at the correct pressures, bubbles will naturally form. According to some embodiments of the present invention, AFF creation may be optimized by using a liquid pressure (set by regulator 7 ) that is higher than an air pressure (set by regulator 10 ). This bubbling may be maximized by optionally using a foam generator 16 in fluid communication with the “T” junction; foam generator 16 may be a conduit with a stainless or similar mesh enclosed, for example. Finally, the line 17 coming out of the foam generator 16 is connected to the operating line 18 which is to be purged; such a connection may be accomplished with a T-joint 19 , for example. As used herein, the phrase “in fluid communication” is used in its broadest sense to refer to elements between or through which fluid may flow, either directly or indirectly.
[0022] Ideally, a backpressure check valve 20 may be used before this junction 19 to protect the entire system 100 and/or foam generator 16 from backflow and high pressures. The generated AFF flows through the line 18 to the outlet 21 . According to some embodiments of the present invention, the ECU 2 may be programmed to open the solenoids 3 , 4 only long enough for the AFF to entirely displace the freezable liquid in the line 18 . The ECU 2 may then close the solenoids and wait for a line to be used again. Based on the disclosure provided herein, one of ordinary skill in the art will appreciate the various ways in which the ECU 2 and/or related sensors 22 may be wired and/or programmed to perform the various monitoring and/or control functions described herein.
[0023] The following exemplary decision process illustrates logic which may be programmed into the ECU, according to embodiments of the present invention:
Step One—Is the the temperature below freezing? If no, repeat Step One (redundant check for change in temperature). If yes, proceed to Step Two. Step Two—Is antifreeze currently in the line (as opposed to an environmentally freezable liquid)? If no, proceed to Step Three. If yes, revert back to Step One. Step Three—Is the line currently in use (water or chemical flowing through it)? If no, proceed to Step Four. If yes, wait until line is no longer in use, then proceed to Step Four. Step Four—Wait for user-definable time period delay (site specific estimation necessary—testing successful in Colorado at 60 seconds). After successful delay, proceed to Step Five. If line is used again during delay period, revert back to Step Three. Step Five—Open air and antifreeze solenoids for user-definable time period (dependent on length of line/conduit which antifreeze foam must travel though - testing successful in Colorado at one location at 7 seconds). If line becomes in use, close solenoids and revert back to Step Three. If allowed to flow for user definable time period without interruption, the line is freeze protected - revert back to Step One. Step Six—Repeat as necessary for all lines to be protected at all times in a redundant fashion.
[0030] Based on the disclosure provided herein, one of ordinary skill in the art will appreciate that additional features may be programmed into the ECU 2 in order to further enhance efficiency of operation. For example, under freezing conditions, a line start-up delay (user definable—testing successful at 3 seconds) can be programmed in such a way that the system will not permit any freezable fluids to flow unless the operator has chosen to wait during the aforementioned delay, according to embodiments of the present invention. Such a procedure minimizes risk of the lines accidentally filling with freezable liquids, and serves as a verification that the operator has intended to use the line even though the environment will cause a freezing condition, according to embodiments of the present invention.
[0031] Again, lines can feed any number of items or equipment. Typically foam brushes, applicator guns, tire brushes, and/or (in most cases) automated car wash units have a relatively large output orifice, and the foaming characteristics of the AFF may easily be achieved according to embodiments of the present invention. A high-pressure wand, however, may create a high-pressure discharge by forcing a high volume through a very small orifice. Such a configuration may inhibit creation of AFF and/or proper displacement of freezable liquids (as opposed to simply mixing with the freezable liquids). Such an unfavorable configuration may be avoided, however, by using a special type of high-pressure wand. Typically referred to as a “dump gun” 23 , this type of pressure gun features two outlets: a high-pressure outlet 24 and a low-pressure outlet 21 . When the trigger is not pulled, the low-pressure outlet 21 is open allowing a high volume to easily be pushed through the gun 23 , thereby facilitating the easy creation of AFF and the purging of line 18 therewith, while still permitting gun 23 to be used to create a high-pressure discharge through outlet 24 upon activation of the trigger 25 .
[0032] On high-pressure automated car wash units, a similar problem with volume may be encountered. However, this is also easily circumvented by installing a “dump” solenoid valve 26 with a high-pressure/small orifice state and a low-pressure/large orifice state (or in some embodiments, a completely closed state and a completely open state), which the ECU 2 could open to drain the freezable liquid from the onboard lines and allow the AFF to easily flow. Conversely, some manufacturers already have in place the ability to “blow down” (by forcing high pressure air through the lines) the system; such a configuration may also provide an ideal environment for the AFF to flow and purge the remaining freezable liquid that inevitably settles in the low spots of the lines. According to embodiments of the present invention, creation of AFF and displacement of freezable liquid in the lines by AFF may be maximized by providing a higher-volume outlet from line 18 .
[0033] Beyond use of embodiments of the present invention for freeze proofing lines, utilizing “dump” technology, such as, for example, dump gun 23 and/or a dump solenoid 26 in line 18 , may create several other benefits which may be realized by an operator of system 100 . For example, a self-serve dump gun may be used which includes two separate barrels, one barrel including a large orifice type nozzle (i.e. a “4030”-type nozzle). Such a configuration may eliminate the use of much additional hardware often necessary for new features currently popular in the carwash industry. Included among these are foam wax, foam conditioner, foam presoak, foam tire cleaner, foam bug remover, etc. Utilizing this type of gun allows the complete elimination of the low pressure (i.e. foaming gun) and all related hardware—eliminating a source of confusion for some customers. According to such embodiments of the present invention, in addition to facilitating creation and deployment of AFF in line 18 during the non-use foam injection phase, a low pressure outlet 21 of dump gun 23 may be used by a customer to dispense various foam products currently dispensed by an entirely separate piece of hardware in conventional self-serve carwashes. Additionally, proper use of the dump mechanism 23 can eliminate the use of an unloader, allow for low pressure rinsing at high volume, allow for low pressure wax at high volume, and allow for high speed chemical changeover. Such features, singly and/or in combination, may allow for higher wash speeds, higher throughput, and an all around higher quality of service for the customer.
[0034] Although some embodiments of the present invention have been described as applicable to conduits in car wash bays, embodiments of the present invention may also be used to inject antifreeze foam into other conduits. For example, plumbing in a house may be winterized using injected antifreeze foam such as, for example, antifreeze foam made with food grade propylene glycol, according to embodiments of the present invention. For injecting antifreeze foam into water pipes in a house, the low pressure outlets (e.g. faucets and spouts) may be opened to facilitate the injection of the antifreeze foam and the volumetric displacement of the freezable fluids with the antifreeze foam, according to embodiments of the present invention.
[0035] Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present invention. For example, while the embodiments described above refer to particular features, the scope of this invention also includes embodiments having different combinations of features and embodiments that do not include all of the described features. Accordingly, the scope of the present invention is intended to embrace all such alternatives, modifications, and variations as fall within the scope of the claims, together with all equivalents thereof. | Systems according to embodiments of the present invention include an antifreeze manifold carrying pressurized antifreeze liquid, the pressurized antifreeze liquid having a foam surfactant, an air manifold carrying pressurized air, a junction of the antifreeze manifold and the air manifold, the junction configured to combine the pressurized antifreeze liquid and the pressurized air to form antifreeze foam, a foam generator configured to enhance bubble formation, and an outlet conduit to receive the foam. Methods according to embodiments of the present invention include storing an antifreeze liquid having a foam surfactant, pressurizing the antifreeze liquid to a first pressure, pressurizing a gas to a second pressure, wherein the second pressure is different from the first pressure, combining the antifreeze liquid at the first pressure with the gas at the second pressure to form an antifreeze foam, and injecting the antifreeze foam into a conduit to displace freezable fluid in the conduit. | 4 |
This application is a continuation of application Ser. No. 07/741,596, filed on Aug. 7, 1991 now abandoned.
BACKGROUND OF THE INVENTION
This invention generically relates to a magnetic resonance inspection apparatus. More specifically, the present invention relates to an external trigger imaging method and apparatus in a magnetic resonance inspection apparatus which will be suitable for the preparation of a plurality of slice images by continuous imaging, and which can facilitate breath holding scan imaging for reducing body motion-induced artifacts.
An ordinary imaging process in a conventional magnetic resonance inspection apparatus involves the steps of determining an inspection sectional plane or planes (slice plane(s)) of a subject, setting a sequence condition, starting a data fetch sequence by a scan start command by an operator and forming various images. In this case, imaging is generally carried out continuously by gradually changing the slice position of the subject and a plurality of sectional plane images are formed. This method is referred to as a "plurality-of-slices imaging".
Conventionally, the time required for imaging one slice image, for example, has been longer in the magnetic resonance inspection apparatus than in an X-ray CT, or the like. Particularly when those portions of a patient which move with his breathing such as the abdomen are to be imaged, therefore, body motion of the patient occurs unavoidably during the imaging process for a long time, and artifacts which result from breathing motion have been a serious problem. As to this problem, high speed imaging has been achieved in recent years and breath holding imaging has become possible with the reduction of the imaging time by the patient cooperation of holding his breath during imaging. Thus, the reduction of the artifacts have become technically possible.
An example of the timing chart of the conventional sequence for imaging a plurality of slice images is shown in FIG. 1 and the problems with the conventional method will be explained with reference to this timing chart. In the imaging process for imaging a plurality of slice images in the timing chart shown in FIG. 1, setting is made to image six slice images, for example. As other conditions, a scan parameter TR or in other words, the period of an RF (Radio Frequency) pulse is set to 240 ms, a data collection matrix is set to 256×256 and the number of times of integration of imaging under the same condition for improving an S/N ratio is set to once. The conventional process for imaging a plurality of slice images is constituted so as to sequentially obtain imaging data from slices 1 to 6 by setting a scan parameter TR to 240 ms.
In other words, since the data are measured in the sequence of 1, 2, 3, . . . , n as shown in FIG. 2, the scan time of 61.5 seconds is necessary to obtain the data for forming the images of the slice 1 to 6 by the calculation 0.24×256×1. This time is the inspection time required for the patient. In this manner, the conventional imaging sequence method needs a long inspection time and breath holding imaging of an ordinary patient is not practically possible. This problem cannot be solved so easily even if the imaging time can be shortened to certain extents.
In the imaging method in the conventional magnetic resonance inspection apparatus, the imaging sequence is operated by the "scan start" instruction of the operator. In this case, even if breath holding imaging becomes possible by high speed imaging, the breath holding timing must be given by the operator to the patient due to the structural limitation of the conventional apparatus. Since the magnetic resonance inspection apparatus operates in accordance with the control sequence that is in advance set for imaging, on the other hand, it is extremely difficult to establish synchronization between the instruction of the operator and the operation of the apparatus, and to time the breath holding timing.
The use of a contrast medium for magnetic resonance imaging has been permitted recently and imaging by the use of the contrast medium has been carried out to improve the contrast inside a tissue having a small difference of signal parameters. In such an imaging process, imaging must be carried out a plurality of times at certain intervals after the administration of the contrast medium so as to measure the changes of contrast due to the contrast medium with the passage of time. In this case, the imaging condition for each imaging sequence must be set whenever the predetermined time elapses and this increases the burden of the operator.
When a plurality of slice images are to be taken, the repetition time of each sequence is set in accordance with the number of slices, so that the imaging time gets elongated and breath holding imaging becomes practically impossible.
When one sectional image is taken by high speed imaging as shown in FIG. 3, pre-processing sequence (such as the optimization of the application of a gradient magnetic field, the RF irradiation system and the RF reception system) must be incorporated before the imaging sequence in the high speed imaging process by the conventional magnetic resonance inspection apparatus. If breath holding scan imaging is effected in this case, the patient cannot easily catch the optimum timing for breath holding but moves during the imaging sequence.
SUMMARY OF THE INVENTION
In a continuous imaging process of a plurality of slices by the same or different sequences, it is an object of the present invention to provide an external trigger imaging method and apparatus which reduces the imaging time by high speed imaging, makes it possible to conduct breath holding imaging by changing a control sequence, can thus reduce body motion-induced artifacts and enables a patient to time the start timing of breath holding imaging.
To accomplish the object described above, the present invention includes an input device for collectively setting imaging control data such as an imaging portion of a patient, the kinds of sequences, time intervals between a plurality of sequences inclusive of a pre-processing sequence, the number of times of repetition of a plurality of sequences, and so forth, and executes imaging sequences by trigger signals that are generated after the pre-processing sequence is completed.
The present invention is characterized in that when the control sequence for continuous imaging is executed, all the data necessary for the formation of a sectional image are collected whenever imaging of each slice is effected.
The present invention is further characterized in that an operation device for outputting a signal that indicates the start of the execution of each sequence is disposed in the proximity of the patient and the signal generated by the patient's operation of this operation device is used as an instruction signal for the start of imaging when the time interval is not set to a definite interval.
The present invention is further characterized in that when the time intervals between a plurality of sequences are not set to definite intervals by the input device but rather an indication of not a definite interval is set by the input device, the operator generates the trigger signal for the start of execution of each sequence by the use of this input device.
In accordance with the present invention, the time intervals between the sequences are not necessarily set to definite intervals, but an indication of not a definite interval can be set when the control sequences are set, and the timing of the start of the scan operation can be set arbitrarily by the operation device disposed near the patient and operated by the patient or by the input device operated by the operator. Accordingly, the rate of operation can be improved. Particularly because the timing of the scan operation can be determined by the instruction of the patient, breath holding imaging can be carried out extremely easily.
The rate of operation can be further improved because the time intervals between the sequences can be set to an arbitrary time interval by setting in advance collectively the imaging condition of each imaging sequence. When imaging by the use of a contrast medium is carried out, the contrasted images can be taken with the passage of appropriate time by appropriate sequences.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a timing chart of an imaging sequence by a conventional apparatus;
FIG. 2 shows the data measurement order in accordance with the sequence shown in FIG. 1;
FIG. 3 shows a timing chart showing the sequence when one sectional image is taken by the conventional apparatus;
FIG. 4 is a block diagram showing the structure of a magnetic resonance inspection apparatus in accordance with the present invention;
FIG. 5 shows a flowchart of an imaging control in accordance with the present invention; and
FIG. 6 shows a timing chart representing the imaging sequence in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings.
FIG. 4 is a block diagram showing the structure of a magnetic resonance inspection apparatus in accordance with the present invention. This magnetic resonance inspection apparatus forms a sectional image of a predetermined portion of a patient (subject) by utilizing the principle of magnetic resonance imaging based on nuclear magnetic resonance.
In FIG. 4, reference numeral 1 represents a cylindrical superconductive magnet. This magnet 1 has the function of generating a predetermined electrostatic magnetic field inside an internal space 1A near its axis. In a magnetic resonance inspection apparatus, a patient or subject is set to the center position of the internal space 1A of the superconductive magnet 1 while lying on a bed 3.
A cylindrical gradient magnetic field coil 4 is disposed coaxially on the inner surface portion of the cylindrical superconductive magnet 1. The gradient magnetic field coil 4 includes a gradient magnetic field coil for generating a gradient magnetic field in a Z-axis direction which is in conformity with the axial direction of the cylindrical shape and X- and Y-axes gradient magnetic field coils for generating gradient magnetic fields in the X- and Y-axes directions crossing orthogonally the Z-axis direction, respectively. However, these three coils are not depicted dividedly in the drawing for the purpose of illustration. A gradient magnetic field power supply 5 supplies currents to the X-, Y- and Z-axes gradient magnetic field coils of the gradient magnetic field coil 4 to independently generate the gradient magnetic fields. The body portion of the patient the sectional image of which is to be taken is stipulated by the combination of the gradient magnetic fields generated by the X-, Y- and Z-axes gradient magnetic field coils, and necessary magnetic resonance signals can be picked up from this portion.
Reference numeral 6 represents a radio frequency magnetic field generator. This generator 6 supplies a radio frequency current to a radio frequency irradiation coil 7 disposed near the patient 2 and irradiates a radio frequency magnetic field from the radio frequency irradiation coil 7 to the patient 2. When the radio frequency magnetic field is applied to the patient who is set inside the electrostatic magnetic field, nuclear magnetic resonance takes place in the body of the patient 2.
When magnetic resonance signals develop due to this nuclear magnetic resonance, the signals are detected by a radio frequency reception coil 8. The signals thus received by the radio frequency reception coil 8 are inputted to a reception circuit 9.
The operations of the gradient magnetic field power supply 5, the radio frequency magnetic field generator 6, and so forth, are controlled on the basis of the imaging sequence instruction that is outputted from a pulse sequencer 12 disposed inside a central processing/operation unit 11. The imaging portion of the patient 2 is stipulated in accordance with the imaging sequence and the echo of the magnetic resonance signal generated from that portion is obtained by the reception coil 8 and the reception circuit 9, is fetched into the pulse sequencer 12 through a data fetch portion 10 and is further inputted to a computer 13 which executes signal processing as well as image processing. The central processing/operation unit 11 is provided further with an input operation device 14 and a display device 15. The input operation device 14 is operated by an operator and can set the imaging sequence and input instructions such as the imaging start instruction. A CRT, for example, is used as the display device 15, and the computer 13 effects data processing of the acquired image signals and image processing to display a sectional image on the display device 15. In such data processing and image processing, measurement of the echo signals is made a plurality of times in the same phase encoding to improve a signal-to-noise (S/N) ratio and the data are integrated. Thereafter, image reconstruction is made by two-dimensional high speed Fourier transform.
Reference numeral 16 represents an operation switch which is disposed near at hand of the patient 2. This operation switch 16 is for applying a scan start instruction to the central processing/operation unit 11. When the operation switch 16 is pushed by the patient 2, a trigger signal outputted from a trigger generator 17 is applied to the pulse sequencer 12 of the central processing/operation unit 11 and the scan operation is started.
Next, the operations of the magnetic resonance inspection apparatus having the structure described above will be explained. FIG. 5 shows a control flowchart when a plurality of imaging sequences are executed by the use of the magnetic resonance inspection apparatus of the present invention.
To begin with, the operator operates the input operation device 14 of the central processing/operation unit 11 and sets the sequences for imaging the sectional images, the time interval of each sequence, the number of times of repetition of the imaging operations, and so forth.
Setting can be made in the following various ways.
(1) When the same sequence is set a plurality of times and the time interval between each sequence is not set to a definite time interval and therefore is considered to be set to "indefinite":
In this case, the computer 13 detects the input of an indication "indefinite" or not definite and recognizes the time interval of each sequence as infinity. Accordingly, the apparatus does not by itself start the scan operation automatically. The patient 2 operates the operation switch 16 at hand in accordance with this physical condition to generate the trigger signal from the trigger generator 17. The scan operation of each sequence is thus started. In this case, the trigger signal from the trigger generator 17 can be inputted to the computer 13. In this case, it is also possible to set the condition for imaging from the operator side and to start the scan operation of each sequence by the use of the signal from the input operation device 14 as the trigger for the start of the scan operation.
(2) When the same sequence is set a plurality of times and the time interval between the sequences is set to a predetermined time:
The computer 13 generates in this case the trigger signal for the start of the scan operation of each sequence. The time interval between the sequences when the apparatus executes automatically the scan operation is set by the operator through the input operation device 14, and this time interval can be set to an arbitrary time depending on various conditions.
(3) When different sequences are combined and the time interval between the sequences is set to "indefinite":
This is the same case as the item (1) described above with the exception that only the content of each sequence is different. Therefore, the trigger signal for the start of the scan operation is given either by the patient 2 or by the operator.
(4) When different sequences are combined and the time interval between the sequences is set to a predetermined time:
This is the same case as the item (2) described above with the exception that only the content of each sequence is different.
Turning back to FIG. 5, after the imaging condition is set, a scan start switch disposed in the input operation device 14 of the central processing/operation unit 11 is pushed at Step 21. Then, the pulse sequencer 12 executes the control sequence on the basis of the set content and the scan operation is started in the magnetic resonance inspection apparatus.
The pre-processing sequence is executed at Step 22 to optimize the timing of application of the gradient magnetic field, the RF irradiation system and the RF reception system.
The pre-processing sequence to optimize the timing of the application of the gradient magnetic field and the RF irradiation system is executed for each patient.
The pre-processing sequence to optimize the RF reception system is executed for each different sequence.
Next, whether the time interval of a plurality of sequences is a predetermined time or not a predetermined time (not definite) indefinite is checked at Step 23.
If the time interval is set to the predetermined time, the passage of this set predetermined time occurs (Step 24) and then the first set imaging sequence is executed (Step 25).
If the time interval is found set to "indefinite" at Step 23, whether or not the trigger for the start of the scan operation is inputted in checked (Step 26). The imaging sequence is executed only after the external trigger is inputted (Step 27).
After one imaging sequence is completed, image processing of the resulting data is carried out and the image is displayed on the display device (Step 28).
Thereafter, whether or not all the sequences are completed is checked (Step 29).
If the sequence or sequences yet to be executed remain, whether or not the sequence(s) is the same as the previous sequences is checked (Step 30). If it is the same, the flow returns to Step 23 because the pre-processing sequence is not necessary, and if it is not the same as the previous sequence, the flow returns to Step 22 because a new pre-processing must be executed.
In the imaging sequence of a plurality of slices based on continuous imaging by the same or different sequences in accordance with the present invention, collection of data for each slice imaging is completed before collection of data for next slice imaging is started. If the scan parameters are set to the same condition as the condition shown in FIG. 1 in this imaging, the scan time necessary for imaging the sectional image of one slice is 0.04×256×1, that is, 10.24 seconds, because TR is 40 ms. Therefore, if imaging is made dividedly for each slice and data collection is effected, this period of 10.24 seconds is sufficiently short for the patient to hold his breathing, so that breath holding imaging can be carried out.
When breath holding imaging is carried out, setting of the item (1) or (3) described already is made as the setting of the imaging sequence of the magnetic resonance inspection apparatus. In other words, the timing of the start of the scan operation for imaging is set either by the patient 2 or by the operator. It is the most appropriate and the most desirable method which lets the patient 2 himself select the timing of the start of the scan operation. In this case, the patient 2 operates by himself the operation switch 16 before the start of each slice imaging to provide the signal to the trigger generator 17. Receiving this signal, the trigger generator 17 generates the trigger signal and gives this signal to the pulse sequence. Consequenctly, the scan operation is started and slice imaging is carried out. This imaging method allows the patient 2 to sufficiently prepare himself in advance for breath holding and imaging can be started as soon as he is ready. Accordingly, breath holding imaging can be carried out extremely easily. The time interval T1 between the sequences in this case is determined by the patient 2. It is also possible to employ the structure wherein the trigger instruction for the start of the scan operation is given when the operator operates the scan start switch of the input operation device 14 of the central processing/operation unit 11.
When the change, with time, of the contrast inside the tissue after the administration of the contrast medium is inspected in the sequence shown in FIG. 6, the time interval between the sequences can be selected appropriately.
Furthermore, an audio output device may be provided to the magnetic resonance imaging apparatus described above so that the patient and the operator can communicate with each other. | An external trigger method in a magnetic resonance inspection apparatus includes the steps of inputting collectively imaging control data including an imaging portion of a subject, the kind of sequences, a time interval between the sequences and the number of times of repetition of the sequences, executing a pre-processing sequence corresponding to the imaging sequence set to be first executed, and checking whether the time interval until the start of the imaging sequence to be next executed is set to a predetermined value. The imaging sequence is started by an external trigger when the time interval is set to the indefinite value. The imaging sequence is started after the passage of the time of the predetermined value when the time interval is set to the predetermined value. | 6 |
This application is a division of U.S. Ser. No. 08/472,657, filed Jun. 7, 1995, now U.S. Pat. No. 5,664,420, which is a continuation-in-part of prior U.S. application Ser. No. 08/378,733 filed Jan. 26, 1995, now U.S. Pat. No. 5,525,034, which is a continuation-in-part of prior U.S. application Ser. No. 07/878,605 filed May 5, 1992, now U.S. Pat. No. 5,385,446.
BACKGROUND OF THE INVENTION
This invention relates generally to two-phase turbines, and more particularly to an improved multistage, single rotor turbine driven by an input mixture of gas and liquid, and capable of generating shaft power, while simultaneously separating the gas and liquid phase components in one or more expansions, and also increasing the pressure of the separated liquid phase component.
There is need for an improved two-phase turbine having the above multistage characteristics. There is need for improved processes in which such a turbine is employed.
SUMMARY OF THE INVENTION
It is a major object of the invention to provide an improved turbine structure and processes in which it is employed meeting the above needs. Basically, the improved multistage two-phase turbine has one or more stages to receive fluid, each stage having an inlet and an outlet, and comprises:
a) nozzles at the inlet to each stage to accelerate the fluid that consists of a mixture of gas and liquid, to form two-phase jets,
b) a rotating separator structure to receive and separate the two-phase jets into gas streams and liquid streams in each stage,
c) the turbine having a rotating output shaft, and there being means to convert the kinetic energy of the liquid streams into shaft power,
d) means to remove the separated liquid from at least one stage and transfer it to nozzles at the next stage,
e) means to remove the separated liquid from the last stage and transfer it to primary outlet structure,
f) means to remove the separated gas from each stage and transfer it to secondary outlet structure or optionally,
g) means to remove the separated gas from each stage and transfer it to the nozzles at the next stage.
It is another object to provide such a turbine, and including means in at least one stage to convert the kinetic energy of the gas stream to shaft power. Means may also be employed in at least one stage to recover the kinetic energy of the separated liquid stream as pressure.
Another object is to provide turbine axial flow blades associated with at least one rotating separator structure to convert the gas stream kinetic energy to shaft power.
A further object includes the provision of means separating the stages wherein the nozzles are an integral part of the means.
Yet another object includes the provision of means to separate two components of the separated liquid stream from at least one stage, and to separately remove each liquid component from the stage. In this regard, a diffuser may be positioned to remove the heavier of two liquid components from at least one stage, or a liquid stream receiving nozzle may be employed to remove the heavier of two liquid components from at least one stage. Additionally, structure may be provided to coalesce a dispersed liquid component into a continuous phase in the rotating separator structure of at least one stage.
The improved turbine may be used in a process requiring one or more successive reductions in pressure of a mixture of steam and brine flowing from a geothermal well. The referenced turbine produces power, while separating the steam, so that it can be utilized at lower pressures in a conventional steam turbine. The separated brine pressure can be increased such that it can be re-injected into the ground with no pump.
The turbine can also be used in a process involving combined liquid and gas flows require several successive reductions in pressure with separation at each succeeding pressure level. One example is the production of oil and gas from a high pressure well. The two-phase flow is flashed at several pressures, each lower than the preceding pressure. At each flash the gas is separated from the liquid, so that it can be recompressed. The separated liquid is subsequently flashed to a lower pressure and the evolved gas again separated.
The turbine can also be utilized in a process requiring multiple two-phase flashes in the conversion of waste heat from a prime mover to useful power. In this regard, if a liquid is heated and flashed several times to produce vapor at several pressures to operate a multiple pressure vapor turbine, a more efficient conversion of the waste heat to power is possible.
These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which:
DRAWING DESCRIPTION
FIG. 1 is a system block diagram showing use of a two-phase turbine in generation of power from geothermal fluids;
FIG. 2 is a system block diagram showing a high production oil/gas process with four stages of pressure reduction;
FIG. 3 is a graph of heat transfer vs. temperature, waste heat bottoming cycles;
FIG. 4 is a system block diagram showing coupling of a multistage two-phase turbine with a steam turbine and generator;
FIG. 5 is an axial cross section taken through a multistage two-phase turbine;
FIG. 6 is a cross section taken through diffuser and nozzle structure of a multistage two-phase turbine;
FIG. 7 is an axial cross section taken through a multistage two-phase turbine characterized by processing of two separated liquid stream components;
FIG. 7a is a fragmentary section showing details of a rotor with a diffuser for water;
FIG. 7b is a fragmentary section showing details of a rotor with a liquid nozzle for water;
FIG. 8 is a partial axial cross section taken through the installation of a multistage, or single stage, two-phase turbine in the bore of an oil and gas well, such that separated water is injected into another part of the field;
FIG. 9 is a partial axial cross section taken through the installation of a multistage or single stage two-phase turbine in the bore of an oil and gas well, such that separated water is transported to the surface;
FIG. 10 is a system block diagram showing a multistage, or single stage, two-phase turbine installed on the sea floor, producing separated gas, oil and water streams and power from an oil and gas well; and
FIG. 11 is a system block diagram showing a multistage, or single stage, two-phase turbine installed on the sea floor, producing separated gas, oil, and water streams from an oil and gas well, and driving a gas compressor to produce high-pressure gas.
DETAILED DESCRIPTION
A single rotor turbine has previously been developed to generate power from a mixture of gas and liquid, while simultaneously separating the gas from the liquid and increasing the pressure of the separated liquid phase. This turbine produces power from a single reduction in pressure of the mixture of gas and liquid.
An example is the reduction of pressure of a mixture of steam and brine flowing from a geothermal well, as seen in FIG. 1. The referenced turbine 10 drives a generator 11 to produce power, while separating the steam, so that it can be utilized at a lower pressure in a conventional steam turbine. See steam flow at 12 to a flash tank 13, and steam flow at 14, to the steam turbine. The pressure of separated brine at 15 can be increased such that it can be re-injected into the ground at 16 with no pump. The geothermal wall is seen at 17.
Some processes involving combined liquid and gas flows require several successive reductions in pressure with separation at each succeeding pressure level. One example, as seen in FIG. 2, is the production of oil and gas from a high pressure well. The two-phase flow at 20 is flashed at several pressures, noted at 21-24, each lower than the preceding pressure. At each flash, the gas is separated from the liquid, so that it can be recompressed. See gas discharges at 21a to 24a connected to recompression stages 25 to 27 discharging at 28. The separated liquid is subsequently flashed to a lower pressure, and the evolved gas again separated. See liquid lines 30-33.
Another process requiring multiple two-phase flashes is the conversion of waste heat from a prime mover to useful power. FIG. 3 shows the transfer of heat from an exhaust stream into a vaporizing fluid (curve A). The constant temperature region of the vaporizing fluid means the energy conversion efficiency at each point (for example T v ) is much lower than the efficiency which could be attained if energy conversion occurred at the exhaust temperature T. The Carnot efficiency, η c , for converting the element of heat, dQ, to power is η c =1-T 3 /T v for the vapor bottoming cycle of FIG. 3. The Carnot efficiency for a cycle operating at the hot gas temperature, T, is η c =1-T 3 /T. If liquid is heated (curve B) and flashed several times to produce vapor at several pressures to operate a multiple pressure vapor turbine, a more efficient conversion of the waste heat to power is possible.
FIG. 4 shows a power cycle, which operates on this principle. Liquid is heated in flowing from 113 to 104 in a heat exchanger 119 by heat from an exhaust steam at 102 to 103 in duct 99. The liquid is flashed to a lower pressure at 105 in a multistage two-phase turbine 114 (to be described later). The vapor from the turbine flows through a superheater 120 and is heated to a higher temperature at 106. The vapor is then ducted to the inlet of a vapor turbine 115.
The separated liquid at pressure within the multistage two-phase turbine is flashed to a lower pressure at 107. The vapor is separated at pressure 107 and is ducted to an induction port 115a of the vapor turbine 115. The separated liquid is flashed within the multistage two-phase turbine to a yet lower pressure at 108. The vapor is separated at pressure 108 and is ducted to another induction port 115b of the vapor turbine.
The mixed vapor flows within the vapor turbine 115 are expanded to an outlet pressure at 109. The vapor flows are condensed in a condenser 116 and pumped to a mixer 117.
The separated liquid at 108 is internally pressurized and delivered at 118, and flows to the mixer 117 where it is mixed with the condensed vapors. The resulting liquid flow is pumped back to the liquid heat exchanger 119.
For some applications, the liquid heat exchanger 119 may be used to produce a mixture of heated liquid and vapor at 104, which is ducted to the multistage two-phase turbine 114 and flashed to lower pressure at 105.
The multistage two-phase turbine utilized in the power cycle shown in FIG. 4 is seen in FIG. 5. A gas and liquid mixture, or flashing liquid, is introduced through a port 234, to nozzles 213. The pressure is reduced in the nozzles, accelerating the gas and liquid mixture, to form high-velocity, two-phase jets at 201. The jets impinge onto a rotating separator member 214 of a multistage rotor 215 separating the liquid into a liquid layer 203.
If the tangential jet velocity is greater than the circumferential velocity of the rotating separator member 214, the liquid velocity is reduced by frictional coupling to the member, and power is transferred to the rotor. If the tangential velocity is less, the liquid velocity is increased by frictional coupling to the member, and power is transferred from the rotor. This mechanism provides a method for producing power from high velocity jets in one stage of the rotor, to be used to increase the liquid velocity in another stage of the rotor, where the jet velocity may be lower.
The separated gas flows through gas blading 221 to the first exit port 202. The axial gas blading shown converts the gas kinetic energy to power of the rotor.
The separated liquid from the first rotating separator flows into a scoop 216 and is transferred through a pipe 204 and passage 217 in the diaphragm between the first and second stage to nozzles 205. The pressure is lowered in the nozzles to the pressure in the next stage. High velocity two-phase jets 218 are formed, which impinge on the second stage separator rotor 219. The separated liquid forms a layer 220. The separated gas flows through gas blades 206, transferring power to the rotor, and subsequently out the second stage port 207.
The separated liquid from the second rotating separator flows into a scoop 222 and is fed by a pipe 208 into a passage in the diaphragm between the second and third stage. The passage feeds the liquid into nozzles 224, where it is flashed to the pressure in the third stage forming high velocity jets 209. The two-phase jets impinge on the third stage separator rotor 225. The liquid separates, forming a layer 226. The separated gas flows through gas blades 210, transferring power to the rotor. The gas then leaves through the third stage port 211.
The separated liquid flows into a scoop 227, which may be contoured to slow the liquid to a lower velocity than the entering velocity, effecting a pressure increase. The liquid is ducted through a pipe 212 to the liquid exit port 218.
The rotating structure 215, shaft 233, and separator rotors 214, 219, and 225 are fixed together, and all rotate as one body at the same speed. Seals 229 and 230 are provided at each end to seal the gas from leaking. Seals 231 and 232 are provided in each diaphragm to seal the gas from leaking from a stage at high pressure to one at lower pressure.
A detail of a scoop or diffuser arrangement is shown in FIG. 6. The separated liquid layer 301 enters the scoop 302. The scoop structure 303 may feature a diverging area, in which case the liquid velocity is slowed to a lower value than the entering value at 302.
The liquid enters a passage 304 and flows to a nozzle 305, which is interconnected to the passage. The pressure is reduced in the nozzle, causing the liquid to flash and form a two-phase jet at 306. The two-phase jet impinges on the rotating separator surface 307 of the next stage, forming a liquid layer 308. The separated gas flows through gas blades 309.
The complex oil and gas process shown in FIG. 2 may be replaced by a single multistage two-phase turbine shown in FIG. 7, simplifying and greatly reducing the size of needed apparatus.
A high-pressure mixture of oil, gas, and water is introduced to the unit through inlet ports (1)'. The mixture flows through passages (2)' to two-phase nozzles (3)'.
The pressure is reduced in the nozzles, causing the mixture to be accelerated and additional light components in the oil to vaporize. Two-phase jets (4)' are formed. The jets impinge on the rotating surface of the first stage rotating separator surface (5)'. Energy transfer occurs, as described in FIG. 5.
The liquid forms a layer of oil and water. The oil, which is lighter, forms a layer on the surface and flows through passages (8)' to the opposite side of the supporting disc (10)'. The oil is collected by a scoop (9)' which is submerged in the oil layer.
The water, which has a higher density than the oil, is centrifuged to the outer part (7)' of the rotating separator (11)'. A coalescing structure (12)' may be provided to assist the separation of the water from the oil. The water, at high pressure, due to the centrifugal force, expands through liquid nozzles (13)', flowing through passages (14)' to an annulus (15)'. The water flows from the turbine through an outlet port (16)'. The reaction forces from the water jets leaving the nozzles (13)' transfer power to the rotor.
Another method of removing the separated water is shown in FIG. 7a. A diffuser 401 is wholly submerged in the water layer 402. The water flows out the tube 403 at a rate controlled by the inlet size and a throttling valve. This method may be used for any stage.
Referring back to FIG. 7, the separated gas flows through gas blades (17)', which may be radial inflow as shown, or axial flow, and leaves the turbine through an exit port (18)'. Kinetic energy and pressure in the gas is converted to power in the rotor by the gas blades.
The separated oil from the first stage flows from the diffuser (9)' into passages (19)', which carry the flow to two-phase nozzles (20)'. The flow is flashed to the pressure of the second stage in the nozzles, causing additional light components of the oil to vaporize, forming two-phase jets (21)'. The jets impinge on the surface (22)' of the second rotating separator structure (23)' forming a layer of oil. The oil flows to the opposite side of the supporting disc (25)' through passages (24)'. The oil enters the inlet of a diffuser (26)' immersed in the oil layer. The oil flows into passages (27)', which feed nozzles (28)'.
Water, which may still be entrained in the oil, is centrifuged to the outer part (30)' of the second stage rotating separator. The water at high pressure is expanded through liquid nozzles (31)' and flows through passages (32)' to a volute (33)'. The separated water subsequently flows through the turbine through the second stage water exit port (34)'. The separated gas flows from the turbine through the second stage gas exit port (35)'.
The oil from the second stage is expanded to the third stage pressure in the third stage nozzles (28)'. Remaining light components in the oil flash, forming two-phase jets (29)'.
The jets impinge on the surface (36)' of the third rotating separator structure (37)' forming a layer of oil. The oil flows to the opposite side of the supporting disc (38)' through passages (39)'. The oil enters the inlet of a diffuser (40)' immersed in the oil layer. The oil is pressurized by slowing the inlet velocity in the diffuser structure (41)'. The pressurized oil leaves the turbine through the oil exit ports (42)'.
Water, which may still be entrained in the oil, is centrifuged to the outer part (43)' of the third stage rotating separator. The water at high pressure is expanded through liquid nozzles (44)' and flows through passages (45)' to a volute (46)'. The separated water subsequently flows through the turbine through the second stage water exit port (47)'. The separated gas flows from the turbine through the third stage gas exit port (54)'.
The multistage two-phase turbine for oil, gas and water has seals (48)' and (49)' on each end of the shaft (55)' to prevent gas from leaking from the casing. The unit has seals (50)' and (51)' in the diaphragms (52)' and (53)' between stages to reduce gas leakage from a high pressure stage to a lower pressure stage.
Power is transferred to the rotor by the liquid for stages where the two-phase nozzle jet (4)', (21)' and (29)' tangential velocity is greater than the circumferential velocity of the separator surface (6)', (22)' and (36)', and from the separated gas energy in at least the first stage. Power is transferred from the rotor to the liquid, if the tangential velocity of any stage is less than the circumferential velocity of the separator surface.
An induction generator can be connected to the shaft (55)'. See generator 80. If there is a net power transfer to the rotor from the states, power will be generated at 81. If not, the generator will require power input at 82, and will be operated as a motor to maintain the desired circumferential velocity. A power input control is seen at 83.
In FIG. 8, a rotary separator turbine 503 is installed in the bore of a gas or oil well 517. Two-phase flow consisting of gas and oil and/or water at 501 flows into the rotary separator turbine through entrance ports 502. The flow is expanded and separated in one or more stages, as shown in FIGS. 5 and 7.
Separated water and other liquids 509 and 510 for a two-stage unit are discharged through pipes 511 and 512 at a pressure higher than the pressure of the entering flow 501. The separated water and liquids may be piped to another part of the strata 518 and discharged at a higher pressure 519 than the pressure of the entering flow 501. The two strata may be separated by a seal 520. The separated oil, if any, at 514 and 515 may be piped to the surface at 513 and 515. Separated gas at 505 and 506 may be piped to the surface at 507. Power generated may be transmitted to the surface through cables 516. The pressure of the two-phase flow 501 can be isolated from the lower pressure region of the well 521 by a seal 504.
In another variation shown in FIG. 9, the separated water at 505' and 509' leave the rotary separator turbine and are piped at 510' and 511' to the surface or another location for disposal.
In FIG. 10, the multistage two-phase turbine 604 is installed on the sea floor 601 within a protective enclosure 620 on a support 619. A mixture of gas and oil and/or water and/or sand 603 flows from a well head 602 into the rotary separator turbine 604. The flow is expanded in one or more stages, as seen in FIG. 7. Separated gas 605, 607, and 609 (for three stages) leave the multistage two-phase turbine and are piped at 606, 608, and 610 to a delivery point or compressor. Separated oil at 621 is piped at 622 to a delivery point.
Separated water and/or solids at 611, 613 and 615 are piped at 612, 614 and 616 for disposal. The multistage two-phase turbine unit may drive a generator 617. The power is transmitted by cables 618 to the surface or to other components within the protective enclosure 620 or elsewhere requiring power.
In FIG. 11, which is similar to FIG. 10, the multistage two-phase turbine drives a gas compressor 623 instead of a generator. The gas flow is expanded internally through each pressure drop. The gas leaving the last stage at 609 flows through external or internal passages 610 to gas compressor 623. The compressor increases the pressure, and the high pressure outlet gas 624 flows through a pipe 625 to a delivery point.
The general method of operation contemplated by the FIG. 8 form of the invention, for processing a multi-component fluid mixture in a sub-surface well, and employing a rotary separator, includes the steps:
a) positioning the separator in the well at a depth to receive the mixture,
b) operating the separator to separate and pressurize at least one component of the mixture,
c) and flowing the pressurized and separated component lengthwise of the well, away from the separator.
The one component typically consists of one of the following:
i) gas
ii) liquid
iii) water
iv) hydrocarbon gas
v) hydrocarbon liquid.
The positioning step may include lowering the separator 503 in the well to the operating depth, as shown; and a pipe string or strings may be lowered in operative relation to the separator, and flowing the separated component upwardly in the pipe string. Such strings may include one or more of the strings shown at 515, 505, 506, 507, and 513. Upper extents of such strings may be considered as constituting one form of lowering means.
The method also contemplates the flowing step to include flowing the component under pressure into the formation in which the well is located.
As referred to above, a rotary separator, usable in the above method, includes nozzle means to accelerate the fluid, to form a two-phase jet, and the operating step includes recovering at least one phase produced by the two-phase jet.
Also, the operating step may include centrifugally pressurizing another phase produced by the jet. The rotary structure in 503 may be considered as advantageously driven by the pressure of the inlet fluid at 501.
The disclosure of the above referenced U.S. patent applications are incorporated herein by reference. | A multistage two-phase turbine having multiple stages to receive fluid, each stage having an inlet and outlet comprising nozzles at the inlet to each stage to accelerate the fluid that consists of a mixture of gas and liquid, to form two-phase jets; a rotating separator structure to receive and separate the two-phase jets into gas streams and liquid stream in each stage; the turbine having a rotating output shaft, and there being structure to convert the kinetic energy of the liquid streams into shaft power; structure to remove the separated liquid from at least one stage and transfer it to nozzles at the next stage; structure to remove the separated liquid from the last stage and transfer it to primary outlet structure; and structure to remove the separated gas from at least one stage and transfer it to a secondary outlet structure. | 1 |
RELATED APPLICATIONS
[0001] This application is a Divisional of, claims priority to, and herein incorporates in its entirety U.S. patent application Ser. No. 11/969,905 filed Jan. 6, 2008.
[0002] This application also incorporates by reference in their entirety: U.S. patent application Ser. No. 11/753,979 filed on May 25, 2007, entitled “Apparatus and Method for Providing Location Information on Individuals and Objects Using Tracking Devices”; U.S. patent application Ser. No. 11/933,024 filed on Oct. 31, 2007, entitled “Apparatus and Method for Manufacturing an Electronic Package”, U.S. patent application Ser. No. 11/784,400 filed on Apr. 5, 2007, entitled “Communication System and Method Including Dual Mode Capability”; U.S. patent application Ser. No. 11/784,318 filed on Apr. 5, 2007, entitled “Communication System and Method Including Communication Billing Options”; and U.S. patent application Ser. No. 11/935, 901 filed on Nov. 6, 2007, entitled “System and Method for Creating and Managing a Personalized Web Interface for Monitoring Location Information on Individuals and Objects Using Tracking Devices.”
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The invention relates generally to the field of location and tracking communication systems. More particularly, the present invention relates in one embodiment to an accelerometer incorporated as part of portable electronic tracking device for individuals and objects to improve monitoring by a wireless location and tracking system and/or wireless communication system (WCS).
[0005] 2. Description of Related Technology
[0006] Accelerometers are conventionally integrated into electronics systems that are part of a vehicle, vessel, and airplane to detect, measure, and monitor deflections, vibrations, and acceleration. Accelerometers, for example, may include one or more Micro Electro-Mechanical System (MEMS) devices, In particular, MEMS devices include one or more suspended cantilever beams (e.g., single-axis, dual-axis, and three-axis models), as well as deflection sensing circuitry. Accelerometers are utilized by a multitude of electronics manufacturers.
[0007] For instance, electronics gaming manufacturers exploit an accelerometer's deflection sensing capability, for instance, to measure device tilt and control game functionality. In another instance, consumer electronics manufacturers, e.g., Apple, Ericsson, and Nike, incorporate accelerometers in personal electronic devices, e.g., Apple iPhone, to provide a changeable screen display orientation that toggles between portrait and landscape layout window settings; to manage human inputs through a human interface, e.g., Apple iPod® touch screen interface; and to measure game movement and tilt, e.g., Wii gaming remotes. Still others including automobile electronics circuitry manufacturers utilize MEMS accelerometers to initiate airbag deployment in accordance with a detected collision severity level by measuring negative vehicle acceleration.
[0008] Other electronics manufacturer products, e.g., Nokia 5500 sport, count step motions using a 3D accelerometer, and translate user information via user's taps or shaking motion to select song titles and to enable mp3 player track switching. In another instance, portable or laptop computers include hard-disk drives integrated with an accelerometer to detect displacement or falling incidents. For instance, when a hard-disk accelerometer detects a low-g condition, e.g., indicating free-fall and expected shock, a hard-disk write feature may be temporarily disabled to avoid accidental data overwriting and prevent stored data corruption. After free-fall and expected shock, the hard-disk write feature is enabled to allow data to be written to one or more hard-disk tracks. Still others including medical product manufacturers utilize accelerometers to measure depth of Cardio Pulmonary Resuscitation (CPR) chest compressions. Sportswear manufacturers, e.g., Nike sports watches and footwear, incorporate accelerometers to feedback speed and distance to a runner via a connected iPod® Nano.
[0009] Still others including manufacturers of conventional inertial navigation systems deploy one or more accelerometers as part of, for instance, on-board electronics of a vehicle, vessel, train and/or airplane. In addition to accelerometer measurements, conventional inertial navigation systems integrate one or more gyroscopes with the on-board electronics to assist tracking including performing various measurements, e.g., tilt, angle, and roll. More specifically, gyroscopes measure angular velocity, for instance, of a vehicle, vessel, train, and/or airplane in an inertial reference frame. The inertial reference frame, provided, for instance, by a human operator, a GPS receiver, or position and velocity measurements from one or more motion sensors.
[0010] More specifically, integration of measured inertial accelerations commences with, for instance, original velocity, for instance, of a vehicle, vessel, train, and/or airplane to yield updated inertial system velocities. Another integration of updated inertial system velocities yields an updated inertial system orientate, e.g., tilt, angle, and roll, within a system limited positioning accuracy. In one instance to improve positioning accuracy, conventional inertial navigation systems utilize GPS system outputs. In another instance to improve positioning accuracy, conventional inertial navigation systems intermittently reset to zero inertial tracking velocity, for instance, by stopping the inertial navigation system. In yet other examples, control theory and Kalman filtering provide a framework to combine motion sensor information in attempts to improve positional accuracy of the updated inertial system orientation.
[0011] Potential drawbacks of many conventional inertial navigations systems include electrical and mechanical hardware occupying a large real estate footprint and requiring complex electronic measurement and control circuitry with limited applicability to changed environmental conditions. Furthermore, many conventional inertial navigation system calculations are prone to accumulated acceleration and velocity measurement errors. For instance, many conventional inertial navigations accelerations and velocity measurement errors are on the order of 0.6 nautical miles per hour in position and tenths of a degree per hour in orientation.
[0012] In contrast to conventional inertial navigation systems, a conventional Global Positioning Satellite (GPS) system uses Global Positioning Signals (GPS) to monitor and track location coordinates communicated between location coordinates monitoring satellites and an individual or an object having a GPS transceiver. In this system, GPS monitoring of location coordinates is practical when a GPS transceiver receives at least a minimal GPS signal level. However, a minimal GPS signal level may not be detectable when an individual or object is not located in a skyward position. For instance, when an individual or object carrying a GPS transceiver enters a covered structure, e.g., a garage, a parking structure, or a large building, GPS satellite communication signals may be obstructed or partially blocked, hindering tracking and monitoring capability. Not only is a GPS transceiver receiving a weak GPS signal, but also the GPS transceiver is depleting battery power in failed attempts to acquire communications signals from one or more location coordinates monitoring satellites, e.g., GPS satellites, or out-of-range location coordinates reference towers. Furthermore, weak GPS communication signals may introduce errors in location coordinates information.
[0013] In summary, electronic tracking device and methodology is needed that provides additional advantages over conventional systems such as improved power management, e.g., efficient use of battery power, and provide other improvements including supplementing conventional electronic tracking device monitoring, e.g., increased measurement accuracy of location coordinates of objects and individuals traveling into and/or through a structure, e.g., a partially covered building, a parking structure, or a substantially enclosed structure, such as a basement or a storage area in a high-rise office building.
SUMMARY OF THE INVENTION
[0014] In a first aspect of the present invention, a portable electronic apparatus for a tracking device is disclosed. The electronic apparatus includes a transceiver, an accelerometer, and an antenna. The antenna is disposed on the tracking device. The antenna is configured to communicate signal strength to a signal processor associated with the tracking device. In one variant, responsive to the signal strength, a battery management module (e.g., battery monitor) controls electronic components associated with the tracking device. In one variant, an accelerometer performs an acceleration measurement. In one variant, prior or nearby location coordinates associated with the tracking device are utilized or assist to compute current location coordinates information of the tracking device.
[0015] In a second aspect of the present invention, a method is disclosed to communicate location coordinates of a first, tracking device. In this method, a transceiver communicates measured signal strength. In response to measured signal strength level, a power management circuitry (e.g., battery monitor) controls power levels associated with the first tracking device to reduce or increase power consumption of a transceiver and its associated circuitry. In one variant, a user defines a first signal level, e.g., a threshold level, to commence accelerometer measurements. In one variant, if a first signal level is detected, an accelerometer measures displacement from prior location coordinates of the first tracking device. In another variant, if a first signal level is detected, an accelerometer measures relative displacement from prior location coordinates of a second tracking device. In yet another variant, if a first signal level is detected, the relative displacement is utilized to compute current location coordinates information of the first tracking device. In another variant, the accelerometer may be activated to measure impacts of an object or an individual to determine if the object or individual may be medical attention (e.g., be injured).
[0016] These and other embodiments, aspects, advantages, and features of the present invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art by reference to the following description of the invention and referenced drawings or by practice of the invention. The aspects, advantages and features of the invention are realized and attained by means of the instrumentalities, procedures, and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 illustrates a schematic of an electronic tracking device in accordance with an embodiment of the present invention.
[0018] FIG. 2 illustrates a location tracking system associated with the electronic tracking device and the wireless network in accordance with an embodiment of the present invention.
[0019] FIG. 3 illustrates a flow diagram to manage and control circuitry associated with the electronic tracking device of FIGS. 1 and 2 in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0020] Reference is now made to the drawings wherein like numerals refer to like parts throughout.
[0021] As used herein, the terms “location coordinates” refer without limitation to any set or partial set of integer, real and/or complex location data or information such as longitudinal, latitudinal, and elevational positional coordinates.
[0022] As used herein, the terms “tracking device” and “electronic tracking device” refer to without, limitation, to any hybrid electronic circuit, integrated circuit (IC), chip, chip set, system-on-a-chip, microwave integrated circuit (MIC), Monolithic Microwave Integrated Circuit (MMIC), low noise amplifier, power amplifier, transceiver, receiver, transmitter and Application Specific Integrated Circuit (ASIC) that may be constructed and/or fabricated. The chip or IC may be constructed (“fabricated”) on a small rectangle (a “die”) cut from, for example, a Silicon (or special applications, Sapphire), Gallium Arsenide, or Indium Phosphide wafer. The IC may be classified, for example, into analogue, digital, or hybrid (both analogue and digital on the same chip and or analog-to-digital converter). Digital integrated circuits may contain anything from one to millions of logic gates, invertors, and, or, nand, and nor gates, flipflops, multiplexors, etc. on a few square millimeters. The small size of these circuits allows high speed, low power dissipation, and reduced manufacturing cost compared with board-level integration.
[0023] As used herein, the terms “data transfer”, “tracking and location system”, “location and tracking system”, “location tracking system”, and “positioning system,” refer to without limitation to any system, that transfers and/or determines location coordinates using one or more devices, such as Global Positioning System (GPS).
[0024] As used herein, the terms “Global Positioning System” refer to without limitation to any services, methods or devices that utilize GPS technology to determine position of a GPS receiver based on measuring a signal transfer time of signals communicated between satellites having known positions and the GPS receiver. A signal transfer time is proportional, to a distance of a respective satellite from the GPS receiver. The distance between a satellite and a GPS receiver may be converted, utilizing signal propagation velocity, into a respective signal transfer time. The positional information of the GPS receiver is calculated based on distance calculations from at least four satellites to determine positional information of the GPS receiver.
[0025] As used herein, the terms “wireless network” refers to, without limitation, any digital, analog, microwave, and millimeter wave communication networks that transfer signals from one location to another location, such as, but not limited to IEEE 802.11g, Bluetooth, WiMax, IS-95, GSM, IS-95, CGM, CDMA, wCDMA, PDC, UMTS, TDMA, and FDMA, or combinations thereof.
Major Features
[0026] In one aspect, the present invention discloses an apparatus and method, to provide an improved capability electronic tracking device. In one embodiment, the device provides electronic circuitry including an accelerometer to measure location coordinates without requiring GPS signaling. In this embodiment, location coordinates of an electronic tracking device are measured when the electronic tracking device is located in a partially enclosed structure, e.g., a building or parking lot, up to a fully enclosed structure. In one embodiment, the electronic tracking device conserves battery power when the device is partially or fully blocked access to location coordinates from one or more GPS satellites, e.g., a primary location tracking system. In yet another embodiment, accelerometer measures force applied to the electronic tracking device and provides an alert, message to a guardian or other responsible person. In one embodiment, the alert message includes location coordinates of the electronic tracking device and other information, e.g., magnitude or nature of force, as well as possibility of injury of an object or individual having the electronic tracking device. As described throughout the following specification, the present invention generally provides a portable electronic device configuration for locating and tracking an individual or an object.
Exemplary Apparatus
[0027] Referring now to FIGS. 1-2 exemplary embodiments of the electronic tracking device of the invention are described in detail. Please note that the following discussions of electronics and components for an electronic tracking device to monitor and locate individuals are non-limiting; thus, the present invention may be useful in other electronic signal transferring and communication applications, such as electronic modules included in items such as: watches, calculators, clocks, computer keyboards, computer mice, and/or mobile phones to locate and track trajectory of movement and current location of these items within boundaries of or proximity to a room, building, city, state, and country.
[0028] Furthermore, it will be appreciated that while described primarily in the context of tracking individuals or objects, at least portions of the apparatus and methods described herein may be used in other applications, such as, utilized, without limitation, for control systems that monitor components such as transducers, sensors, and electrical, and/or optical components that are part of an assembly line process. Moreover, it will be recognized that the present invention may find utility beyond purely tracking and monitoring concerns. Myriad of other functions will be recognized by those of ordinary skill in the art given the present disclosure.
Electronic Tracking Device
[0029] Referring to FIG. 1 , tracking device 100 contains various electronic components 101 such as transceiver 102 , signal processing circuitry 104 (e.g., a microprocessor or other signal logic circuitry), and accelerometer 130 . In one non-limiting example, the electronic components 101 are disposed, deposited, or mounted, on a substrate 107 (e.g., Printed Circuit Board (PCD)). The PCB 107 , for example, may be manufactured from: polyacrylic (PA), polycarbonate (PC), composite material, and arylonitrile-butadiene-styrene (ABS) substrates, blends or combinations thereof, or the like (as described in more detail, in incorporated by reference U.S. patent application Ser. No. 11/933,024 filed on Oct. 31, 2007). The signal processing circuitry 104 , in one example, associated with the tracking device 100 configured to store a first identification code, produce a second identification code, determine location coordinates, and generate a positioning signal that contains location data (as described in more detail in incorporated by reference U.S. patent application Ser. No. 11/753,979 filed on May 25, 2007). For instance, the location data includes longitudinal, latitudinal, and elevational position of a tracking device, current address or recent address of the tracking device, a nearby landmark to the tracking device, and the like. In one example, electronic tracking device 100 is portable and mobile and fits easily within a compact volume, such as standard pocket of an individual's shirt having approximate dimensions of 1.5 inch by 2.5 inch by 1.0 inch. In yet another example, electronic tracking device 100 may be one integrated circuit having dimensionality in the mm range in all directions (or even smaller).
[0030] In one embodiment, location tracking circuitry 114 , calculates location data received and sends the data to signal processing circuitry 104 . Memory 112 stores operating software and data, for instance, communicated to and from signal processing circuit 104 and/or location tracking circuitry 114 , e.g., GPS logic circuitry. In one embodiment, a signal detecting circuitry 115 detects and measures signal power level. In another embodiment, the signal processing circuitry 104 processes and measures signal power level. Battery level detection circuitry (e.g., battery level monitor 116 ) detects a battery level of battery 118 , which contains one or more individual units or a plurality of units grouped as a single unit.
[0031] In one non-limiting example, antennas 122 a , 122 b electrically couple to transceiver 102 . In one variant, transceiver 102 includes one integrated circuit or, in another embodiment, may be multiple individual circuits or integrated circuits. Transceiver 102 communicates a signal including location data between tracking device 100 and the monitoring station 110 , for example, by any of the following including: wireless network, wireless data transfer station, wired telephone, and Internet channel. A demodulator circuit 126 extracts baseband signals, for instance at 100 KHz, including tracking device configuration and software updates, as well as converts a low-frequency AC signal to a DC voltage level. The DC voltage level, in one example, is supplied to battery charging circuitry 128 to recharge a battery level of the battery 118 . In one embodiment, a user of monitoring station 110 , e.g., a mobile personal digital assistant, mobile phone, or the like, by listening (or downloading) one or more advertisements to reduce and/or shift, usage charges to another user, account, or database (as described in more detail in previous incorporated by reference U.S. patent application Ser. Nos. 11/784,400 and 11/784,318 each filed on Apr. 5, 2007).
[0032] In another embodiment, an accelerometer 130 , for example, a dual-axis accelerometer 130 , e.g. ADXL320 integrated circuit manufactured by Analog Devices having two substantially orthogonal beams, may be utilized. The data sheet ADXH320L from Analog Devices is incorporated by reference. In one embodiment, the accelerometer 130 activates upon one or more designated antenna(s), e.g., antennas 122 a , 122 b , detecting a first signal level, e.g., a low signal level or threshold value, as specified by, for instance, a user or system administrator. In one variant of this embodiment, electrical circuitry associated with GPS signal acquisition, e.g., all or a portion of amplifier block 120 , may be, for instance, placed on standby or in a sleep mode. In another embodiment, the accelerometer 130 remains in a standby mode until, for instance, a system administrator, a specified time period, or a user activates the accelerometer 130 . In one embodiment, the amplifier block 120 includes multiple electronic functions and blocks including a low noise amplifier, a power amplifier, a RF power switch, or the like, placed in a sleep or standby mode, for instance, to conserve a battery level of the battery 118 .
[0033] In another variant of this embodiment, circuitry, such as amplifier block 120 or location tracking circuitry 114 , may be placed in a sleep or standby mode to conserve a battery level of the battery 118 . In one variant, the tracking device 100 periodically checks availability of GPS signal, e.g., performs a GPS signal acquisition to determine if a receive communication signal is above a first signal level. Referring to embodiment depicted in FIG. 2 , electronic tracking device 100 exits an opening 150 in partially enclosed structure 210 ; thus, electronic tracking device 100 may resume GPS signal acquisition using GPS satellite 143 (e.g., in response to a periodic check by the tracking device 100 of a receive communication signal level above a first signal level).
[0034] In one embodiment, system administrator selects a signal noise bandwidth, e.g., within a range of 3 to 500 Hz, of the accelerator 130 to measure dynamic acceleration (e.g., due to vibration forces applied, to electronic tracking device 100 ). In another embodiment, system administrator selects a signal noise bandwidth, e.g., within a range of 3 to 500 Hz, to measure static acceleration (due to gravitational forces applied to electronic tracking device 100 ). In particular, external forces on electronic tracking device 100 cause, for example, internal structural movements, e.g., deflection of dual-axis beams, of the accelerometer 130 . The deflection of dual-axis beams generates differential voltage(s).
[0035] Differential voltage(s) are proportional to acceleration measurements, e.g., discrete acceleration measurements, of electronic tracking device 100 , for instance in x, y, and z directions. Differential voltage(s), in one instance, are relative to, for instance, last known GPS location coordinates of electronic tracking device 100 . By performing electronic device proximity measurements, e.g., measuring acceleration vectors of electronic tracking device 100 at time intervals, e.g., T 1 , T 2 , T 3 . . . TN, monitoring station 110 computes electronic tracking device velocity at time intervals, e.g., T 1 , T 2 , T 3 . . . TN. In one embodiment, time intervals, e.g., T 1 , T 2 , and T 3 . . . TN are measured in accordance with instructions by a system administrator or user. In one embodiment, time intervals are selected within a range of one micro-second to several minutes.
[0036] In one embodiment, the monitoring station 110 performs an integration of the acceleration measurements as a function of time to compute electronic tracking device velocity at time intervals, e.g., T 1 , T 2 , and T 3 . . . TN. By referencing prior location coordinates, e.g., last known accurate location data of the electronic tracking device 100 or last known location data of nearby electronic tracking device (e.g., second tracking device 101 in proximity to electronic tracking device 100 ), monitoring station 110 computes a current location of electronic tracking device 100 utilizing electronic tracking device velocity computations. Advantageously, monitoring station 110 , in an above described embodiment, uses above described device proximity measurements to monitor current location data of electronic tracking device 100 without connectivity to receive communication signals from GPS satellites.
[0037] In one embodiment, the monitoring station 110 may include a mobile phone having connectivity to wireless network 140 electrically coupled to electronic tracking device 100 ( FIG. 2 ). In this variant, the wireless network 140 resides or circulates within at least a portion of a semi-enclosed, partially-enclosed, or fully enclosed structure, e.g., building, parking structure, closet, storage room, or the like (e.g., structure 210 in FIG. 2 ). Furthermore, in one embodiment, the present invention conserves battery power by placing on standby, low power mode, or disabling entirely GPS signal, acquisition, circuitry and other associated devices, e.g., all or a portion of amplifier block 120 including power amplifiers, LNAs, switches, and the like. Furthermore, during supplemental location coordinates tracking, e.g., electronic device proximity measurements, the transceiver circuitry (e.g., transceiver 102 , location tracking circuitry 114 , and signal, processing circuitry 104 ) consumes reduced battery power for GPS circuitry while the electronic tracking device 100 communicates displacement vectors (e.g., differential location coordinates) to monitoring station 110 (e.g., a mobile phone, a personal digital assistant) through a wireless network 140 . As described above, when GPS signaling is not practicable, electronic device proximity measurements provide differential location coordinate information to calculate current location coordinate information.
[0038] In one embodiment, accelerometer, e.g., accelerometer 130 , determines if electronic tracking device 100 in a stationary position for a period, for instance, designated by system administrator or user. For example, electronic tracking device 100 may be, for example, located on a counter top, within, a pocket of clothing, or in suitcase, not being moved, or not currently in use. Continuing with this embodiment, electronic tracking device 100 communicates a code, e.g., a stationary acknowledgement code, to communication network, e.g., wireless network 140 . In one variant, when or if monitoring station 110 requests location data through communication network, electronic tracking device 100 determines whether it is located in a stationary or substantially stationary position and electronic tracking device 100 communicates its last-known location to the monitoring station 110 without accessing or requiring GPS signaling or active GPS circuitry, e.g., location tracking circuitry 114 . Advantageously, in this embodiment, when electronic tracking device 100 does not utilize and require GPS circuitry, e.g., location tracking circuitry 114 , or functionality, the power resources are preserved of battery 118 in contrast to many conventional GPS communication systems, which continue powering-on GPS circuitry. In one embodiment, electronic tracking device 130 associated with a person or object remains at a substantially stationary position approximately one-fourth to one-third of a calendar day; thus, this feature of not accessing GPS circuitry preserves battery power.
[0039] In another embodiment, an accelerometer, such as accelerometer 130 , detects tapping against electronic tracking device 100 . For instance, upon wake-up, user prompt, system, administrator prompt, or active, accelerometer 130 detects a person or object tapping a sequence on electronic tracking device 100 . In one embodiment, electronic tracking device 100 includes digital signal programming circuitry (such as of signal, processing circuitry 104 ). The digital signal programming circuitry recognizes programmed motions received by accelerometer, such as accelerometer 130 , and transmits an alert message to the monitoring station 110 upon receiving a recognized motion pattern. For example, electronic tracking device 100 may be programmed to recognize an “SOS tap cadence”. Thus, it electronic tracking device 100 is repeatedly tapped, for instance, in a “dot-dot-dot, dash-dash-dash, dot-dot-dot” pattern, signal processing circuitry 104 recognizes a motion pattern and transmit an alert message to wireless network 114 to monitoring station 110 . In one instance, alert message may be associated with a distress pattern and may require an appropriate response. In one variant, the accelerometer may recognize when an object or individual spins or turns motion of electronic tracking device 100 . Continuing with this embodiment, signal processing circuitry 104 recognizes programmed motions, and transceiver 102 transmits an alert message to wireless network 114 associated with programmed motions. In another variant, electronic tracking device 100 is programmed to recognize other motion patterns, such as when it is tumbled or flipped. Depending upon duration, time, or cadence of these movements or motion patterns, electronic tracking device 100 communicates an alert message to the wireless network 114 . In one variant, wireless network 114 performs an appropriate action, such as communicating information signal to monitoring station 110 .
[0040] In another example, physical impacts on electronic tracking device 100 are measured to determine if an individual or object may be injured. In one embodiment, magnitude of displacement vectors may be measured by one or more accelerometers, such as accelerometer 130 , disposed at various inclinations and orientations, e.g., disposed substantially orthogonal to one another. Continuing with this embodiment, when a measured physical impact is above a predetermined level, an object or individual associated with electronic tracking device 100 may have suffered a fall or be in need of medical attention. In one variant of this embodiment, a user (e.g., a system administrator, or person located in a contact book) at monitoring station 110 becomes alerted, e.g., by text message, email, or voice mail (as more fully described in previously incorporated by reference U.S. patent application Ser. No. 11/935,901 filed on Nov. 6, 2007, entitled “System and Method for Creating and Managing a Personalized Web Interface for Monitoring Location Information on Individuals and Objects Using Tracking Devices”). In one variant of this embodiment, if a user does not affirmatively respond, another individual, guardian, medical personnel, or law enforcement officer is contacted by monitoring station 110 (as more fully described in Ser. No. 11/935,901). In yet another variant of this embodiment, monitoring station 110 continues to contact individuals until the alert message is affirmatively answered.
Battery Conservation
[0041] Referring to FIG. 3 , a flow chart 300 illustrates battery conservation for electronic tracking device 100 as described in FIGS. 1 , 2 in accordance with one embodiment of the present invention. In step 302 , antenna 122 a associated with electronic tracking device 100 acquires a snapshot of receive communication signal including location coordinates data. In step 304 , processing unit 104 processes the snapshot of receive communication signal including location coordinates data. In step 306 , processing unit 104 determines a power level of receive communication signal.
[0042] In step 308 , accelerometer 130 activates if a power level of the receive communication signal is insufficient for processing. In one variant of step 308 , accelerometer 130 measures acceleration of electronic tracking device 100 at time intervals, e.g., T 1 , T 2 , T 3 . . . TN.
[0043] In step 310 , processing unit 104 computes current location coordinates using acceleration measurements. In step 312 , all or a portion of amplifier block 120 and associated circuitry, e.g., location tracking circuitry, are activated at selected time intervals to determine if receive communication signal is of sufficient signal strength. In one variation of step 312 , upon determining receive communication signal of sufficient signal strength, location tracking circuitry 114 are activated, and processing unit 104 determines location coordinates from the receive communication signal. In another variation of step 312 , upon determining receive communication signal of sufficient signal strength, accelerometer 130 is deactivated and location tracking circuitry 114 are activated, and processing unit 104 determines location coordinates from the receive communication signal.
[0044] It is noted that many variations of the methods described above may be utilized consistent with the present invention. Specifically, certain steps are optional and may be performed or deleted as desired. Similarly, other steps (such as additional data sampling, processing, filtration, calibration, or mathematical analysis for example) may be added to the foregoing embodiments. Additionally, the order of performance of certain steps may be permuted, or performed in parallel (or series) if desired. Hence, the foregoing embodiments are merely illustrative of the broader methods of the invention disclosed herein.
[0045] While the above detailed description has shown, described, and pointed out novel features of the invention as applied to various embodiments, it will be understood that various omissions, substitutions and changes in the form and details of the device or process illustrated may be made by those skilled in the art without departing from the spirit of the invention. The foregoing description is of the best mode presently contemplated of carrying out the invention. This description is in no way meant to be limiting, but rather should be taken as illustrative of the general principles of the invention. The scope of the invention should be determined with reference to the claims. | A device and method to monitor location coordinates of an electronic tracking device are disclosed here. The device includes transceiver circuitry to receive at least one portion of a receive communication signal comprising location coordinates information; accelerometer circuitry to measure displacements of the portable electronic tracking device; a battery power monitor configured to selectively activate and deactivate at least one portion of the transceiver circuitry and location tracking circuitry; and processor circuitry configured to process the at least one portion of the receive communication signal. The method includes receiving at transceiver circuitry of a portable electronic tracking device at least one portion of a receive communication signal comprising location coordinates information; measuring displacements of the portable electronic tracking device; activating and deactivating at least one portion of the transceiver circuitry and location tracking circuitry; and processing the at least one portion of the receive communication signal using processor circuitry. | 7 |
RELATED U.S. APPLICATION DATA
[0001] This application is a non-provisional of, and claims the benefit of the filing date of U.S. Provisional application No. 6,125,0221 filed on Oct. 9, 2009.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to the field of knives, and more specifically, relates to a knife block having multiple enclosures capable of securing a knife.
[0004] 2. Description of the Related Art
[0005] Knives used for boning, carving, and cutting of meat, vegetables, and other comestibles may be used and stored in modern kitchens. A typical knife comprises the following parts: a point, a tip, an edge, a heel, a spine, a bolster, a finger guard, a return, a tang, scales, rivets, handle, guard, and the tip. Kitchen knives are used in preparing food for human consumption and are typically stored in sheaths, drawers or blocks for ease of access by cooks and other users. Dangers of these current storage schemes may include knives poking or piercing the hand of a cook when rifling through a cutlery drawer looking for the appropriate knife, when a block is tipped over, or when a knife is accidentally dislodged from its sheath. Moreover, standard knife blocks do not prevent the knives from spilling out if the block is knocked over or upended. Children are often able to reach into drawers or remove a knife from a block sometimes without even being able to see the knives and can be seriously injured. Knives stored in blocks on a kitchen counter, can easily be upended or accidentally knocked over, thus spilling the knives and increasing the risk of serious injury.
[0006] Various attempts have been made to provide a safe means of protecting users of knives via storage means. There are a variety of knife storage systems available on the market. These range from individual sheaths to wooden blocks with cut-outs into which the knife is inserted. These solutions do not provide an adequate means for preventing the injuries discussed above.
[0007] For example, many knife storage blocks are simply blocks of wood or other materials with cut-outs to slide a knife in to. There is no restraint; a knife stays in the block by gravity alone and will slip out of the block is accidentally knocked over. Some attempts to secure a knife in a storage system such as a block can require a notched blade on a knife to operate a locking mechanism. This requires the user to purchase specially designed knives that can only be secured with that particular system. Further, the knives are not capable of being individually locked; if a user wants to unlock one knife, he or she must unlock all of the knives. Therefore, once one knife is unlocked, all knives are unlocked. This does not overcome the dangers related to spilling as discussed above. This type of system also requires two hands to lock or unlock the system which can be cumbersome and further increases the chance for injury.
[0008] Other attempts to secure a knife involve securing an individual knife in a sheath. While these systems do provide some security, they can also be cumbersome to use because the user must still use two hands Further, not all sheaths contain a locking mechanism, and for those that do, the locking mechanism in or on the sheath can wear down with repeated use. This can make it more difficult to remove the knife over time and at the same time increase the chance for injury as more force is needed to remove the knife. Additionally, these sheaths do not permit the user to store her knives in a single location (such as a block) and must be stored in a drawer. Chance for injury still remains if, for example, a knife is not inserted into the sheath properly or slips out without the user knowing it. Injuries can result as the user unknowingly rifles through a cutlery drawer filled with unsheathed knives.
[0009] Ideally, a locking knife block system should operate reliably as a safe storage means for knives, and be manufactured at a modest expense. A need exists for a reliable, safe, universal locking knife block system that permits the user to efficiently unlock a single knife thus mitigating injury and to avoid the above-mentioned problems. What is also needed is a locking knife storage system which safely stores the knives, prevents their accidental removal, and is capable of securely storing multiple knives of varying types and sizes in one location. Also needed is a knife storage system whereby the user is capable of safely inserting and removing a knife using only one hand. The current invention overcomes the problems with current knife storage systems in several ways.
BRIEF SUMMARY OF THE INVENTION
[0010] Accordingly, in one aspect, the invention broadly provides a secure housing mechanism and locking arrangement for safe and secure removal and insertion of the individual knives of varying sizes as members of a set of knives. A knife locking system is disclosed herein comprising an enclosure with a plurality of cavities, at least one lockable case, a stay, and at least one pivoting means. The lockable case and pivoting means are coupled together and are located within cavity 106 of housing 104 for lockably storing a knife or set of knives. The pivoting means comprises a compressible spring and pin. The pin and compressible spring work simultaneously when a knife is inserted or withdrawn from the lockable case. The knife locking system further comprises a peg. The peg restricts the case from pivoting while in the locked position. The pivoting means permits the lockable case to pivot through an angle less than about 45 degrees. The lockable case(s) are capable of being positioned within the enclosure in a diagonal or parallel relation to one another or in various combinations of diagonal and parallel orientations. The enclosure may further comprise a stay where the stay may or may not be integral with the enclosure. The stay may be perpendicular to the lockable case and works in conjunction with the peg to lockably store the individual members of a set of knives.
[0011] A method of storing a knife in a knife locking system is disclosed herein comprising the steps of: inserting a knife into a sheath within a lockable case enclosed within a cavity; depressing a compressible spring; pivoting the lockable case within the enclosure; and allowing the compressible spring to go back into tension thereby creating a locking relationship between the lockable case and the housing. The locking relationship within the method of storing may comprise a peg and a stay. The compressible spring may be depressed allowing the peg to move under and then behind the stay thereby creating a locking relationship between the components. Unlocking the knife may comprise depressing the compressible spring, pivoting the lockable case to move the peg under and then in front of the stay thereby allowing the knife to be removed. The spring returns to a state of tension.
[0012] The present invention holds significant improvements and serves as a knife storage and locking system. These and other features, aspects, and advantages of the present invention will become better understood with reference to the following drawings and description, which are given by way of example only.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 shows a perspective view illustrating knife locking system 100 according to an embodiment of the present invention.
[0014] FIG. 2 shows a perspective side view of lockable case 200 within cavity 106 of knife locking system 100 according to an embodiment of the present invention of FIG. 1 .
[0015] FIG. 3 , consisting of FIGS. 3A , 3 B, and 3 C, illustrates an exploded view of pivoting means 300 by which lockable case 200 functions within knife locking system 100 according to an embodiment of the present invention of FIGS. 1 and 2 .
[0016] FIG. 4 illustrates shield 400 and lockable case 200 in locked position 310 and unlocked position 320 according to an embodiment of the present invention of FIG. 1 .
[0017] FIG. 5 shows a perspective top view illustrating the relative positioning of lockable sheath 200 in locked position 230 and unlocked position 240 , according to an embodiment of the present invention of FIG. 1 .
[0018] FIG. 6 shows flowchart of a method of use 600 for knife locking system 100 , according to an embodiment of the present invention of FIG. 1 .
[0019] The various embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like designations denote like elements.
DETAILED DESCRIPTION
[0020] Referring now to FIG. 1 , showing a perspective view illustrating knife locking system 100 according to an embodiment of the present invention. Knife locking system 100 comprises housing 104 ; stay 130 ; cavity 106 ; and at least one lockable case 200 for lockably storing at least one knife 110 .
[0021] Housing 104 may comprise wood, ferrous and/or non-ferrous metals, composites, alloys, plastics, marble, and other such suitable materials. Housing 104 further comprises a plurality of cavity 106 . Cavity 106 may be of any dimension sufficient to house a plurality of lockable case 200 . Lockable case 200 further comprises sheath 215 . It should be understood that sheath 215 is within lockable case and may be the portion of lockable case 200 that knife 110 is inserted to. Sheath 215 may be of any size sufficient to contain a standard kitchen knife of any type. By way of example, a standard set of kitchen knives may include a butcher knife, a paring knife, a bread knife, a vegetable knife, and a set of steak knives. It should be understood that sheath 215 may be configured to contain, but is not limited to the dimensions to any of the aforementioned knives Knife 110 may be inserted into sheath 210 substantially enclosing knife 110 within lockable case 120 . In this manner, knife locking system 100 is capable of storing and locking any knife or set of knives as selected by the user.
[0022] Lockable case 200 may similarly be of any size sufficient to contain varying sizes and types of knife 110 as contained by sheath 215 . It should be understood that sheath 215 is of sufficient size to contain the user-selected knife, but the dimensions do not have to conform exactly to the dimensions of the knife. In other words, knife 110 is not required to fit snugly within sheath 215 . It is sufficient if the knife fits inside the sheath; any extra space created by a sheath that is larger than a knife will not affect the functionality of knife locking system 100 . It should also be understood that housing 104 is of a sufficient size and shape to permit storing any number and size of cavity 106 and/or lockable sheath 200 according to the user's needs. In this manner, knife locking system 100 can, but is not limited to, storing one particular type or size of knife 110 . In this manner, and by way of example, a paring knife may easily be stored along side of and with a set of steak knives, butcher knives, or any other type and combination of knives For example, a standard set of kitchen knives can include a combination of different types and sizes of knives.
[0023] As discussed above, cavity 106 is of a sufficient volume to receive at least one lockable case 200 . In this manner, cavity 106 functions to contain lockable case 200 and permit movement of the same from locked position 240 to unlocked position 230 and vice versa (shown and discussed in FIGS. 2-5 ). Lockable case 200 may be secured within cavity 106 in any manner sufficient to accomplish a secured fit within cavity 106 such as molding, nails, adhesives, friction fit, or any other means sufficient to accomplish such purpose.
[0024] Knife locking system 100 further comprises at least one stay 130 . Stay 130 may be positioned directly over one end of lockable case 200 as shown. Further, stay 130 may be attached to the surface of housing 104 via brads, nails, adhesives, screws, rivets, or any other suitable attaching means. Stay 130 may be comprised of wood, plastics, metals and/or metal alloys, or any material sufficient to secure knife 110 within lockable case 200 . When lockable case 200 is in locked position 230 , stay 130 is positioned directly over the area between the handle and finger guard of knife 110 (further discussed in FIGS. 2-5 ). Finally, Stay 130 may be integral or non-integral with housing 104 as also shown and discussed in FIGS. 4 and 5 .
[0025] Further, housing 104 may compromise a plurality of cavity 106 and lockable case 200 of different heights as shown. In this manner, knife 110 may be inserted or removed from its lockable case 200 without interfering with the remaining plurality of lockable case 200 when stored within housing 104 of knife locking system 100 . It should be understood that cavity 106 may be structured so as to be perpendicular relative to a substrate (such as a counter top) or at an angle relative to the substrate (as depicted in FIG. 1 ) depending on user preference.
[0026] Referring now to FIG. 2 , showing a perspective side view of lockable case 200 within cavity 106 of knife locking system 100 according to an embodiment of the present invention of FIG. 1 . Lockable case 200 comprises end 205 ; sheath 210 (shown in FIG. 1 ); sheath extension 215 , at least one peg 220 ; pivoting means 300 (shown and discussed in FIG. 3 ); and at least one shield 400 (discussed in FIG. 4 ).
[0027] End 205 (shown and discussed in further detail in FIG. 3 ) may be located at the bottommost portion of lockable case 200 and serves the purpose of providing support for sheath 210 . Further, end 205 may comprise wood, ferrous and/or non-ferrous metals, composites, alloys, plastics, marble, and other such suitable materials for providing support to a knife.
[0028] Lockable case 200 further comprises sheath extension 215 (discussed in further detail in FIG. 3 ) may be positioned directly beneath end 205 as shown. Sheath extension 215 further comprises first aperture 250 (shown and discussed in further detail in FIG. 3 ). Further, sheath extension 215 may comprise wood, ferrous and/or non-ferrous metals, composites, alloys, plastics, marble, and other such suitable materials.
[0029] Lockable case 200 is shown in locked position 230 wherein sheath 210 is at a substantially perpendicular relationship to the base of housing 104 such that the handle of knife 110 (not shown) is similarly perpendicular to base of housing 104 . In locked position 230 , peg 220 rests against stay 130 . In this manner, sheath extension 215 works in conjunction with second extension 340 to attach lockable case 200 to second extension 340 of pivoting means 300 (as discussed in FIG. 3 ).
[0030] Lockable case 200 is also shown in unlocked position 240 wherein sheath 210 is at a substantially angular relationship such as, for example, approximately 45 degrees to the base of housing 104 such that the handle of knife 110 (not shown) is similarly at an angle, such as, for example, approximately 45 degrees, to the substrate as shown. In unlocked position 230 , peg 220 may be behind stay 130 as shown. Locked position 230 and unlocked position 240 are also shown and discussed in FIGS. 4 and 5 . Peg 220 may comprise a bar, dowel, or any other means suitable for restraining movement of lockable case 200 . Peg 220 may be made of wood, ferrous and/or non-ferrous metal, marble, plastic, ceramic, or any other suitable material. When in locked position 230 , peg 220 substantially prevents lockable case 200 from rotating about centerline axis of pivoting means 300 .
[0031] Referring now to FIG. 3 , consisting of FIGS. 3A , 3 B, and 3 C, illustrating an exploded view of pivoting means 300 by which lockable case 200 functions within knife locking system 100 according to an embodiment of the present invention of FIGS. 1 and 2 . Pivoting means 300 further comprises spring 310 , plate 320 , pin 330 , and second extension 340 . Pivoting means 300 may comprise wood, ferrous and/or non-ferrous metals, composites, alloys, plastics, marble, and other such suitable materials. Further, pivoting means 300 may be secured within cavity 106 by brads, nails, screws, rivets, adhesives, or any other suitable attaching means.
[0032] As mentioned above, pivoting means 300 may comprise plate 320 . Plate 320 serves the purpose of providing a flat surface to support second extension 340 . As mentioned in FIG. 2 , lockable case 200 further comprises end 205 . End 205 may be located at the bottommost portion of lockable case 200 and serves the purpose of providing support for sheath 210 . Further mentioned in FIG. 2 , sheath extension 215 may be positioned directly beneath end 205 . Plate 320 may be coupled to spring 310 and end 205 . In this manner, sheath extension 215 and second extension 240 may be situated between plate 320 and end 205 as shown. Sheath extension 215 works in conjunction with second extension 340 to attach lockable case 200 to second extension 340 of pivoting means 300 . End 205 may be affixed to sheath extension 215 via brads, nails, rivets, screws, molding, adhesives, or any other material suitable for such purpose. Plate 320 may be connected to spring 310 via brads, rivets, nails, adhesives, molding, or any other suitable means. Further, plate 320 may be connected to end 205 via brads, rivets, nails, adhesives, molding, or any other suitable means. Finally, plate 320 may comprise wood, ferrous and/or non-ferrous metals, composites, alloys, plastics, marble, and other such suitable materials.
[0033] As mentioned above, pivoting means 300 further comprises second extension 340 . Second extension 340 may be positioned directly above plate 320 as shown. Further, second extension 340 may be attached to plate 320 by molding, adhesives, or any other material suitable for such purpose. Second extension 340 may further comprise at least two identical protrusion 350 . Protrusion 350 (shown in FIG. 3C ) further comprises second aperture 345 . Second extension 340 further comprises at least one protrusion 350 . As shown in FIG. 3 , second extension comprises two protrusion 350 . It should be understood that the present invention contemplates at least one protrusion 350 . Second extension 340 may function to surround sheath extension 215 as shown. In this manner, sheath extension 215 may operate as a female end and second extension 340 may operate as a male end. In an alternative embodiment, sheath extension 215 may be comprised of protrusion 350 . In this manner, sheath extension 215 may operate as a male end and second extension 340 may operate as a female end.
[0034] Sheath extension 215 further comprises first aperture 250 . Similarly, second extension 340 further comprises second aperture. The diameter and placement of first aperture 250 of sheath extension 215 and the diameter and placement of second aperture 345 of second extension 340 are complementary, meaning that when sheath extension 215 is positioned in or over or around protrusion 350 of second extension 340 , first aperture 250 and second aperture 345 will line up exactly.
[0035] Pivoting means 300 may further comprise pin 330 . Pin 330 may comprise brads, nails, screws, rivets, or any other suitable attaching means suitable to permit it to function as a coupling means between sheath extension 215 and second extension 340 . In this manner, pin 330 may be inserted through first aperture 250 and second aperture 345 and functions as the means by which pivoting means 300 allows lockable case 200 to be moved along an axis from locked position 230 to unlocked position 240 . Pin 330 may Further, pin 330 comprise wood, ferrous and/or non-ferrous metals, composites, alloys, plastics, marble, and other such suitable materials.
[0036] FIG. 3A shows a perspective side view of pivoting means 300 in unlocked position 240 , according to an embodiment of the present invention of FIGS. 1 and 2 . Similarly, FIG. 3B shows a perspective side view of pivoting means 300 in locked position 230 according to an embodiment of the present invention of FIGS. 1 and 2 . When the user wishes to insert and lock knife 110 (not shown) into lockable case 200 , he or she may grasp the handle of knife 110 , insert knife 110 into sheath 210 within lockable case 200 and apply pressure in a downward motion to compress spring 310 . Once spring 310 is compressed, peg 220 is at a height lower than stay 130 . The user may then maintain the downward pressure and move lockable case 200 toward the user so that peg 220 is now in front of stay 130 and lockable case 200 is resting against the front end of cavity 106 . In locked position 310 the bottom edge of lockable case 120 comprises an angle parallel to the base of housing 104 . In this position, knife 110 may be substantially resting beneath stay 130 , which may be positioned directly over the area between the bolster and finger guard of knife 110 .
[0037] When the user wishes to unlock lockable case 200 , he or she may grasp the handle of knife 110 (not shown) and apply pressure in a downward motion to compress spring 310 . Once spring 310 is compressed, peg 220 is at a height lower than stay 130 . The user may then maintain the downward pressure and move lockable case 200 away from the user so that peg 220 is now behind stay 130 and lockable case 200 is resting against the opposite end of cavity 106 . Similarly, when the user wishes to lock lockable case 200 , he or she may grasp the handle of knife 110 (not shown) and apply pressure in a downward motion to compress spring 310 . The user may then maintain the downward pressure and move lockable case 200 toward the user so that peg 220 is now moved from behind stay 130 , passing underneath stay 130 and coming to rest in front of peg 220 . In this manner, the spine and bolster of knife 110 (as enclosed by sheath 210 of lockable case 200 ) provides the mechanism by which sheath 210 of lockable case 200 is pivoted within cavity 106 via pivoting means 300 .
[0038] When spring 310 is compressed, lockable case 200 within knife locking system 100 comprises unlocked position 240 . When lockable case 200 is in unlocked position 240 , the front portion of sheath 210 rests against one side of cavity 106 . Lockable case 200 is shown pivoted so that lockable case 200 is moved away from the user's body, however, it should be appreciated that in other embodiments of knife locking system 100 , knife locking system may be configured such that the user may pull the knife toward her (as opposed to away) to place lockable case 200 in unlocked position 230 . In this manner, lockable case 200 may move from locked position 310 to unlocked position 320 .
[0039] Referring now to FIG. 4 , illustrating shield 400 and lockable case 200 in locked position 230 and unlocked position 240 according to an embodiment of the present invention of FIG. 1 . As discussed above, lockable case 200 further comprises at least one shield 400 . Shield 400 may be affixed to lockable case 200 as shown. In an alternative embodiment, shield 400 may be an integral part of housing 104 . Shield may be affixed to lockable case 200 or to housing 104 via brads, nails, adhesives, screws, or any other suitable attaching means. Further, shield 400 may comprise plastic, rubber, or any other suitable elastomeric or pliant material sufficient to allow shield 400 to conform to the gap between lockable case 200 and cavity 106 .
[0040] Shield 400 may be attached to the front or back portion of sheath 210 , or both, as shown. Further, shield 400 may be sufficient in size to cover the gap between lockable case 200 and cavity 106 that is created when lockable case 200 is in unlocked position 240 or locked position 230 . In this manner, food and other debris are thereby prevented from entering cavity 106 within an embodiment of the present invention. When the user moves lockable case 200 from locked position 230 to unlocked position 240 and vice versa, shield 400 moves with lockable case 200 to form a protective barrier as shown in dotted lines. In this manner, when lockable case 200 is moved from unlocked position 230 to locked position 240 and vice versa, shield 400 occupies the space between lockable case 200 and cavity 106 as shown.
[0041] Referring now to FIG. 5 showing a perspective top view illustrating the relative positioning of lockable sheath 200 in locked position 230 and unlocked position 240 , according to an embodiment of the present invention of FIG. 1 . Peg 220 may be affixed to lockable case 200 as also shown in FIGS. 2 and 4 . In an alternative embodiment, peg 220 may be an appendage of housing 104 . Peg 220 may comprise a bar, dowel, nail, brad, or any other means suitable for restraining movement of lockable case 120 . Further, peg 220 may be made of wood, ferrous and/or non-ferrous metal, marble, plastic, ceramic, or any other suitable material. As discussed above, when in locked position 230 , peg 220 substantially prevents lockable case 200 from rotating about centerline axis of pivoting means 300 . In this manner, lockable case 200 may move from locked position 230 to unlocked position 240 .
[0042] When knife 110 is inserted into sheath 210 such that finger guard 405 and handle 410 are the only visible portions of knife 110 . When lockable case 200 is moved from locked position 230 to unlocked position 240 , shield 400 operates to cover the resulting open space of cavity 106 . In locked position 230 , finger guard 405 is substantially underneath stay 130 and peg 220 is in front of stay 130 as shown. In locked position 230 , lockable case 200 is positioned so that lockable case 200 is in a position within housing 104 closest to the user as shown. In unlocked position 240 , finger guard 405 and handle 410 of knife 110 are no longer beneath stay 130 . Further, in unlocked position 240 , lockable case 200 is positioned so that lockable case 200 is in a position in housing 104 further away from the user as shown. Peg 220 is no longer in front of stay 130 as shown. In unlocked position 240 , stay 130 may be positioned directly over the area between finger guard 405 and handle 410 of knife 110 . In an alternative embodiment of the present invention, unlocked position 240 may be in housing 104 in the position closest to the user and locked position 230 may be in housing 104 in the position furthest from the user.
[0043] Referring now to FIG. 6 showing a flowchart of a method of use 600 for knife locking system 100 , according to an embodiment of the present invention of FIG. 1 . Method of use 600 of storing a knife in a knife locking system may comprise the following steps: step 601 inserting a knife into a sheath within lockable case; step 602 depressing a compressible spring; step 603 pivoting the sheath within the enclosure; and step 604 allowing the compressible spring to return to a tension state thereby creating a locking relationship between the lockable case and the enclosure.
[0044] The insertion step may further comprise step 605 depressing the lockable case thereby compressing the spring and pivoting the lockable case about the centerline axis. The rotation comprises about 45 degrees from the unlocked to the locked position. Insertion is completed by step 606 releasing the pressure on the lockable case thereby allowing the knife to rest under the stay and the peg behind the stay. Step 607 may include unlocking which comprises depressing the compressible spring, rotating the pivotor to move the peg under then in front of the stay and releasing the pressure thereby allowing the knife to be removed.
[0045] It should be noted that optional steps 605 - 607 may not be implemented in all cases. Optional steps of method 600 are illustrated using dotted lines in FIG.6 so as to distinguish them from the other steps of method 600 .
[0046] It should be noted that the steps described in the method of use can be carried out in many different orders according to user preference. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other methods of use arrangements such as, for example, different orders within above-mentioned list, elimination or addition of certain steps, including or excluding certain maintenance steps, etc., may be sufficient.
[0047] The embodiments of the invention described herein are exemplary and numerous modifications, variations and rearrangements can be readily envisioned to achieve substantially equivalent results, all of which are intended to be embraced within the spirit and scope of the invention. | A knife locking system is disclosed herein comprising a housing containing a plurality of cavities, a plurality of lockable cases, and a plurality of pivoting means. The lockable case and pivoting means are coupled together and are located within the cavity of housing for lockably storing a knife or set of knives. The pivoting means comprises a compressible spring, a pin, and extensions. The pivoting means and compressible spring work simultaneously when a knife is inserted or withdrawn from the lockable sheath. The lockable case further comprises a peg and extensions. The peg restricts the sheath from moving while in the locked position. The extensions work with the pivoting means and permit the lockable case to pivot through an angle less than about 45 degrees. The lockable sheath(s) are capable of being positioned within the enclosure in a diagonal or parallel relation to one another or in various combinations of diagonal and parallel orientations. The enclosure may further comprise a stay where the stay may or may not be integral with the enclosure. | 0 |
CROSS-REFERENCE
[0001] This application is a CONTINUATION application that claims priority to U.S. application Ser. No. 12/277,443 which claims the benefit of U.S. Provisional Application No. 60/991,682, filed Nov. 30, 2007, and Application No. 61/033,368 filed Mar. 3, 2008, which applications are incorporated herein by reference.
[0002] This application has related subject matter to U.S. Utility patent application Ser. No. 12/277,338, filed Nov. 25, 2008, entitled “Methods, Devices, Kits and Systems for Defunctionalizing the Cystic Duct” by Jacques Van Dam, J. Craig Milroy, and R. Matthew Ohline and U.S. Utility patent application Ser. No. 12/277,491, filed Nov. 25, 2008, entitled, “Biliary Shunts, Delivery Systems, Methods of Using the Same, and Kits Therefor” by Jacques Van Dam, J. Craig Milroy, and R. Matthew Ohline, which applications are incorporated herein by reference.
FIELD OF THE INVENTION
[0003] The invention described in this patent application addresses challenges confronted in the treatment of biliary disease. Biliary disease includes conditions affecting the gallbladder, cystic duct, and common bile duct.
Biliary System Function and Anatomy:
[0004] Bile is a greenish-brown digestive fluid produced by the liver 10 illustrated in FIG. 1 , and is vital for the digestion of fatty foods. Bile is secreted by liver cells and collected by a network of ducts that converge at the common hepatic duct 12 . While a small quantity of bile drains directly into the lumen of the duodenum 30 (the section of small intestine immediately downstream of the stomach), most travels through the common hepatic duct 12 and accumulates in the lumen of the gallbladder 14 . Healthy gallbladders are pear-shaped sacs with a muscular wall that, on average, measure 10 cm in length and can store approximately 50 ml of fluid within its lumen. When fatty foods are ingested, the hormone cholecystokinin is released, which causes the gallbladder 14 to contract. Contraction of the gallbladder 14 forces bile to flow from the gallbladder 14 , through the cystic duct 16 , into the common bile duct 18 , out the papilla 28 , and finally into the duodenum 30 of the small intestine. Here, it mixes and reacts with the food that exits the stomach. The Sphincter of Oddi 26 controls secretions from the liver, pancreas 24 , and gallbladder 14 into the duodenum 30 of the small intestine. The opening on the inside of the descending duodenum 30 after the Sphincter of Oddi 26 is called the major duodenal papilla 28 (of Vater). Together, the biliary ducts, the gallbladder 14 , the cystic duct 16 and the common bile duct 18 comprise the biliary system ( FIG. 1 ).
[0005] The pancreas 24 is a gland organ in the digestive and endocrine system of vertebrates. It is both an endocrine gland (producing several important hormones, including insulin, glucagon, and somatostatin), as well as an exocrine gland, secreting pancreatic juice containing digestive enzymes that pass to the small intestine. These enzymes help in the further breakdown of the carbohydrates, protein, and fat in the chyme. The pancreatic duct 22 , or duct of Wirsung, is a duct joining the pancreas 24 to the common bile duct 18 to supply pancreatic juices which aid in digestion provided by the exocrine pancreas. The pancreatic duct 22 joins the common bile duct 18 just prior to the major duodenal papilla 28 , after which both ducts perforate the medial side of the second portion of the duodenum 30 at the major duodenal papilla.
Biliary Disease:
[0006] The most common problem that arises in the biliary system is the formation of gallstones, a condition called cholelithiasis. Approximately 20 million Americans have gallstones, and about 1-3% will exhibit symptoms in any given year. In the US, gallstones are more common among women, with 25% of women having gallstones by the age of 60 and 50% by the age of 75. Pregnancy and hormone replacement therapy increase the risk of forming gallstones. Prevalence is lower for American men: approximately 25% will develop gallstones by the age of 75. In the US, gallstones are responsible for the highest number of hospital admissions due to severe abdominal pain.
[0007] Gallstones 20 , 20 ′ are most often composed of cholesterol, but may also be formed from calcium bilirubinate, in which case they are called pigment stones. They range in size from a few millimeters to several centimeters, and are irregularly shaped solids resembling pebbles. They can form in the gallbladder 14 , cystic duct 16 , and/or the common bile duct 18 ( FIG. 2 ). By themselves, gallstones 20 do not necessarily result in disease states. This is the case 90% of the time. However, stones can cause infection and inflammation, a condition known as cholecystitis, which is generally the result of restricting or blocking the flow of bile from the gallbladder 14 and common bile duct 18 , or the fluids secreted by the pancreas 24 .
[0008] Gallbladder disease may be chronic, and patients who suffer from this may periodically experience biliary colic. Symptoms include pain in the upper right abdomen near the ribcage, nausea, and/or vomiting. The pain may resolve within an hour of onset, may prove unresponsive to over-the-counter medicines, and may not decrease with changes of position or the passage of gas. Recurrence is common, with pain often recurring at the same time of day, but with frequency of less than once per week. Fatty or large meals may cause recurrence several hours after eating, often awakening the patient at night. Patients may elect to suffer from these symptoms for very long periods of time, such as years or even decades.
[0009] Patients with chronic cholecystitis have gallstones and low-grade inflammation. Untreated, the gallbladder 14 may become scarred and stiff over time, leading to a condition called dysfunctional gallbladder. Patients who have chronic cholecystitis or dysfunctional gallbladder may experience gas, nausea, and abdominal discomfort after meals, and chronic diarrhea.
[0010] Acute cholecystitis (a surgical emergency) develops in 1-3% of those with symptomatic gallstone disease, and is due to obstruction of the common bile duct 18 or cystic duct 16 by stones or sludge. Symptoms are similar to biliary colic, though they are more severe and persistent. Pain in the upper right abdomen can be constant and severe, the intensity may increase when drawing breath, and it may last for days. Pain may radiate to the back, under the breastbone or the shoulder blades, and it may be perceived on the left side of the abdomen. In addition to nausea and vomiting, one third of patients experience fever and chills. Complications from acute cholcystitis can be serious and life threatening, and include gangrene, abscesses, perforation of the gallbladder 14 which can lead to bile peritonitis, pus in the gallbladder wall (empyema), fistulae, and gallstone ilius (when a gallstone creates a blockage in the small intestine).
[0011] When gallstones 20 ′ become lodged in the common bile duct 18 ( FIG. 2 ), the condition is known as choledocholithiasis. Symptoms for this condition include pain, nausea and vomiting, and some patients develop jaundice, have dark urine and/or lighter stools, rapid heartbeat, and experience an abrupt drop in blood pressure. These symptoms can also be accompanied by fever, chills, and/or severe pain in the upper right abdomen. Complications from choledocholithiasis can also be very serious, and include infection of the common bile duct 18 (cholangitis) and inflammation of the pancreas 24 (pancreatitis).
[0012] A smaller patient population suffers from gallbladder disease that occurs in the absence of gallstones. This condition, called acalculous gallbladder disease, can also be chronic or acute. Chronic acalculous gallbladder disease, also called biliary dyskinesia, is thought to be caused by motility disorders that affect the gallbladder's ability to store and release bile. Acute acalculous gallbladder disease occurs in patients who suffer from other serious illnesses which can lead to inflammation of the gallbladder 14 because of a reduction in the supply of blood to the gallbladder 14 or a reduced ability to contract and empty bile into the duodenum 30 .
[0013] Cancer can also develop in the gallbladder 14 , though this condition is rare. Gallstones have been found in 80% of patients with gallbladder cancer. Gallbladder cancer typically develops from polyps, which are growths inside the gallbladder 14 . When polyps 15 mm across or larger are observed, the gallbladder is removed as a preventive measure. Polyps smaller than 10 mm are widely accepted as posing low risk and are not generally removed. When detected early, before the cancer has spread beyond the mucosa (inner lining) of the gallbladder, the 5-year survival rate is approximately 68%. However, gallbladder cancer is not usually detected until patients are symptomatic, by which time the disease is more advanced.
Treatment of Biliary Disease:
[0014] The most effective treatment for biliary disease has been surgical removal of the gallbladder 14 , a procedure called cholecystectomy. Surgical removal of the gallbladder 14 is indicated for patients who experience a number of less severe gallstone attacks, cholecystitis, choledocholithiasis, pancreatitis, acalculous biliary pain with evidence of impaired gallbladder 14 emptying, those at high risk for developing gallbladder cancer, and those who have previously undergone endoscopic sphincterotomy for common bile duct stones. Other treatment modalities exist and are frequently used, but gallbladder disease tends to recur in the majority of patients who forgo cholecystectomy and pursue alternatives. Removal of the gallbladder 14 is highly successful at permanently eliminating biliary disease. Cholecystectomy is one of the most commonly performed procedures on women. The gallbladder 14 is not an essential organ, and after a period of adjustment post surgery, patients tend to return to more or less normal digestive function.
[0015] Cholecystectomy can be performed either as open surgery, which requires a single larger incision in the upper right abdomen, or laparoscopic surgery, in which several small instruments are inserted through much smaller incisions in the abdomen. Approximately 80% of cholecystectomies are performed laparoscopically. The primary benefits of this minimally invasive approach are faster recovery for the patient, and a reduction in overall healthcare costs. Patients who receive laparoscopic cholecystectomy are usually released the same day. By contrast, patients receiving open cholecystectomies typically spend 5-7 days in a hospital before release. 5-10% of laparoscopic procedures convert to open procedures when difficulties arise, such as injury to major blood vessels, inadequate access, inadequate visualization, previous endoscopic sphincterotomy, and thickened gallbladder wall. Complications from cholecystectomy (open or laparoscopic) include bile duct injuries (0.1-0.5% for open, 0.3-2% with a declining trend for laparoscopic), pain, fatigue, nausea, vomiting, and infection. In up to 6% of cases, surgeons fail to identify and remove all gallstones present.
[0016] In some cases, the degree of infection and inflammation prevents patients from undergoing immediate cholecystectomy. In these cases, the gallbladder 14 must be treated with antibiotics and anti-inflammatory agents, and drained through a tube into a reservoir outside the abdomen. Placement of this tube occurs in a procedure called percutaneous cholecystostomy, in which a needle is introduced to the gallbladder 14 through the abdomen, fluid is withdrawn, and a drainage catheter is inserted. This catheter drains into an external bag which must be emptied several times a day until the tube is removed. The drainage catheter may be left in place for up to 8 weeks. In cases where no drainage catheter is inserted, the procedure is called gallbladder aspiration. Since no indwelling catheter is placed, the complication rate for gallbladder aspiration is lower than that of percutaneous cholecystostomy.
[0017] Treatment methodologies other than cholecystectomy include expectant management, dissolution therapy, endoscopic retrograde cholangiopanctreatograpy (ERCP) with endoscopic sphincterotomy, and extracorporeal shockwave lithotripsy (ESWL).
[0018] Expectant management is appropriate for patients who have gallstones but no symptoms, and for non-emergency cases with less severe symptoms. This approach is not recommended when patients are in high risk categories (e.g. high risk for gallbladder cancer) or have very large gallstones (e.g. greater than 3 cm).
[0019] Oral dissolution therapy involves the administration of pills containing bile acids that can dissolve gallstones. This approach is only moderately effective, and the rate of recurrence of gallstones after completion of treatment is high. It is not appropriate for patients with acute inflammation or stones in the common bile duct (more serious conditions). Dissolution therapy tends to be more effective for patients with cholesterol stones, and is sometimes used in conjunction with lithotripsy. Despite its relative ineffectiveness, it is costly: treatment can last up to 2 years and the drugs cost thousands of dollars per year.
[0020] Related to oral dissolution therapy is contact dissolution, a procedure that involves injection of a solvent such as methyl tert-butyl ether (MTBE) directly into the gallbladder 14 . This approach is highly effective at dissolving gallstones, but patients may experience severe burning pain.
[0021] ERCP (endoscopic retrograde cholangiopancreatograpy) is a procedure in which an endoscope is introduced through the mouth of a patient, past the stomach to the papilla 28 , where the common bile duct 18 empties into the duodenum 30 . The overall goal of the procedure is to insert instruments and tools into the common bile duct 18 via the papilla 28 in order to treat biliary disease. Typically, endoscopic sphincterotomy is performed, which is a procedure that enlarges the opening of the papilla 28 in the small intestine. This can be accomplished surgically or via balloon dilation. Contrast agent is introduced into the common bile duct 18 to visualize the biliary tree fluoroscopically. Tools for clearing blockages, such as mechanical lithotripsy devices, can be deployed to crush gallstones and remove the resulting debris. Drainage catheters and stents may also be inserted to facilitate the drainage of bile past obstructions. Complications from this challenging procedure occur at a rate of 5-8%, and include recurrence of stone formation, pancreatitis, infection, bleeding, and perforation.
[0022] Extracorporeal shockwave lithotripsy (ESWL) is a technique in which focused, high-energy ultrasound is directed at the gallbladder 14 . The ultrasound waves travel through the soft body tissue and break up the gallstones. The resulting stone fragments are then usually small enough to pass through the bile duct into the small intestine. Oral dissolution therapy is often used in conjunction with ESWL. This treatment is not in common use, as less than 15% of the patient population are good candidates. However, ESWL is used to treat patients who are not candidates for surgery. Complications from ESWL include pain in the gallbladder area, pancreatitis, and failure of the gallstone fragments to pass into the small intestine.
SUMMARY OF THE INVENTION
[0023] An aspect of the invention is directed to devices for treating biliary disease. Suitable devices comprise: a component configured for defunctionalizing a gallbladder of a patient which has a proximal end and a distal end with a lumen extending therethrough and one or more apertures at a distal end adaptable to deliver a fluid to a lumen within the gallbladder or a gallbladder duct. Other suitable devices comprise: a means for defunctionalizing a gallbladder of a patient having a proximal end and a distal end with a lumen extending therethrough and one or more means for accessing the lumen at a distal end adaptable to deliver a fluid to a lumen within the gallbladder or a gallbladder duct. The distal end of the device can be configured to provide an angular orientation, to deliver a fluid with at least one of a 360 degree radial pattern, a sharp stream, and a cone shape, and/or to have an articulating member. Additionally, the device can further be adapted to apply a vacuum. The devices can further provide a means for applying a vacuum. In some instances, the lumen includes a means for restricting fluid flow. In some instances, the distal end is adapted to apply an adhesive to a lumen of the gallbladder. Devices can also be configured for deployment by an endoscope, a needle, guidewire, or guidance catheter. In some instances, the lumen is configurable to provide restrictable fluid flow, such as with the use of one or more fluid control components. Alternatively, one or more valves can be used, including at least one of a flow-restrictor or one-way valve. Additionally, devices can be configured such that they are flexible. In some configurations, the device is an elongate tube adapted and configured to extend into the gastrointestinal tract.
[0024] An aspect of the invention is directed to a method of treating biliary disease. The method comprises the steps of: accessing a lumen associated with a gallbladder or a gallbladder duct; defunctionalizing at least one of the gallbladder duct or the gallbladder; and leaving the gallbladder in situ. Additionally, the step of defunctionalizing the gallbladder can further comprise the step of delivering a substance to at least one of the gallbladder duct or the gallbladder, for example, such that it occupies a lumen of at least one of the gallbladder duct or the gallbladder, and/or is one or more of antibiotics, inflammatory agents, and anti-inflammatory agents. Delivery of substances can be performed sequentially or concurrently, as desired. Another aspect of the method includes the step of preventing bile from entering the gallbladder lumen. In some aspects the method further comprises the step of localizing the gallbladder via endoscopic ultrasound. In other aspects of the invention, the method can comprise the step of accessing the gallbladder via the gastrointestinal tract, such as via a duodenum. In still other aspects of the methods the step of defunctionalizing at least one of the gallbladder duct or the gallbladder further comprises one or more of sclerosing, necrotizing or ablating tissue. Suitable ablation techniques include, for example, cryoablation, thermal ablation, chemical ablation, radio frequency ablation, microwave ablation, and ultrasound ablation. Fluid delivery can be achieved with an angular orientation, or with at least one of a 360 degree radial pattern, a sharp stream, and a cone shape. Moreover, the step of delivering a fluid can be achieved with a device comprising an articulating member. Defunctionalizing at least one of the cystic duct or the gallbladder can further comprise applying a vacuum to a lumen of the cystic duct or the gallbladder, applying an adhesive to the lumen of the gallbladder duct or the gallbladder, and/or physically blocking a lumen of the gallbladder duct or the gallbladder. In some instances, the additional steps of altering gallstones and/or removing gallstones can also be performed. Similarly, obstructions can be cleared within the gallbladder. In other aspects of the invention, the method includes the step of visualizing a treatment area. Additionally, the device can be delivered via an endoscope, via a needle, via a guidewire or via a guidance catheter. The method can also include the step of restricting flow from the gallbladder lumen to the gastrointestinal tract, such as by operating a valve to restrict fluid flow. Additionally, the step of defunctionalizing the gallbladder can be performed in situ. The step of defunctionalizing can be achieved by delivering a substance into a space within the gallbladder, such as by delivering a gel or foam. In some instances the delivered substance, such as the gel or foam, can be activated in situ. Moreover, the amount of substance delivered can fill, or substantially fill, the gallbladder lumen either upon delivery or activation. Defunctionalizing can also be achieved by one or more of sclerosing or necrotizing a tissue within the gallbladder, such as by using an ablation technique such as cryoablation, thermal ablation, chemical ablation, radio frequency ablation, ultrasound ablation, and microwave ablation.
[0025] Yet another aspect of the invention is directed to kits for treating biliary disease. Kits can comprise: (a) a device adaptable to deliver to a lumen of a gallbladder or gallbladder duct; and optionally (b) a compound for delivery to a tissue. Additional components of a kit can include, for example, one or more of: a catheter, a needle, a guidewire, and a guidance catheter. Additionally, the kits can include an ablation device. One or more agents can also be included in the kit including, for example, a sclerosing agent, antibiotics, inflammatory agents, anti-inflammatory agents, biocompatible gels, and biocompatible foams. Still other components of the kits can include, for example, one or more of a pair of scissors, a scalpel, a swab, a syringe, a hemostat, a lubricant, a needle, a snare, an antiseptic, and an anesthetic.
[0026] Another aspect of the invention is directed to the use of any of the devices disclosed herein for use in the treatment of biliary disease.
INCORPORATION BY REFERENCE
[0027] All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The novel features of the invention will be set forth with particularity in any claims presented based on this application. A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the invention are utilized, and the accompanying drawings of which:
[0029] FIG. 1 illustrates an overview of the biliary system;
[0030] FIG. 2 illustrates the biliary system with gallstones;
[0031] FIG. 3 illustrates an endoscope accessing the biliary system via the intestinal system;
[0032] FIGS. 4A-E illustrate fluid applicator embodiments;
[0033] FIG. 5 illustrates a gallbladder defunctionalization method with a working fluid whose temperature is altered; and
[0034] FIG. 6 illustrates a gallbladder defunctionalization device in combination with a guidance element.
DETAILED DESCRIPTION OF THE INVENTION
[0035] Devices, systems, methods and kits provided herewith can obviate the need for a plurality of procedures, including, for example: 1) percutaneous cholecystostomy, 2) cholecystectomy, 3) percutaneous trans-hepatic cholangiography (PTHC), and 4) endoscopic retrograde cholangiopancreatography (ERCP). Additionally, disclosed treatment modalities enable treatment of a distal common bile duct 18 obstruction, e.g. secondary to pancreatic carcinoma, cholagiocarcinoma, and/or ampullary carcinoma. As will be appreciated by those skilled in the art, the conventional standard of care for treating biliary disease has been surgical removal of the gallbladder 14 and closure of the cystic duct 16 . While this has proven to be an effective mechanism for permanently eliminating biliary disease and its recurrence, the present invention seeks to accomplish the same end in a less invasive and less costly way. This may be achieved by treating biliary disease without requiring the removal of the gallbladder 14 . Methods and apparatus are described in this application that are intended to effectively treat biliary disease with the gallbladder 14 and cystic duct 16 left in situ by defunctionalizing the gallbladder.
Defunctionalization of the Gallbladder:
[0036] By treating the gallbladder in situ in such a way that the biliary disease necessitating treatment is addressed and the likelihood of recurrence is low or altogether eliminated, the need for additional treatment, e.g. cholecystectomy, may be obviated. One method for achieving these goals may be defunctionalization of the gallbladder. A gallbladder that is treated and remains in situ but is otherwise non-functional may lead to the desired result. Alternatively, for example, this goal may be achieved by altering the configuration of the gallbladder 14 in such a way that the underlying condition is addressed and prevented from recurring. The gallbladder can be accessed by any suitable mechanism including, percutaneously, endoscopically, laparascopically, and the like. Moreover, any of the materials and substances delivered to the gallbladder can be delivered concurrently or sequentially. Delivery of substances can occur sequentially in time or the sequence of delivery can be separated by seconds, minutes, or hours.
[0037] A method of treating biliary disease involves using an endoscope 310 to access a region in the gastrointestinal (GI) tract ( FIG. 3 ) to which the gallbladder 14 is in close proximity 350 , locating the gallbladder 14 , accessing the gallbladder 14 , and then treating the underlying condition that led to the need for intervention ( FIG. 3 ). Treatments may also include, but are not limited to: providing for drainage of the gallbladder 14 and/or the biliary tree, delivering suitable substances or materials, such as antibiotics, inflammatory, and/or anti-inflammatory agents (any of which may be short-term acting, fast acting, or time release), and/or other substances (e.g. adhesives, bioadhesives, etc.) to the gallbladder 14 and/or biliary tree, removing gallstones 20 , facilitating the destruction and subsequent removal of gallstones, clearing obstructions, delivering catheters, delivering stents (drug coated or not drug coated), temporarily or permanently defunctionalizing the cystic duct 16 , temporarily or permanently defunctionalizing the gallbladder 14 . Devices and therapies can be delivered in a single treatment, with minimal likelihood of or necessity for follow-up or repeat procedures.
[0038] Localization of the gallbladder 14 can be performed via endoscopic ultrasound (EUS) by accessing the wall of the GI tract with an endoscope 310 as shown in FIG. 3 . Localization may also be achieved by any other method that visualizes anatomical features, such as fluoroscopy, x-rays, magnetic resonance imaging (MRI), computed axial tomography (CT) scans, ultrasound imaging from outside the body, or any method of anatomical imaging and visualization.
[0039] Once the gallbladder 14 has been located, it may be accessed and/or treated 350 through the wall of the GI tract (or any lumen in proximity to the gallbladder 14 ) with tools and devices (e.g. needles, guidewires, guidance catheters, dilators, shunts, etc.) delivered through or by, for example, an endoscope 310 . Such tools and devices may be inserted down the length of the endoscope's working channel 312 , or loaded onto or near the distal end of the endoscope 310 . Alternately, tools and other devices may be used that do not require the aid of the endoscope for navigation or delivery. Direct visualization may be provided by the endoscope 310 during the procedure, as well as irrigation, suction, and insufflation.
[0040] Though the preferred location for accessing the gallbladder lumen is the duodenum 30 , it may also be readily achieved through the wall of other regions of the GI tract, such as the stomach or the jejunum, for example. Thus, any lumen in close proximity to the gallbladder 14 is a candidate for access to and treatment of the gallbladder 14 and other members of the biliary system.
[0041] In order to defunctionalize the gallbladder 14 , it may be beneficial to sclerose or necrotize the tissue inside the lumen of the gallbladder 14 . This may involve only the tissue within the gallbladder 14 , but it may also include, for example, the tissue comprising the cystic duct 16 , which is the passageway leading into the gallbladder 14 from the common bile duct 18 . Sclerosing or necrotizing the tissue within the gallbladder 14 may be achieved by using any ablating technique, such as cryoablation, thermal ablation, chemical ablation, radio frequency (RF) ablation, microwave ablation, and ultrasound ablation.
[0042] In the case of cryoablation, cold fluids (such as liquids, sprays, mists, and gases) may be applied to the walls of the lumen of the gallbladder 14 with an applicator 420 having a proximal end 402 and distal end 404 ( FIG. 4 ). Any non-solid sclerosing agent may be similarly applied with an applicator. Such fluids may be applied evenly so that the effect is consistent throughout the affected areas, or they may be applied selectively or unevenly. The applicator 420 optionally includes a user controllable valve 440 , as illustrated in FIG. 4E , within its lumen to facilitate control and application of the fluids or gases during the defunctionalization process. The user controllable valve can be positioned proximally from the delivery tip. The applicator 420 can be delivered through a working channel 412 of an endoscope 410 .
[0043] During defunctionalization part or all of the walls may be treated. In order to have the ability to apply therapy anywhere within the gallbladder, it may be necessary to direct the application of such fluids by the applicator 420 at a variety of depths within the gallbladder 14 , and at any or all angular orientations. The applicator 420 has one or more apertures 422 in communication with a central lumen through which fluid 423 or material is delivered. As discussed above, a valve 440 is positioned within the interior lumen of the applicator 420 to provide control of the amount and timing of delivery. Different applicators 420 or nozzles may be useful for achieving this, such as those configurable to direct flow in a 360° radial pattern ( FIG. 4A ), a sharp stream or a cone shape directed forward by the applicator ( FIG. 4B ), or a sharp stream or a cone shape directed sideways by the applicator ( FIG. 4C ). The applicator 420 may be capable of articulating so that it may be selectively aimed ( FIG. 4D ). In order to distinguish treated areas from untreated areas, a pigment may be added to the fluid. Alternately, treated tissue may have a different appearance from untreated tissue due to the resulting sclerosis or necrosis. Applicators may be guided by one or more of a needle, a guidewire, and/or a guidance catheter, and controlled proximally by a clinician, as illustrated in FIG. 6 . Alternately, applicators may navigate freely within the gallbladder. Applicators 620 may be delivered to the gallbladder lumen 14 through the tool channel 612 of an endoscope 610 and may remain within the endoscope during their use, or they may be guided into the gallbladder 14 using alternate guidance elements 630 (e.g. a needle, a guidewire, and/or a guidance catheter). In some instances, directly visualizing the devices and navigational devices used may also be desirable, and may facilitate control and treatment. Visualization may be achieved by any suitable mechanism known in the art, including, for example, endoscopic ultrasound (EUS), or by using a small daughter endoscope (e.g. a cystoscope), or by using catheters incorporating small imaging sensors at the distal end (e.g. Avantis' Third Eye) and fiber optic imaging bundles (e.g. Boston Scientific's SpyGlass). Visualization and guidance may also be achieved via external imaging methods, such as fluoroscopy (with or without the use of contrast agent), ultrasound, X-ray, etc. The outer diameter of the applicator 620 is smaller than a mammalian esophagus and can be larger than, for example, the diameter of the cystic duct 16 as illustrated.
[0044] Additionally, cryoablation can be used to effect treatment by flooding the entire gallbladder lumen or duct lumen with a fluid 517 ( FIG. 5 ). Localization of the gallbladder 14 can be performed via endoscopic ultrasound (EUS) by accessing the wall of the GI tract with an endoscope 510 as shown in FIG. 5 . Thereafter, this can, for example, be performed with a liquid, but a gas may also be used. Filling the lumen, or substantially filling the lumen, with such a working fluid 517 ensures even distribution of treatment. The fluid or gas may be initially a first temperature and then be altered such that the temperature achieves a desired therapeutic level. An applicator for this approach may have one or more apertures 522 for introducing fluids 587 into the gallbladder and optionally withdrawing fluids 586 from the gallbladder. A stirrer 524 can be provided that stirs or mixes the fluid or gas 517 that is delivered into the lumen. This feature may ensure uniformity of properties throughout the working fluid or gas and increase the rate of temperature change ( FIG. 5 ). The working fluid 517 may be left in place, or actively withdrawn after treatment is completed. As will be appreciated from FIG. 5 , access to the gallbladder 14 can be achieved through the wall of the duodenum 30 . The outer diameter of the applicator 520 is smaller than a mammalian esophagus and larger than, for example, the diameter of the cystic duct 16 as illustrated.
[0045] In cases when the activatable material, such as a working fluid or gas 517 , remains in the gallbladder lumen or duct lumen, it may be selected so that it becomes a biocompatible gel or foam once it has reached a specific state, such as a low or high temperature, or contact with an activating agent, or when sufficient time has passed. The activating agent may be selected to be bile, so that the gel or foam becomes further activated in the presence of flow of bile. In this way, it a self-sealing mechanism is established. Such a foam or gel may also be selected so that it is bioabsorable, and is self dissipating after a desired period of time.
[0046] An amount of fluid, gas, or material delivered as described throughout can be such that it fills the gallbladder, substantially fills the gallbladder (e.g., fills more than 50% of the gallbladder, more than 75% of the gallbladder, more than 85% of the gallbladder, more than 90% of the gallbladder, more than 95% of the gallbladder, or more than 99% of the gallbladder) or is activatable to fill or substantially fill the gallbladder. Alternatively, in some instances, e.g., where a vacuum is applied, the amount of fluid, gas, or material delivered as described throughout can be such that it coats the interior lumen of the gallbladder, or substantially coats the interior lumen of the gallbladder (e.g., coats more than 50% of the gallbladder, more than 75% of the gallbladder, more than 85% of the gallbladder, more than 90% of the gallbladder, more than 95% of the gallbladder, or more than 99% of the gallbladder).
[0047] In contrast to cryoablation, thermal (or heat) ablation may be applied to effect treatment. The same methods outlined above for cryoablation may also be used in the application of therapies based on heat ablation. This includes using working fluids that may be applied using a spray applicator, working fluids that completely fill, or substantially fill, the lumen, working fluids that are introduced at a non-therapeutic temperature and then altered so that the temperature is increased to therapeutic levels, and fluids that becomes gels or foams at a desired elevated temperature. These techniques may be used with any fluid or non-solid sclerosing agents in addition to those described above. In another approach thermal ablation is achieved through the use of infrared light to heat the tissue comprising the gallbladder 14 and/or cystic duct 16 .
[0048] Another alternate method of defunctionalizing the gallbladder 14 involves applying a vacuum. After occlusion of, for example, the cystic duct 16 , application of a vacuum to the gallbladder lumen causes it to collapse to a smaller volume. The internal volume of the gallbladder lumen may be eliminated altogether. Making this collapsed volume permanent or semi-permanent results in the goal of defunctionalizing the gallbladder 14 . Substances may be applied to the gallbladder walls prior to the application of vacuum, such as a bioadhesives, sclerosing agents, or fluids used in cryo- or thermal ablation. These fluids may serve to enhance the outcome or improve the efficacy of the treatment.
[0049] The devices and methods disclosed herein facilitate defunctionalizing the gallbladder without the need for surgery.
Kits:
[0050] All of the devices required to deliver and install a conduit, treat and/or defunctionalize the gallbladder, may be packaged in a kit. Bundling all devices, tools, components, materials, and accessories needed to perform these procedures into a kit may enhance the usability and convenience of the devices, and also improve the safety of the procedure by encouraging clinicians to use the items believed to result in the best outcomes. The kit may be single-use or reusable, or it may incorporate some disposable single-use elements and some reusable elements. The kit may contain, but is not limited to, the following: implantable and/or non-implantable devices; delivery devices (e.g. needles, guidewires, guidance catheters, dilators, etc.); balloon inflation/deflation accessories; syringes; fluid flow, temperature, and pressure measurement instruments; scissors; scalpels; clips; ablation catheters; endoscopic tools (e.g. lithotripsy devices, snares, graspers, clamps, forceps, etc.); fluids; gels; gas cartridges adaptable to communicate with the devices. The kit may be supplied in a tray, which organizes and retains all items so that they can be quickly identified and used.
Description of Other Uses
[0051] The techniques and devices described in this application may prove beneficial in applications beyond their initial use in the treatment of biliary disease.
[0052] For example, they may prove to be an effective mechanism of treating cholangitis (infection of the common bile duct 18 ). This condition is usually bacterial, and occurs when the bile duct is blocked by gallstones 20 ′ or a tumor. Traditional treatment involves the insertion a stent or drainage catheter into the common bile duct 18 to allow bile to drain into the duodenum from locations above the obstruction. Placement of a conduit into the gallbladder 14 may allow for an alternate method of draining bile and/or other fluids into the duodenum. Any blockage in the common bile duct 18 between the entrance of the cystic duct and the duodenum may be treated in this way. See FIG. 2 .
[0053] Another use of the devices and techniques described herein is for drainage of any body lumen into another body lumen in proximity, for example, the drainage of pancreatic pseudocysts.
[0054] While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is intended that the following claims define the scope of the invention and that methods and structures within the scope of these claims and their equivalents be covered thereby. | The application discloses devices, systems, kits and methods for treating biliary disease. Device comprise, for example, a component configured for deployment to a lumen of a gallbladder or gallbladder duct which has a proximal end and a distal end with a lumen extending therethrough and a fluid or gas delivery apparatus at its distal end. | 0 |
CROSS REFERENCE TO RELATED PATENT APPLICATION
The present patent application claims the right of priority under 35 U.S.C. §119 (a)-(d) of German Patent Application No. 101 004 04.4, filed Jan. 5, 2001.
FIELD OF THE INVENTION
The present Application relates to a process for producing polycarbonate by the transesterification and to the recovery of diaryl carbonate produced thereby.
SUMMARY OF THE INVENTION
The present Application relates to a process for producing polycarbonate by the transesterification in the melt of diaryl carbonates with dihydroxy aryl compounds. The vapor streams generated in the course of the process contain diaryl carbonate (DAC) that in accordance with the invention is recovered in high quality. The recovered DAC may be reused in the transesterification process. The monohydroxy aryl compounds isolated in high purity in course of the claimed process may be reused either for the production of diaryl carbonate as well as for the production of dihydroxy aryl compounds.
BACKGROUND OF THE INVENTION
For the production of polycarbonate by transesterification in the melt, dihydroxyaryl compounds are reacted with diaryl carbonate, wherein the monohydroxy aryl component is separated from the diaryl carbonate in the sense of a transesterification reaction. This condensation reaction initially results in the formation of low molecular weight polycarbonate oligomers, which react further to form high molecular weight polycarbonates as the separation of monohydroxy aryl components proceeds. The progress of the reaction can be assisted by the use of suitable catalyst. Moreover, in order to obtain high molecular weights, it is necessary to remove the monohydroxy aryl component which is formed from the reaction space and thus to assist the progress of the reaction. Various measures are implemented industrially in order to efficiently remove the monohydroxy aryl component, such as increasing the temperature of the reaction medium, reducing the pressure in the gas space over the reaction medium, flashing the reaction mixture into a gas space under reduced pressure, introducing inert gases or the vapors of volatile solvents as entraining agents, and the use of special reaction apparatuses which assist the removal of the monohydroxy aryl component by a continuous renewal of the surface, particularly if highly viscous melts are produced. In all the aforementioned embodiments, gaseous vapor streams are produced, which mainly contain the monohydroxy aryl component of the diaryl carbonate. Depending on the type of dihydroxy aryl compound used and on the diaryl carbonate used, the mass of the vapor stream which is obtained can be greater than the mass of the polycarbonate which is obtained. Reuse of the vapor stream obtained is therefore necessary in order to achieve economic production of polycarbonate by the method of transesterification in the melt.
One very important industrial process is the production of high molecular weight polycarbonate from 2,2-bis(4-hydroxyphenyl)-propane bisphenol A; hereinafter called BPA) and diphenyl carbonate hereinafter called DPC). In this case, the aforementioned vapor streams mainly consist of phenol. The phenol which is obtained in the course of this process can be reused in the sense of a recycling operation for producing DPC, which has been published for the first time in Schnell Chemistry and Physics of Polycarbonates, Polymer Reviews, H. Schnell, Vol. 9, J. Wiley and Sons, Jnc (1964). Further details to the reuse of the phenol as obtained are found for example in WO 93/3084 and LU A 88569. LU A 88564 also describes the use of the phenol obtained for the production of BPA by reaction with acetone. Both for the production of DPC and for the production of BPA, stringent demands are imposed on the purity of the phenol used in order to obtain products of high quality.
U.S. Pat. No. 5,922,827 describes a process for the reuse of the phenol from the transesterification of diphenols and diaryl carbonates. The phenol obtained is used there for producing diaryl oxalate by conversion of dialkyl oxalates by transesterifications into diaryl oxalates which in turn is converted by decarbonylation into diaryl carbonate.
There is no mention of the reuse of DAC in the above patent, however. In U.S. Pat. No. 6,277,945 B1 as well as Japanese Specifications JP 2000053759 A and JP 2000128976 A, phenol is also recovered from the transesterification process and is used for the production of BPA or DPC. In EP A 992 522, a monohydroxyaryl compound is likewise recovered from the transesterification process, but is only used as a solvent/support for the catalyst which is added.
In the practical production of polycarbonates, it has been shown that in addition to the monohydroxy aryl compound of the diaryl carbonate, which is the main component, the vapor streams also contain other components which are either present in the reaction medium directly or which are formed under the prevailing reaction conditions by secondary reactions from components of the reaction medium. Examples of secondary components such as these which can be formed include diaryl carbonates, dihydroxy aryl compounds, catalyst residues or secondary products of spent catalysts, as well as cleavage and rearrangement products of the diaryl carbonate used and of the dihydroxy aryl compounds used, and secondary products thereof. In the case of the industrially important synthesis of polycarbonates from BPA and DPC, the vapor streams contain, in addition to phenol, secondary components such as DPC, BPA, low molecular oligomers from BPA and DPC phenyl salicylate, isopropenylphenol and dimers and oligomers thereof, hydroxyindanes, hydroxychromanes, catalyst residues and secondary products thereof. In particular, the content of DPC in the vapor streams may, under some polycondensation reaction conditions, be greater than 5% by weight in the vapor streams. In the conventional process, this valuable substance is thus lost in not inconsiderable amounts.
Furthermore, additional by-products may also occur in the vapor streams under the prevailing conditions, even after the separation of the polycarbonate, due to cleavage and/or recombination reactions of the aforementioned secondary components. Thus, for example, the reaction of isopropenylphenol and phenol in the vapor streams may result in the formation of BPA.
In principle, separation of the aforementioned secondary components, such as isopropenylphenol, phenyl salicylate or hydroxyindanes, from the polycarbonate melt via the gas phase is desirable, since a higher purity of the polycarbonate obtained would be achieved by the removal of these components. However, the presence of these secondary components in the vapor streams means that the phenol obtained from the condensation of the vapor streams cannot be used directly for producing DPC or BPA or for other chemical reactions, since extremely high purity criteria are generally imposed on the phenol used for reactions such as these. High purity phenol may in fact be obtained from the vapor streams by customary purification methods such as simple distillation or recrystallisation, but valuable substances such as DPC, which are present as secondary components, are not isolated for reuse by such methods.
The above processes therefore have the disadvantage that the DPC which is used in excess is incinerated with the bottom product which remains from the recovery of phenol by distillation. DPC may be present in the bottom product at a content of about 90% by weight, which therefore results in a considerable loss of DPC.
Attempts to obtain highly pure DPC by overhead distillation have generally resulted in failure, on account of the secondary reactions which occur at the high bottom product temperatures which are required.
Thus the object of the present invention, starting from the prior art was to provide a process for producing polycarbonate by means of transesterification in the melt, which makes it possible to recover unreacted diaryl carbonate with high purity from the vapor streams and which at the same time considerably reduces the consumption of raw materials.
Ideally, success should be achieved with a process such as this in separating the vapor streams from the production of polycarbonates by means of transesterification in the melt by a suitable combination of purification operations so that valuable materials (which are generally the monohydroxy aryl compound of the diaryl carbonate and the diaryl carbonate, and in the situation exemplified, namely the production of polycarbonate from BPA and DPC, these are phenol and DPC) are isolated at high yield, wherein the monohydroxy aryl compound which is obtained is of sufficient purity for the production of the corresponding diaryl carbonate and the isolated diaryl carbonate is of sufficient purity to be recycled as a raw material directly to the polycarbonate synthesis comprising transesterification in the melt, without impairing the quality of the polycarbonate. Ideally, secondary components from the process should be removed as completely as possible, and the amount of non-reusable residual substances from the work-up of the vapor, which have to be disposed of, should be <5%, preferably <4%, most preferably <3.5% with respect to the amount introduced into the vapor work-up stage, in order to achieve a low level of unwanted losses of material.
BRIEF DESCRIPTION OF THE FIGURE
FIG. 1 illustrates the process of the invention.; The reaction vapors are fed into the 1st column at the mid-height ( 1 ) thereof, are separated overhead with the high-purity phenol ( 2 ) and are recycled, e.g. to the diaryl carbonate synthesis stage. The bottom product ( 3 ) is in turn fed at mid-height into a second column, in which the high-boiling by-products are separated via the bottom product ( 4 ), and the remaining constituents are fed overhead and at mid-height ( 6 ) into a third column from which the low-boiling fractions are then taken off overhead ( 7 ) and are fed together with the bottom product from column 2 to a resin incineration stage, whilst the bottom product from the third column, which consists of diaryl carbonate of outstanding Hazen color, is taken off via ( 8 ) and is recycled directly to the transesterification process. Alternatively, it is possible to take off the diaryl carbonate as described above as a side stream from the third column.
DETAILED DESCRIPTION OF THE INVENTION
Surprisingly, a process for producing polycarbonate has now been identified which achieves this object. The process according to the invention is characterized by a step comprising the work-up of the combined vapor streams, which makes it possible to separate the monohydroxy aryl compound, diaryl carbonate and the byproducts from the reaction vapors by distillation, wherein the surprisingly high quality of the substances which are recovered in this manner enables them to be reused directly for the synthesis of diaryl carbonate or a dihydroxy aryl compound (monohydroxyaryl compound) or for transesterification in the melt (diaryl carbonate).
The present Application accordingly relates to a process for producing polycarbonate by the transesterification of a diaryl carbonate and an aromatic dihydroxy aryl compound to form oligo-/polycarbonate by splitting of the monohydroxyaryl compound, wherein the monohydroxy aryl compound which is produced can be reused for producing diaryl carbonate or a dihydroxyaryl compound, which in turn can be used in the transesterification process, characterized in that the monohydroxy aryl compound is separated by distillation in such a way that the excess diaryl carbonate is simultaneously recovered in a quality such that it can be recycled directly to the melt transesterification process.
The process is illustrated schematically, and in simplified form, in the following flow diagram:
Separation according to the invention of the monohydroxy aryl compounds and of the diaryl carbonate is effected in a special sequence of separation stages which differs from customary distillation trains in that the diaryl carbonate in the last column is not taken off overhead, but instead the bottom product of the column is taken off in high purity. Surprisingly, it is also possible as an alternative to effect separation of the diaryl carbonate by taking off a side stream from the last column.
The sequence of separation stages which is familiar to one skilled in the art is in case of the industrially important transesterification process to produce polycarbonate from Bisphenol A (BPA) and diphenyl carbonate (DPC) one in which the low-boiling phenol is taken off overhead from the 1st column, the somewhat less volatile impurities which vaporize are separated overhead from the 2nd column, and the diaryl carbonate is distilled from the 3rd column overhead, whilst the heavy-boiling impurities remain in the bottom product of the 3rd column. High-purity diaryl carbonate cannot be obtained by this process, however.
Surprisingly, the possibility of taking off diaryl carbonate of outstanding quality from the bottom product respectively from a side stream enables a lower column temperature to be used, and prevents the decomposition of diaryl carbonates and others of the present compounds, which is otherwise observed and which has hitherto prevented the effective recovery by distillation of highly pure diaryl carbonate from the vapors.
The sequence of separation stages according to the invention is illustrated in FIG. 1 .
The reaction vapors are fed into the 1 st column at the mid-height ( 1 ) thereof, are separated overhead with the high-purity monohydroxy aryl compound ( 2 ) and are recycled, e.g. to the diaryl carbonate or the dihydroxy aryl compound synthesis stage. The bottom product ( 3 ) is in turn fed at mid-height into a second column, in which the high-boiling by-products are separated via the bottom product ( 4 ), and the remaining constituents are fed overhead and at mid-height ( 6 ) into a third column from which the low-boiling fractions are then taken off overhead ( 7 ) and are fed together with the bottom product from column 2 to a resin incineration stage, whilst the bottom product from the third column, which consists of diaryl carbonate of outstanding Hazen color and Quality is taken off via ( 8 ) and is recycled directly to the transesterification process to produce polycarbonate. Alternatively, it is possible to take off the diaryl carbonate as described above as a side stream from the third column.
The purity of the monohydroxy aryl compound which is separated overhead in the process according to the invention is >99%, preferably >99.8%, most preferably >99.95%. The purity of the diaryl carbonate ( 8 ) is >99.0%, preferably >99.5%, most preferably >99.9%. The diaryl carbonate which is thus recovered is characterized by a Hazen color less than 5.
The secondary component which is separated as a purge in the sense of the process amounts to <5%, preferably <4%, most preferably <3.5%, with respect to the amount of vapors introduced into the vapor work-up stage.
Therefore, whereas in the process comprising the removal of monohydroxy aryl compound from the vapor streams of the transesterification process which was known hitherto, the remaining residues were incinerated, including the diaryl carbonate present therein, in the process according to the invention the diaryl carbonate is also isolated in high purity and is recycled to the process. This results in a saving of raw materials and in a reduction both of off-gases and of energy.
Diphenols which are suitable for the process according to the invention are those of formula (1):
wherein X=a C 1 -C 8 alkylidene or cycloalkylidene, S, SO 2 , O, C═O or a single bond, R═CH 3 , Cl or Br and n=zero, 1 or 2.
Examples of preferred diphenols include:
4,4′-dihydroxydiphenyl,
α,α′-bis-(4-hydroxyphenyl)-m-diisopropylbenzene,
4,4′-dihydroxydiphenyl sulphide,
2,2-bis-(4-hydroxyphenyl)-propane,
2,2-bis-(3,5-dimethyl4-hydroxyphenyl)-propane,
2,2-bis-(3,5-dichloro-4-hydroxyphenyl)-propane,
2,2-bis-(3,5-dibromo-4-hydroxyphenyl)-propane,
1,1-bis-(4-hydroxyphenyl)-cyclohexane, and
1,1-bis-(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane.
Phenols which are particularly preferred from those mentioned above are 4,4′-dihydroxy-diphenyl, α,α′-bis-(4-hydroxyphenyl)-m-diisopropylbenzene, 2,2-bis-(4-hydroxy-phenyl)-propane and 1,1-bis-(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane. 2,2-bis-(4-hydroxyphenyl)-propane is most particularly preferred.
When mono hydroxy aryl compounds recovered from the 1st column are used directly for the production of dihydroxy aryl compounds, it has to be ensured that the aryl compounds which are used each time bear the same substituents. Either one dihydroxy aryl compound of formula (1) can be used for the formation of homopolycarbonates, or a plurality of dihydroxy aryl compounds of formula (1) can be used for the formation of copolycarbonates.
Diaryl carbonates in the sense of present invention are di-C 6 -C 14 aryl carbonates, preferably carbonates of phenol or alkyl-substituted phenols, namely diphenyl carbonate or dicresyl carbonate, for example. 1.01 to 1.30 mol, preferably 1.02 to 1.2 mol, of diaryl carbonates diesters are used with respect to 1 mol of dihydroxy aryl compound.
The diaryl carbonates are produced in the known manner (EP A 0 483 632, 0 635 476, 0 635 477 and 0 645 364) by the phosgenation (in solution, in the melt or in the gas phase) of monohydroxy aryl compound.
The diaryl carbonates can also be produced by the direct oxidation of monohydroxy aryl compounds with CO and oxygen or other oxidising agents (see DE OS 27 38 437, 28 15 512, 27 38 488, 28 15 501, 29 49 936, 27 38487 etc., for example).
The polycarbonates can be deliberately branched, in a controlled manner, by the use of small amounts of branching agents. Examples of some suitable branching agents are as follows:
phloroglucinol,
4,6-dimethyl-2,4,6-tri-(4-hydroxyphenyl)-heptane,
1,3,5-tri-(4-hydroxyphenyl)-benzene,
1,1,1-tri-(4-hydroxyphenyl)-ethane,
tri-(4-hydroxyphenyl)-phenylmethane,
2,2-bis-[4,4-bis-(4-hydroxyphenyl)-cyclohexyl]-propane,
2,4-bis-(4-hydroxyphenyl-isopropyl)-phenol,
2,6-bis-(2-hydroxy-5′-methyl-benzyl)-4-methylphenol,
2-(4-hydroxyphenyl)-2-(2,4-dihydroxyphenyl)-propane,
hexa-(4-(4-hydroxyphenyl-isopropyl)-phenyl)-orthoterephthalic acid ester,
tetra-(4-hydroxyphenyl)-methane,
tetra-(4-(4-hydroxyphenyl-isopropyl)-phenoxy)-methane,
isatin-bis-cresol,
pentaerythritol,
2,4-dihydroxybenzoic acid,
trimesic acid,
cyanuric acid,
1,4-bis-(4′,4″-dihydroxytriphenyl)-methyl)-benzene, and
α,α′,α″-tris-(4-hydroxyphenyl)-1,3,4-triisopropenylbenzene.
1,1,1-tri-(4-hydroxyphenyl)-ethane and isatin-bis-cresol are particularly preferred.
The 0.05 to 2 mol % of branching agents which are optionally used in conjunction with respect to the dihydroxy aryl compound used can be introduced together with the dihydroxy aryl compound.
It must be ensured that the reaction components for the first step, namely transesterification, i.e. the dihydroxy aryl compound and the diaryl carbonate are free from alkali and alkaline earth cations, although amounts of alkali and alkaline earth cations less than 0.1 ppm can be tolerated. Pure diaryl carbonate or dihydroxy aryl compound of this type can be obtained by recrystallisation, washing or distilling the diaryl carbonate or dihydroxy aryl compound. In the process according to the invention, the content of alkali and alkaline earth cations should be <0.1 ppm, both in the dihydroxy aryl compound and in the diaryl carbonate.
The transesterification reaction between the aromatic dihydroxy aryl compound and the diaryl carbonate in the melt is preferably conducted in two stages. In the first stage of the industrially applied process of producing polycarbonate by reacting diphenyl carbonate (DPC) with bisphenol A (BPA), at normal pressure, fusion occurs of the BPA and of the DPC at temperatures from 80-250° C., preferably 100-230° C., most preferably 120-190° C. in 0-5 hours, preferably 0.25-3 hours. After adding the catalyst, the oligocarbonate is produced from the DPA and the DPC by distilling off the phenol by applying a vacuum (up to 2 mbar) and increasing the temperature (up to 260° C.). The bulk of the vapor is produced from the process in the course of this procedure. The oligocarbonate which is thus produced has an average molecular weight Mw (as determined by measuring the relative solution viscosity in dichloromethane or in mixtures of identical weights of phenol/o-dichlorobenzene calibrated by light scattering) within the range from 2000 to 18,000, preferably from 4000 to 15,000.
In the second stage, the polycarbonate is produced by polycondensation, by further increasing the temperature to 250-320° C., preferably to 270-295° C. at a pressure of <2 mbar. The remainder of the vapors is removed from the process in the course of this procedure. The combined vapors are subsequently worked up according to the invention, and phenol and DPC are preferably recycled to the process for example phenol into the production of BPA or DPC, DPC back into the polycarbonate production, but can be used for other purposes, too.
Catalysts in the sense of the process according to the invention include all inorganic or organic basic compounds, for example: lithium, sodium, potassium, calcium, barium and magnesium hydroxides, carbonates, halides, phenolates, bisphenolates, fluorides, acetates, phosphates, hydrogen phosphates and borohydrides, nitrogen and phosphorus containing compounds such as tetramethylammonium hydroxide, tetramethylammonium acetate, tetramethylammonium fluoride, tetramethylammonium tetraphenylborate, tetraphenylphosphonium fluoride, tetraphenylphosphonium tetraphenylborate, tetraphenylphosphonium phenolate, dimethyldiphenylammonium hydroxide, tetraethyl ammonium hydroxide, DBU, DBN or guanidine systems such 1,5,7-triazabicyclo-[4,4,0]-dec-5-ene, 7-phenyl-1,5,7-triazabicyclo-[4,4,0]-dec-5-ene, 7-methyl-1,5,7-triazabicyclo-[4,4,0]-dec-5-ene, 7,7,-hexylidene-di-1,5,7-triazabicyclo-[4,4,0]-dec-5-ene, 7,7′-decylidene-di-1,5,7-tri-azabicyclo-[4,4,0]-dec-5-ene, 7,7′-dodecylidene-di-1,5,7-triazabicyclo-[4,4,0]-dec-5-ene or phosphazenes such as the phosphazene base P 1 -t-Oct=tert.-octylimino-tris-(dimethylamino)-phosphorane, the phosphazene base P 1 -t-butyl=tert.-butylimino-tris-(dimethylamino)-phosphorane, or BEMP=2-tert.-butylimino-2-diethylamino-1,3-dimethyl-perhydro-1,3-diaza-2-phosphorine. Tetra-phenylphosphonium phenolate and/or sodium hydroxide, -phenolate and -bisphenolate are particularly preferred.
These catalysts are used in amounts of 10 −2 to 10 −8 mol with respect to 1 mol dihydroxy aryl compound.
The catalysts can also be used in combination (two or more) with each other.
If alkali/alkaline earth metal catalysts are used, it may be advantageous to add the alkali/alkaline earth metal catalysts later (e.g. after the synthesis of oligocarbonate by polycondensation in the second stage). The alkali/alkaline earth metal catalyst can be added, for example, as a solid or as a solution in water, phenol, oligocarbonate or polycarbonate. The use in conjunction of basic alkali or alkaline earth metal catalysts is not at variance with the aforementioned purity requirements for the reactants, since specific amounts of defined special compounds are added here.
The reaction of the dihydroxy aryl compound and of the diaryl carbonate to form polycarbonate in the sense of the process according to the invention can be conducted batch-wise or continuously, and is preferably conducted continuously, for example in agitated vessels, thin film evaporators, falling film evaporators, cascades of agitated vessels, extruders, kneaders, simple disc reactors and high-viscosity disc reactors.
The aromatic polycarbonates produced by the process according to the invention should have average molecular weights Mw from 18,000 to 80,000, preferably from 19,000-50,000, as determined as determined by measuring the relative solution viscosity in dichloromethane or in mixtures of identical weights of phenol/o-dichlorobenzene calibrated by light scattering.
Within the industrially applicable process of producing polycarbonate via transeterification of BPA and DPC, the separation of DPC and phenol according to the invention is effected from the vapor streams, generally under the following conditions (see FIG. 1 ):
In column 1 of the separation sequence, phenol is produced from the feed of vapors. This column operates within a pressure range of 5-100 mbar, which corresponds to a temperature range of 65° C. at the top to 220° C. in the bottom product of the column. The preferred working range is 20-30 mbar, with a corresponding temperature range of 80-190° C. The requisite reflux ratio in order to obtain high-purity phenol falls within the range from 0.2-2, preferably 0.2-0.5.
Column 2, which is employed for the removal of high-boiling fractions, also operates within a pressure range of 5-100 mbar, which is equivalent to a temperature range of 140-230° C. over the column. The pressure range is most preferably 10-20 mbar here also, i.e. corresponding to a temperature range of 160-200° C.
The working range of column 3, from which DPC as a bottom product, also falls within the pressure range from 5-100 mbar, corresponding to temperatures between 120 and 220° C. The preferred working range falls between 15 and 25 mbar, corresponding to a preferred temperature range from 135-195° C. In order to separate components with intermediate boiling ranges, the reflux ratios fall between 2 and 40, and are preferably within the range from 10-20.
The purity of the phenol is then >99%, preferably >99.8%, most preferably >99.95%, and that of the DPC is >99.0%, preferably 99.5%, most preferably >99.9%.
The examples below illustrate the process according to the invention, but do not limit it.
EXAMPLES
Example 1
The reaction vapors from a pilot plant for the production of SPC were produced at a rate of 22.8 kg/hour. Separation of phenol was effected by means of a column of 180 mm diameter. The concentrating part and stripping part were packed with fine vacuum packing. Condensation was effected in a condenser which was operated using cooling water at 40° C. The top pressure of the phenol column was 23 mbar, corresponding to a boiling temperature of 83° C. The reflux ratio was selected as 0.54. The purity of the phenol was >99.95%. The bottom product still contained 1% phenol at a temperature of 175° C. The DPC content was 94.9%, and the mass flow thereof was 4 kg/hour. The column was operated with a steam-heated falling film evaporator.
The bottom product was fed into the middle of the column for discharging the high-boiling fraction. The concentrating and stripping parts of the column each consisted of 1 meter of laboratory fine vacuum packing, and the column diameter was 80 mm over the entire length thereof. Condensation was effected using water at 80° C. The top pressure of 18 mbar corresponded to a temperature of 174° C. The phenol concentration increased to 3% as the reaction progressed, and the DPC concentration of the distillate was 96.8%.
At a bottom product temperature of 198° C., the discharged mass flow of bottom product of 338 g/hour still contained 48% DPC. After-reaction still always resulted in a phenol concentration in the bottom product of 0.8%. The column was heated via a glass falling film evaporator, which was supplied with diethylene glycol vapor at 220° C. The distillate from the high-boiling fraction column was fed to the DPC column. 2.5 m of laboratory fine vacuum packing were installed in the concentrating part of the column, and 2 m of laboratory fine vacuum packing were installed in the stripping part. Condensation was again effected using water at 80° C., and evaporation of the bottom product was again effected in a glass falling film evaporator. A vacuum of 34 mbar was applied to the column top, the top temperature was 170° C., and the reflux ratio was 15. In the distillate, which was discharged at 90 g/hour, the DPC concentration was 45%. After-reaction of the oligomers in the high-boiling fraction column resulted in an increase in the mass flow of both phenol and DPC during the test. The mass flow of DPC of 3500 g/hour which was discharged as the bottom product at 195° C. was recycled to the reaction. After a recycle period of 1 week, the final polycarbonate product had a concentration >99.95% and a Hazen color of about 5, and no change in the color thereof was determined.
The behaviour of the diphenyl carbonate during transesterification was employed as an additional characteristic for assessing the suitability thereof for producing polycarbonate. The reaction mixture comprising 17.1 g (0.075 mol) 2,2-bis-(4-hydroxyphenyl)-propane and 17 g (0.07945 mol) of the diphenyl carbonate to be tested was treated in a 100 ml flask with 0.0001 mol % NaOH (with respect to 2,2-bis-(4-hydroxyphenyl)-propane) as a 1% aqueous solution, and was then placed in an oil bath which had been preheated to 270° C. The temperature at which separation of phenol commenced was determined, as was the time after immersion in the oil bath to the commencement of said separation; these parameters were compared with standard values (given below in brackets). Distillation of phenol from the reaction mixture comprising diphenyl carbonate which had been obtained as the bottom product commenced at 257° C. (<260° C.) after 12.5 minutes (<15 minutes). Based on the analysis results, on the pilot plant test results and on its behaviour during transesterification, the diphenyl carbonate produced in the sequence of separations by distillation was thus suitable for the production of polycarbonate.
Example 2
Side Stream Take-off of DPC
The quantitative and operating conditions in the phenol column corresponded to those of Example 1. The difference was that only 3 kg/hour of the bottom product from the phenol column was fed to the high-boiling fraction separation stage, the excess being discarded. The operating conditions of the high-boiling fraction column were altered to a top pressure of 12 mbar, which corresponded a temperature of 163° C. In the bottom product, at a DPC concentration of 52%, the temperature was 190° C. The mass flow of bottom product was 251 g/hour, corresponding to the conditions in Example 1. The distillate from the high-boiling fraction—column was fed to the DPC column. The rate of distillate take-off from the DPC column was 65 g/hour, which therefore approximated to the conditions in Example 1. The variation consisted of taking off DPC as a vapor above the falling film evaporator. The mass flow of condensed DPC was 2.6 kg/hour, the concentration was >99.95% and the Hazen color was <5. Side stream condensation was effected using water at 80° C., and DPC was discharged into interchangeable vessels. Positive results were obtained from the standard transesterification test. The starting temperature was 256° C., and the start time was 12.5 minutes. The excess mass flow of 84 g/hour which was taken off with the bottom product, which was necessary for the operation of the falling film evaporator, exhibited a slight yellow hue due to its long residence time in the falling film evaporator.
Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims. | An improvement to the melt transesterification reaction of diaryl carbonate with dihydroxy aryl compound is disclosed. The improvement entails the following steps (i) introducing the resulting vapor stream at the mid-height of a first distillation column, and (ii) separating the vapor stream into a top product containing high purity monohydroxy aryl compound and a first bottom product, and (iii) recycling the high purity monohydroxy aryl compound of (ii) to the reaction, and (iv) introducing the first bottom product at mid-height of a second distillation column, and (v) separating said first bottom product into high boiling bottom by-product and overhead remaining constituents, and (vi) introducing the overhead remaining constituents at mid-height of a third distillation column, and (vii) separating said overhead remaining constituents into overhead low-boiling fractions and bottom or product side stream that contains diaryl carbonate product, and (viii) recycling the diaryl carbonate product directly to the transesterification reaction. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to method for producing a magnetic recording medium, and more particularly relates to improvements in production of a magnetic recording medium such as a magnetic disk by a process including formation of an anodic oxide layer on an Al or Al-base alloy substrate and precipitation via electrolysis of magnetic substance in pores formed in the anodic oxide layer.
Production of a magnetic recording medium by the above-described process is well known from, for example, Japanese Patent Publication No. Sho. 51-21562 and its products are widely accepted as well suited for use in perpendicular magnetic recording system. In the above-described process, the substrate as an electrode is twice subjected to electrolysis and, for this reason, power has to be supplied to the substrate.
To this end, use of an aluminium lead is conventionally employed in general in connection with a doughnut shaped substrate. More specifically, a thin, high purity aluminium lead is attached to the inner or outer periphery of a substrate by welding. A number of substrates are arranged side by side in an electrolytic bath with their aluminium leads being connected to a common power source so as to act as one electrode during electrolysis. The other electrode is formed by counter plates arranged in the electrolytic bath spacedly facing the group of substrates. The electrolytic bath contains oxalic acid or sulfuric acid soultion.
Despite merits derived from use of the aluminium leads, this power supply system is inevitably accompanied by several drawbacks. In order to obtain a uniform covering layer on each substrate, a large distance should be left between the group of substrates and the counter plates thereby inevitably enlarging the size of the electrolytic bath. Such an enlarged size of the electrolytic bath causes increased installation cost and large consumption of the electrolyte. Difficulty in attachment of the aluminium leands and their reliable insulation makes the process quite unsuited for mass-production. After detachment of the aluminium lead, the substrates have to be subjected to removal of welding scars. In addition, when the aluminium lead is attached to the inner periphery of the substrate, a shade in treatment may be left of the covering layer near the spot of the attachment since presence of the aluminium lead tends to bar smooth formation of the covering layer.
With the above-described process, further, the surface of the product, i.e. the magnetic recording material is totally covered by an insulating alumite layer. When electrostatic accumulation occurs on the magnetic recording medium during its usage, total presence of such an insulating alumite layer hinders smooth discharge of electrostatic accumulation since there is no possibility of grounding. Such electrostatic accumulation often causes generation of harsh noises at pick-up by a magnetic head. Generation of such noises is in particular significant and serious when the magnetic recording medium is driven for rotation in a relatively dry environment.
SUMMARY OF THE INVENTION
It is the primary object of the present invention to remove all the troubles encountered in the prior art due to use of aluminium leads for the powder supply in this environment.
It is another object of the present invention to prevent occurrence of electrostatic accumulation on a produced magnetic recording medium even when used in a highly dry environment.
In accordance with the first aspect of the present invention, a plurality of substrates are mounted at equal intervals to a combination shaft made up of several separable components, the combination shaft is connected to a given power source, counter plates are arranged between adjacent substrates surrounding the combination shaft and the combination shaft with the substrates and the counter plate in an electrolytic bath for rotation during electrolysis.
In accordance with the second aspect of the present invention, each substrate is clamped between a pair of holders in a manner such that a specificed annular region around its center hole should be covered by opposing end of the holders, the conductive sections of the holders are connected to a given power source and the substrate with the holders is placed in an electrolytic bath facing a counter plate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are perspective and side views of one example of the shaft component used for the combination shaft in accordance with the present invention,
FIG. 2 is a side sectional view of the shaft component,
FIG. 3 is a side view for showing formation of a combination shaft from a plurality of shaft component,
FIG. 4 is a side view, partly in section, of a substrate or a counter plate mounted to the combination shaft,
FIG. 5 is a perspective view, partly removed, of one example of the magnetic recording medium produced in accordance with the present invention,
FIGS. 6A and 6B are partly sectional side and front views of another example of the shaft component used for the combination shaft in accordance with the present invention,
FIG. 7 is a side view, partly in section, of one embodiment of the apparatus carrying out the method of the present invention,
FIG. 8 is a front view of a counter plate advantageously used for combination with the combination shaft,
FIG. 9 is a side view partly in section, of another example of the combination shaft in accordance with the present invention, and
FIG. 10 is a sectional side view of an apparatus for the second embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The method in accordance with the first aspect of the present invention will now be explained in more detail in reference to FIGS. 1A, 1B, 2, 3 and 4. This method is characterized by use of a plurality of shaft components such as shown in FIGS. 1A and 1B. Each shaft component 10 is made up of a rear section 11 of the largest outer diameter, a middle section 12 of an intermediate outer diameter and a front section 13 of the smallest outer diameter. Further, as best seen in FIG. 2, the rear section 11 has an axial bore 11a and covered with a surface layer 14 made of a resilient, insulating material such as rubber. The middle section 12 has an axial bore 12a in axial alignment with the axial bore 11a of the rear section 11.
More specifically, the outer diameter of the rear section 11 is larger than the diameter of the center hole of the substrate to be processed and the length of the rear section 11 is chosen according to the distance to be left between adjacent substrates during electrolysis. The diameter and length of the axial bore 11a of the rear section 11 are large enough to snugly receive the middle section 12. The outer diameter of the middle section 12 is slightly small than the diameter of the above-described center hole of the substrate to be processed. The diameter and length of the axial bore 12a of the middle section 12 are large enough to snugly received the front section 13.
Before placing in the electrolytic bath, a plurality of shaft components 10 are axially combined to form a combination shaft whilst sandwiching substrates S and counter plates P at alternate positions as shown in FIG. 3. More specifically as best seen in FIG. 4, the middle section 12 of the first shaft component 10 is inserted into the axial bore 11a of the rear section 11 of the second shaft component 10 and a substrate S, or a counter plate P, is inserted over the middle section 12 of the first shaft component 10. Being clamped between the front end of the rear section 11 of the first shaft component 10 and the rear end of the rear section 11 of the second shaft component 10, the position of the substrate S, or the counter plate P, is stably fixed. When counter plates P are held in position by other proper support, only substrates may be clamped in position between adjacent shaft components 10. The front section 13 may be provided with one or more longitudinal slits 13a for leakage of air at combination of the shaft components. When the outer diameter of the front section 13 is designed slightly larger than the diameter of the axial bore 12a of the middle section 12, presence of such longitudinal slits 13a assures stable combination between the adjacent shaft components 10. After combination, the combination shaft with the substrates and the counter plates is placed in position in an electrolytic bath.
In accordance with this embodiment of the present invention, the distance between the adjacent substrate and counter plate can be exactly and easily set only through axial combination of the shaft components in order to assure uniform layer thickness on the product. Since the substrates and the counter plates can be collected within a small, limited space, the electrolytic bath can be made very compact in construction. Connection of a number of substrates to a common power source without any use of aluminium leads makes the process quite suited for mass production. The power supply does not need any intervention between the substrates and the counter plates, thereby developing no uneven covering on the product.
During electrolysis, a specified annular region around the center hole of the substrate is sealed against formation of the covering layers by the ends of the rear sections 11 of the combined shaft components 10 as shown in FIG. 4. One example of the magnetic recording medium so produced is shown in FIG. 5, in which the magnetic recording medium 20 includes a substrate 21, an alumite layer 22 covering the substrate 23 and a magnetic substance layer 23 covering the alumite layer 22. The magnetic recording medium 20 has an uncovered annular region 24 around its center hole 20a through which electrostatic accumulation can be fairly earth discharged.
A modification of the shaft component is shown in FIGS. 6A and 6B which is well usable when sealing against formation of the covering layer is not so strictly required. Here the shaft component 30 is made up of a rear section 31 of a larger diameter and a front section of a smaller diameter. The rear section 31 has an axial bore 31a and covered with a surface layer 33 made of an insulating material. The inner end of the axial bore 31a is provided with radial serrations 34 and the front end of the front section 32 is also provided with radial serration 35 meshable with the radial serration 34 in the axial bore 31a.
The outer diameter of the rear section 31 is larger than the diameter of the center hole of the substrate to be processed and the length of the rear section 31 is chosen according to the distance to be left between adjacent substrates during electrolysis. The diameter and length of the axial bore 31a in the rear section 31 are large enought to snugly receive the front section 32. The outer diameter of the front section 32 is slightly smaller than the diameter of the above-described enter hole of the substrate.
Like the foregoing embodiment, a plurality of shaft components 30 are axially combined to form a combination shaft on which each substrate is clamped between adjacent shaft components 30.
FIG. 7 depicts one example of the electrolytic bath for carrying out the method of the present invention. The combination shaft 40 made up of the shaft components 10 or 30 is placed in position within an electrolytic bath 45 by a hoist 43 via bearing units 41 and 42 with substrates S being equally spaced apart from each other. In this example, counter plates P are arranged apart from the shaft 40 and at alternate positions with the substrates S surrounding the combination shaft 40. In one bearing unit 41, a bevel gear 40a coupled to one end of the combination shaft 40 meshes with a bevel gear 44a coupled to one end of a drive shaft 44 which is coupled for rotation to a given outside drive source (not shown). The combination shaft 40 is further connected to a proper power source (not shown) via a lead 46. Thus, the combination shaft 40 and the substrates S are driven for rotation during electrolysis.
For easy mounting to the combination shaft 40, the counter plate P may take the form of a split type one such as shown in FIG. 8.
As a substitute for the axial combination of a plurality of shaft component, a combination shaft 50 shown in FIG. 9 is made up of a monolithic, conductive core 51 and a plurality of insulating sleeve components 52 snugly inserted over the conductive core 51. The outer diameter of the core 51 is slightly smaller than the diameter of the center hole of the substrate to be processed. The length of each sleeve component 52 is chosen in accordance with the distance to be left between adjacent substrates during electrolysis. When mounted to the combination shaft 50, each substrate S is clamped firmly between adjacent sleeve components 52.
The method in accordance with the second shaft aspect of the present invention will now be explained in more detail in reference to FIG. 10. This method is suited for the case in which the producer's attention is more focused on formation of the uncovered annular region (see FIG. 5) than compactness in construction due to use of the combination shaft such as shown in FIG. 7. A pair of cylindrical holders 60 and 70 are used for this method. The first holder 60 is made up of a conductive core 61 having a threaded center projection and an insulating sheath 62 embracing the core 61 leaving the side of the center projection. The second holder 70 is made up of a conductive core 71 having a threaded center hole and an insulating sheath 72 embracing the core leaving the side of the center hole, and the core 71 is connectable via a lead 73 to a given power source (not shown). The outer diameters of the holders 60 and 70 are equal to the outer diameter of the uncovered annular region to be formed on the magnetic recording medium (see FIG. 5). The outer diameter of the core 61 of the first holder 60 is slightly small than the diameter of the center hole of the substrate to be processed whereas the outer diameter of the core 71 of the second holder 70 is somewhat larger than the diameter of the above-described center hole. The core 61 of the first holder 60 project from the sheath 62 over a distance roughly equal to the thickness of the substrate.
In assembly, the core 61 of the first holder 60 is inserted into the center hole of the substrate S and the core 71 of the second holder 70 is screwed over the threaded center projection. After setting in a electrolytic bath, the lead 73 is connected to the given power source. | In production of a magnetic recording medium by formation of an anodic oxide layer on an Al or Al-base alloy substrate and preapitation via electrolysis of magnetic substance in pores in the anodic oxide layer, the substrates are mounted at equal intervals to a common combination shaft made up of several components for a compact constructions and uniform electrolytic effect. Preferably, a specified annular region around the center hole of each substrate is sealed against formation of a surface layer. | 2 |
TECHNICAL FIELD
[0001] The present invention relates to processes for separating metals, and in particular for separating precious metals such as platinum and palladium, by solvent extraction. The present invention also provides novel solvent extraction mixtures useful in the processes of the present invention.
BACKGROUND
[0002] Solvent extraction is an important part of many processes for the recovery of precious metals from their ores (e.g. ore concentrates) or from scrap material. Solvent extraction can be employed to separate precious metals from base metals and other substances, and from each other, in order that relatively pure metal samples may be recovered.
[0003] In order to achieve this, typically an aqueous acidified solution comprising species of two or more different precious metals, optionally in combination with base metals, is contacted with an organic phase comprising an extractant. Typically, the extractant is selective for one or more of the precious metals to be separated, thus facilitating their separation by selectively extracting them from the aqueous phase into the organic phase. Further processing steps enable recovery of the separated metal.
[0004] For example, GB 1 495 931 describes organic solvent extraction of platinum and iridium species from an aqueous acidic solution also containing rhodium species by using a solvent containing a tertiary amine extractant. However, this separation does not achieve separation of the metals in the presence of palladium species, and so has the disadvantage of requiring palladium species to be removed before platinum may be liberated.
[0005] EP 0 210 004 describes an extractant which is suitable for extracting platinum from an acidified aqueous solution which also includes palladium. The extractant is a mono-N-substituted amide. This extractant also permits separation of platinum species from other precious metals which may be present in the solution, particularly where ruthenium, iridium and osmium species are present in oxidation state III, while the platinum species is in oxidation state IV. EP 0 210 004 explains that this may be achieved by treating the aqueous phase with a mild reducing agent. Following treatment with the mono-N-substituted amide, further treatment of the aqueous phase is required if the palladium is to be recovered.
[0006] Palladium may be extracted into an organic phase using thioether extractants. For example, as explained in US2009/0178513, DHS (di-n-hexylsulfide) is one of the most commonly used industrial extractants for palladium, which is capable of selectively extracting palladium from an acidic aqueous solution containing palladium, platinum and rhodium. US2009/0178513 proposes a different thioether-containing extractant having the following formula:
[0000]
[0000] where R 1 , R 2 and R 3 each represents a group selected from a chain hydrocarbon group having 1 to 18 carbon atoms. US2009/0178513 states that the extractant described therein enables the extraction of palladium to be performed more rapidly than is possible using DHS, but that the other platinum group metals (including platinum) are hardly extracted at all. The palladium in the organic solution is recovered using ammonia.
[0007] As an alternative to selective extraction, some documents propose simultaneously extracting more than one metal into the organic phase, followed by selectively removing each metal from the organic phase. For example, U.S. Pat. No. 4,654,145 describes co-extraction of precious metals including gold, platinum and palladium into an organic phase using Kelex® 100:
[0000]
[0008] The gold is then precipitated out of the solution, followed by precipitation of the palladium. Platinum is removed from the organic phase by washing with an aqueous phase. However, the processes proposed in this document suffer the disadvantage of including precipitation to separate the metals extracted into the organic phase.
[0009] U.S. Pat. No. 5,045,290 describes a process for the recovery of Pt and Pd from an impure substantially gold-free precious and base metal-bearing acidic chloride or mixed chloride/sulphate solution, comprising the steps of contacting the acidic solution having a pH of less than about 1.5 with an organic solution comprising an 8-hydroxyquinoline solvent extraction reagent, a phase modifier and an aromatic diluent to extract simultaneously platinum and palladium into the organic solution, scrubbing the co-extracted solution to remove co-extracted impurities and acid, stripping the loaded organic with a buffer solution operating in the pH range 2-5 at 20-50° C. to selectively recover the platinum, stripping the platinum-free loaded organic with 3-8 M hydrochloric acid to recover the palladium, and regenerating the organic solution by washing with water.
[0010] Guobang et al. (Reference 1) describes co-extraction of Pt and Pd using petroleum sulfoxides. After washing, Pt is removed from the organic phase using dilute HCl and Pd is removed using aqueous NH 3 .
[0011] US2010/0095807 describes a separation reagent for separating platinum group metals from an acidic solution containing rhodium, platinum and palladium. The reagent has the general formula:
[0000]
[0000] wherein at least one of R 1 , R 2 and R 3 represent an amide group represented by:
[0000]
[0000] wherein each of R 1 to R 3 other than the amide group, and R 4 to R 6 are hydrocarbon groups. In the separation methods described in this document, rhodium, platinum, and palladium are co-extracted using the extractant reagent. Highly concentrated hydrochloric acid solution is then used to recover rhodium from the organic phase. The platinum and palladium are then back-extracted from the organic phase using highly concentrated nitric acid solution, to produce an aqueous solution including both platinum and palladium.
[0012] US4 041 126 describes co-extraction of platinum and palladium from acidic aqueous medium using an organically substituted secondary amine capable of forming complexes of platinum and palladium. Palladium is selectively recovered from the organic phase with an aqueous solution of an acidified reducing agent. Platinum is separately recovered using an alkaline stripping reagent selected from alkali metal and alkaline earth metal carbonates, bicarbonates and hydroxides.
SUMMARY OF THE INVENTION
[0013] There remains a need for improved processes for the separation of metals, particularly those which enable the separation of precious metals, such as platinum and palladium.
[0014] The present inventors have found that by simultaneously employing different extraction mechanisms for the extraction of a plurality of different metals, a simple and convenient process for their separation can be achieved. In particular, the present inventors have found that the use of different extraction mechanisms for simultaneously extracting metals from an aqueous acidic phase into an organic phase enables the extracted metals to be separated by selective stripping from the organic phase using simple and mild conditions. This process is particularly advantageous as it permits two or more metals to be separated following a single solvent extraction step, because of the ability to selectively strip the metals from the organic phase. In current industrial processes, a separate extraction step and a separate stripping step is typically required for each metal, or metals are co-extracted and subsequently separated by selective precipitation.
[0015] In acidified aqueous solutions, metals typically exist as complexes, having ligands coordinated to a central metal atom. For example, in an aqueous HCl solution, platinum may exist as a [PtCl 6 ] 2− complex ion species, where six Cl − or ligands are coordinated to a central Pt atom in oxidation state (IV). Similarly, palladium and other metals typically exist as neutral complexes or charged complexes. For example, Pd typically exists as [PdCl 4 ] 2− .
[0016] Extractants for solvent extraction are typically soluble in the organic phase but predominantly insoluble in the aqueous phase from which the metal species are extracted. Their interaction with metal species increases the solubility of the metal species in the organic phase and decreases its solubility in the aqueous phase, with the effect that the metal species are transferred to the organic phase.
[0017] In order to effect extraction of the metal from the aqueous phase into an organic phase, extractants typically interact with the metal species in one of two ways: by coordination with the metal atom itself (inner sphere interaction), or by interacting with the whole complex or complex ion in an outer sphere interaction (e.g. solvating and/or ion pair interaction). Accordingly, extractants can be categorised as outer sphere (e.g. solvating) extractants or coordinating (or inner sphere) extractants, based on the way in which they typically interact with the metal species during extraction. The behaviour of extractants in extraction of precious metals from acidified solutions is discussed in Reference 2, which is hereby incorporated by reference in its entirety and particularly for the purposes of describing and defining the behaviour of extractants in metal extraction from acidified solutions.
[0018] Species of different metals typically interact more readily with one type of extractant than another. The present inventors have found that two different metals can be extracted simultaneously into an organic phase using a combination of an outer sphere extractant and a coordinating extractant. In the organic phase, each of the extracted metal species remains associated predominantly with either coordinating extractant molecules or outer sphere extractant molecules. The present inventors have found that this difference in the way the two metal species interact with their extractants can be exploited to enable selective stripping of the metal species from the organic phase into aqueous phases in order to separate the metals.
[0019] The way in which a metal species interacts with organic extractants is affected primarily by how labile the metal ion is. In other words, this depends on how readily the ligands coordinating with the central metal atom of the metal species are displaced by coordinating extractant molecules. Where the ligands are readily displaced by a coordinating extractant molecule, the metal will typically interact predominantly with the coordinating extractant. In contrast, where ligands are not readily displaced, the metal species will typically interact predominantly with the outer sphere extractant. This is a kinetic effect.
[0020] For example, palladium species in aqueous acidified solutions typically interact predominantly with coordinating extractants, and platinum species typically interact predominantly with outer sphere extractants. Accordingly, the present inventors have found that platinum and palladium species may be simultaneously extracted from an acidified aqueous phase using a combination of a coordinating extractant and an outer sphere extractant, and then selectively stripped from the organic phase using simple, mild techniques to produce two aqueous solutions—one comprising platinum species and one comprising palladium species. For example, the platinum may be stripped using water or a weakly acidic aqueous solution. Palladium may be stripped using a complexing reagent such as aqueous ammonia.
[0021] As the skilled person will understand, the present inventors' realisation that a combination of complexing and outer sphere extractants may be employed to separate metals by a process involving co-extraction and selective stripping is applicable not only to platinum and palladium, but also to other pairs of labile and non-labile metal species.
[0022] Accordingly, in a first preferred aspect, the present invention provides a method of separating labile metal species and non-labile metal species present in an aqueous acidic phase, comprising
(a) contacting the aqueous acidic phase with an organic phase comprising:
(i) an outer sphere extractant capable of extracting the non-labile metal species into the organic phase; and (ii) a coordinating extractant capable of coordinating with the labile metal atom of the labile metal species, whereby the labile and non-labile metals are extracted into the organic phase, then
(b) selectively stripping the metals from the organic phase by
contacting the organic phase with water or an acidic aqueous solution to provide a first aqueous solution comprising non-labile metal species, and contacting the organic phase with an aqueous phase comprising a complexing reagent capable of complexing with the labile metal atom of the labile metal species to provide a second aqueous solution comprising labile metal species.
[0029] Preferably the labile metal species is a palladium species. Preferably the non-labile metal species is a platinum species. Accordingly, in a more preferred aspect the present invention provides a method of separating platinum species and palladium species present in an aqueous acidic phase, comprising
(a) contacting the aqueous acidic phase with an organic phase comprising:
(i) an outer sphere extractant capable of extracting the platinum species into the organic phase; and (ii) a coordinating extractant capable of coordinating with the palladium atom of the palladium species,
whereby the platinum and palladium are extracted into the organic phase, then (b) selectively stripping the platinum and palladium from the organic phase by
contacting the organic phase with water or an acidic aqueous solution to provide a first aqueous solution comprising platinum species, and contacting the organic phase with an aqueous phase comprising a complexing reagent capable of complexing with the palladium to provide a second aqueous solution comprising palladium species.
[0037] In a second preferred aspect, the present invention provides a solvent extraction mixture comprising a diluent, an outer sphere extractant and a coordinating extractant.
[0038] In a third preferred aspect, the present invention provides use of a solvent extraction mixture according to the second preferred aspect for the separation of labile metal species from non-labile metal species.
[0039] In a fourth preferred aspect, the present invention provides a process for the preparation of a solvent extraction mixture (e.g. according to the second preferred aspect) comprising combining a diluent, an outer sphere extractant and a coordinating extractant.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] FIG. 1 shows the distribution coefficients for Pt, Ir, Rh and Ru at different feed acidities as determined in Example 1.
[0041] FIG. 2 shows the distribution coefficients for Pt strip from an organic phase vs HCl concentration of the aqueous strip solution, as determined in Example 1.
[0042] FIG. 3 shows concentrations of Pt in the organic phase vs the number of contacts with the strip solution, for different HCl concentrations of the aqueous strip solution, as determined in Example 1.
DETAILED DESCRIPTION
[0043] Preferred and/or optional features of the invention will now be set out. Any aspect of the invention may be combined with any other aspect of the invention, unless the context demands otherwise. Any of the preferred or optional features of any aspect may be combined, singly or in combination, with any aspect of the invention, unless the context demands otherwise.
[0044] The skilled person readily understands the terms labile and non-labile as they refer to metal species in acidic aqueous solutions, which are typically coordination complexes having a central metal atom. (As the skilled person will understand, a coordination complex may include more than one metal atom, each having one or more ligands coordinated thereto.) Typically, a labile metal species will readily undergo ligand exchange in an acidic aqueous solution. The result is that a covalent coordination bond may readily be formed between an extractant and the central metal atom of the labile metal species. For example, the coordinating extractant may displace another ligand from the coordination sphere of the labile metal species. Examples of metals which typically form labile metal species in acidic aqueous solutions are Pd (especially in the II oxidation state) and Au (especially in the III oxidation state).
[0045] Conversely, a non-labile metal species typically does not readily undergo ligand exchange in an aqueous acidic solution. The result is that covalent coordination bonds between an extractant and the central metal ion of the non-labile metal species do not readily form. Instead, the ligands of the coordination sphere of the labile metal species remain substantially unchanged during extraction. The extractant interacts with the entire non-labile metal species (i.e. the central metal atom and its associated ligands) by an outer sphere mechanism, typically involving non-covalent bonding interactions such as selected from one or more of electrostatic interactions, hydrogen bonding, dipole-dipole interactions, Van der Waals interactions, ion-ion interactions, ion-dipole interactions, solvation interactions, London interactions, and dipole-induced dipole interactions, but not including covalent bonding. Examples of metals which typically form non-labile metal species in acidic aqueous solutions are Pt (especially in the IV oxidation state), Ir (especially in the IV oxidation state), Os (especially in the IV oxidation state), and Ru (especially in the IV oxidation state).
[0046] Reference 2 describes the lability of precious metal ions in acidified solutions. In particular, FIG. 5 illustrates the differing substitution (ligand exchange) kinetics of chloro complexes of precious metals, relative to Pd(II). This Figure is reproduced below:
[0000]
Ruthenium
Rhodium
Palladium
Silver
Ru(III)
10 −3 -10 −4
Rh(III)
10 −3 -10 −4
Pd(II)
1
Ag(I)
10 −4 -10 −6
Ru(IV)
10 −5 -10 −6
Osmium
Iridium
Platinum
Gold
Os(III)
10 −7 -10 −9
Ir(III)
10 −4 -10 −6
Pt(II)
10 −3 -10 −5
Au(III)
10 1 -10 −1
Os(IV)
10 −10 -10 −12
Ir(IV)
10 −8 -10 −10
Pt(IV)
10 −10 -10 −12
[0047] Pd(II) and Au(III), for example, can be considered to be labile, as their relative substitution kinetics are fast. Os(III), Os(IV), Ir(IV), Ru (IV) and Pt(IV), for example, can be considered to be non-labile, as their relative substitution kinetics are slow. Reference 2 is hereby incorporated by reference in its entirety and particularly for the purposes of describing the ligand substitution kinetics of precious metal chloro complexes and the lability of precious metals. Note that Os(III) is typically unstable in the presence of air.
[0048] In the present invention, a labile metal species may typically be defined as a metal species which is readily extracted from an aqueous acidic phase having an HCl concentration of 6 mol dm −3 into an organic phase consisting essentially of di-n-octyl sulphide in an aromatic petroleum solvent. “Readily extracted” may typically mean that at least 95 mol % of the metal of the labile metal species is extracted into the organic phase in 60 minutes when an excess of di-n-octyl sulphide is provided. In the present invention, a non-labile metal species may typically be defined as a metal species which is not readily extracted from an aqueous acidic phase having an HCl concentration of 6 mol dm −3 into an organic phase consisting essentially of di-n-octyl sulphide in an aromatic petroleum solvent. “Not readily extracted” may typically mean that less than 5 mol % of the metal of the labile metal species is extracted into the organic phase in 60 minutes when an excess of di-n-octyl sulphide is provided.
[0049] As the skilled person will understand, the term coordinating extractant includes extractants which are capable of forming a covalent coordination bond with the metal atom of the labile metal species. Typically, the coordinating extractant does not substantially interact with the non-labile metal species.
[0050] As the skilled person will understand, the term outer sphere extractant includes extractants which interact with a metal species to effect its extraction without forming a covalent coordination bond with the metal atom of the metal species. Typically, this interaction involves bonding interactions selected from one or more of electrostatic interactions (e.g. ion pairing), hydrogen bonding, dipole-dipole interactions, Van der Waals interactions, ion-ion interactions, ion-dipole interactions, solvation interactions, London interactions, and dipole-induced dipole interactions, but not including covalent bonding.
[0051] The outer sphere extractant may be capable of extracting the labile metal species (as well as the non-labile metal species), but this is not essential. If the outer sphere extractant is capable of extracting the labile metal species, the present inventors consider that this may provide an additional advantage. Typically, outer sphere interactions occur faster than coordinating interactions. The present inventors have found that where an outer sphere extractant is included, the rate of transfer of the labile metal species into the organic phase may be increased. Without wishing to be bound by theory, this is believed to be because the labile metal species initially interacts with the outer sphere extractant, effecting its transfer into the organic phase much faster than would be expected using a coordinating extractant. Once in the organic phase, it is believed to form a complex with the coordinating extractant. This reaction happens more slowly, but the present inventors believe that it is this interaction with the coordinating extractant which retains the labile metal species in the organic phase, and enables the advantageous selective stripping described herein. Of course, some of the labile metal species may also interact with the coordinating extractant in the aqueous acidic phase and be extracted by a more conventional coordination extraction process.
Metals to be Separated
[0052] The present invention provides a method of separating labile metal species and non-labile metal species present in an aqueous acidic phase. The nature of the labile and non-labile metal species separated according to the present invention is not particularly limited. As explained above, the inventors' realisation underlying this invention is generally applicable to the separation of labile and non-labile metal species. The metals may be transition metals, for example.
[0053] However, the present inventors consider that the methods of the present invention are particularly applicable to the separation of precious metal species. As used herein, the term precious metals is intended to refer to gold, silver and the platinum group metals. The platinum group metals are platinum, palladium, ruthenium, rhodium, osmium and iridium. The methods of the present invention are particularly suitable for the separation of platinum group metal species. Accordingly, the labile metal species may be a platinum group metal species. The non-labile metal species may be a platinum group metal species.
[0054] For example, the labile metal may be one or more selected from Pd(II) and Au(III), such as Pd(II). The non-labile metal may be one or more selected from Pt(IV), Pt(II), Ir(IV), Ir(III), Os(IV), Ru(IV), Ru(III) and Rh(III). For example, the non-labile metal may be one or more selected from Pt(IV), Ir(IV), Os(IV) and Ru(IV). For example, the labile metal may be Pd(II) and the non-labile metal may be one or more selected from Pt(IV), Ir(IV), Os(IV) and Ru(IV).
[0055] There is a particular need for improved methods for the separation of platinum and palladium, and the present invention is suitable for the separation of these metals. Accordingly, the labile metal species may be a palladium species (e.g. in the II oxidation state), and/or the non-labile metal species may be a platinum species (e.g. in the IV oxidation state). For example, the methods of the present invention may be used to separate Pt(IV) from Pd(II). The methods of the present invention may be used to separate Pt(IV) from Pd(II) in the presence of Ru(III) and/or Rh(III).
[0056] The methods of the present invention may be used to separate Ir(IV) from Au(III).
[0057] The extractants used in the present invention may selectively extract the labile and non-labile metal species from the aqueous acidic phase in the presence of additional metal species which are not significantly extracted into the organic phase. For example, the distribution coefficient for each additional metal species may be preferably 0.1 or less, 0.01 or less or 0.001 or less. It may be zero, or at least 0.0001, for example. Typically, the distribution coefficient of the labile metal and the non-labile metal will be considerably higher than this. For example, the distribution coefficient for extraction of the non-labile metal species into the organic phase is typically at least 2, at least 5, at least 10, at least 20, at least 30, at least 40 or at least 50 and may be considerably higher than this. The upper limit tends to infinity as substantially all of the metal is extracted. Similarly, the distribution coefficient for extraction of the labile metal species into the organic phase is typically at least 2, at least 5, at least 10, at least 20, at least 30, at least 40 or at least 50 and may be considerably higher than this. The upper limit tends to infinity as substantially all of the metal is extracted. (As the skilled person will understand, the distribution coefficient (D A \ O ) is the concentration of the relevant metal species in the organic phase divided by the concentration of that metal species in the aqueous acidic phase.)
[0058] The skilled person is aware of suitable coordinating extractants and suitable outer sphere extractants for selectively extracting particular metal species in the presence of additional metal species. The choice of extractants depends on the nature of the metals to be separated, and in particular the relative lability of (i) the labile metal species, (ii) the non-labile metal species and (iii) any additional metal species present. For example, EP 0 210 004 describes mono-N-substituted amide extractants suitable for selectively extracting platinum, iridium and osmium species having an oxidation state of IV, gold of an oxidation state of III, and ruthenium having whatever oxidation state it has in the compound ruthenium nitrosyl chloride, [RuCl 5 NO] 2− . However, the selectivity of the extractant depends on the oxidation state of the metal to be extracted, and the oxidation state of the additional metals in the aqueous acidic phase. For example, EP 0 210 004 explains that, using its mono-N-substituted amide extractants,
platinum of oxidation state IV may be extracted in preference to palladium of oxidation state II; iridium of oxidation state IV may be extracted in preference to rhodium of oxidation state III; and platinum of oxidation state IV may be extracted in preference to ruthenium, iridium and osmium species of oxidation state III (although Os(III) is typically unstable in the presence of air).
[0062] Accordingly, it can be seen that the selectivity of a particular extractant may depend on the oxidation states of the metal(s) to be extracted, and of the metal(s) which are to be left in the aqueous acidic phase. The skilled person is aware of suitable techniques for adjusting the oxidation state of the metal species in the aqueous acidic phase. For example, EP 0 210 004 explains that it is usual to treat an aqueous acidic solution with a mild reducing agent which largely does not affect the platinum species but which ensures that iridium, osmium and ruthenium species are present in an oxidation state of III. Suitable mild reducing agents include acetone or methyl isobutylketone.
[0063] The methods of the present invention are particularly suitable where the labile metal is Pd(II), the non-labile metal is a platinum group metal (other than Pd) in oxidation state IV, wherein one or more additional metal species are present in the aqueous acidic phase. Particularly suitable additional metal species are platinum group metals in oxidation state II or III (preferably III), and base metals (e.g. in oxidation state II or III). The additional metal species is typically a species which is substantially not extracted by the outer sphere extractant employed and which is substantially not extracted by the coordinating extractant employed. As discussed above, the skilled person is aware of suitable coordinating extractants and suitable outer sphere extractants for selectively extracting particular metal species in the presence of additional metal species.
[0064] In a particularly preferred embodiment, the labile metal species is a palladium species (e.g. in oxidation state II) the non-labile metal species is a platinum species (e.g. in oxidation state IV), and the platinum and palladium species are selectively extracted from an aqueous acidic phase which also includes one or more additional precious metal species, e.g. one or more additional platinum group metal species. The additional precious metal species may be in oxidation state III. The additional precious metal species may be one or more selected from iridium, ruthenium and rhodium species.
[0065] The labile metal species may be a chloro complex. The non-labile metal species may be a chloro complex.
Aqueous Acidic Phase
[0066] The aqueous acidic phase is the phase from which the metal species are extracted using the extractants in the methods of the present invention.
[0067] Typically, the H + concentration of the aqueous acidic phase is at least 3 mol dm −3 or at least 4 mol dm −3 . Typically, the H + concentration of the aqueous acidic phase is 10 mol dm −3 or less, 9 mol dm −3 or less or 8 mol dm −3 or less. As the skilled person will understand, the acidity used will depend on the metal species to be separated and on the extractants employed. A particularly preferred H + concentration is in the range from 4 to 8 mol dm −3 , more preferably 5 to 7 mol dm −3 , or 5.5 to 6.5 mol dm −3 . This is particularly suitable for the separation of Pt(IV) and Pd(II).
[0068] The aqueous acidic phase typically comprises HCl. Typically, the HCl concentration of the aqueous acidic phase is at least 3 mol dm −3 or at least 4 mol dm −3 . Typically, the HCl concentration of the aqueous acidic phase is 10 mol dm −3 or less, 9 mol dm −3 or less or 8 mol dm −3 or less. A particularly preferred HCl concentration is in the range from 4 to 8 mol dm −3 , more preferably 5 to 7 mol dm −3 , or 5.5 to 6.5 mol dm −3 . This is particularly suitable for the separation of Pt(IV) and Pd(II).
[0069] Other suitable acids include sulphuric acid, perchloric acid and nitric acid, which are preferably present at a suitable concentration to give the H + concentrations specified above.
[0070] Typically the labile metal species and the non-labile metal species are each present in the aqueous acidic phase at a concentration of about 150 g L −1 or less, 120 g L −1 or less, 110 g L −1 or less, 100 g L −1 or less, 70 g L −1 or less, 50 g L −1 or less, 25 g L −1 or less or 10 g or less. They may be present at a concentration of at least 0.1 g L −1 , at least 0.5 g L −1 , at least 1 g L −1 or at least 5 g L −1 . The concentrations are with respect to the mass of metal in the metal species.
[0071] Any additional metal species present in the aqueous acidic phase (which are typically substantially not extracted into the organic phase) may for example each be present at a concentration of at least 0.05 g L −1 , at least 0.1 g L −1 or at least 0.5 g L −1 . Each additional metal species may for example be present at a concentration of 100 g L −1 or less, 50 g L −1 or less, 55 g L −1 or less, 10 g L −1 or less, 5 g L −1 or less, or 1 g L −1 or less. The concentrations are with respect to the mass of metal in the metal species.
Organic Phase and Extractants
[0072] Extractants are compounds employed in extracting metals from the aqueous acidic phase into an organic phase. Accordingly, extractants are typically substantially insoluble in the aqueous acidic phase and soluble in the organic phase.
[0073] The nature of the outer sphere extractant is not particularly limited. A range of different outer sphere extractants can be employed in the methods of the present invention, as demonstrated in the Examples below.
[0074] Without wishing to be bound by theory, the present inventors believe that some types of outer sphere extractants become protonated due to the acidity of the aqueous acidic phase, facilitating their outer sphere interaction with the non-labile metal species (which is typically a negatively charged complex ion). Accordingly, it is preferable that the outer sphere extractant includes a protonatable moiety.
[0075] As discussed in Reference 2, outer sphere extractants (“anion exchangers”) can be categorised as strong-base and weak-base extractants. Strong base extractants include extractants which are readily protonated even in weak acid (e.g. weak hydrochloric acid), and typically require alkali treatment to deprotonate them (e.g. with hydroxide). Weak base extractants typically require contact with strong acid (e.g. hydrochloric acid) to become protonated, but are readily deprotonated on contact with water or a weak acid. This is discussed in Reference 2, which is hereby incorporated by reference in its entirety and particularly for the purposes of describing the behaviour of outer sphere extractants.
[0076] In the methods of the present invention, when the non-labile metal species is stripped from the organic phase into the first aqueous solution, typically water or a weak acid are employed. The water or weak acid is believed to deprotonate the outer sphere extractant, thus disrupting its interaction with the non-labile metal species in the organic phase. The non-labile metal species is therefore transferred from the organic phase to the water or weak acid. Accordingly, preferably the outer sphere extractant is a weak base extractant. The skilled person readily understands this term and is able to determine whether a given extractant is a weak base extractant. As the skilled person will understand, typically a weak base extractant includes a protonatable moiety that is readily protonated on contact with a strong acid (e.g. on contact with a solution having an HCl concentration of 3 mol dm −3 or more). Typically, the protonatable moiety is readily deprotonated on contact with water or an acidic solution having an HCl concentration of 1 mol dm −3 or less, e.g. 0.5 mol dm −3 or less.
[0077] Suitable protonatable moieties include, for example, an amide moiety, and a P═O moiety. Particularly suitable outer sphere extractants are specified in Table 1 below. It may be preferred that the outer sphere extractant does not include an amine moiety.
[0078] The outer sphere extractant may include an amide moiety. The amide may be a primary, secondary or tertiary amide. More preferable are secondary or tertiary amide moieties. In some embodiments, a secondary amide moiety is most preferable. For example, the outer sphere extractant may be a compound according to Formula I below:
[0000]
[0000] wherein
[0079] R 1 and R 2 are independently selected from H or an optionally substituted C 1 -C 20 hydrocarbon moiety; and
[0080] R 3 is an optionally substituted C 1 -C 20 hydrocarbon moiety.
[0081] Preferably, R 1 and R 2 are independently selected from H or an optionally substituted C 3 -C 20 hydrocarbon moiety and R 3 is an optionally substituted C 1 -C 20 hydrocarbon moiety.
[0082] It may be preferable that at least one of R 1 and R 2 is H. It may be preferable that at least one of R 1 and R 2 is an optionally substituted C 3 -C 20 hydrocarbon moiety. It may be preferable that R 1 and R 2 are independently selected from H or an optionally substituted C 5 -C 20 hydrocarbon moiety. It may be preferable that R 1 and R 2 are independently selected from H or an optionally substituted C 5 -C 15 hydrocarbon moiety.
[0083] It may be preferable that R 3 is an optionally substituted C 1 -C 15 hydrocarbon moiety.
[0084] It may be preferable that the total number of carbon atoms in R 1 , R 2 and R 3 taken together is at least 10, at least 15 or at least 16.
[0085] In a preferred embodiment:
[0086] R 1 is optionally substituted C 8 -C 18 alkyl;
[0087] R 2 is H; and
[0088] R 3 is optionally substituted C 8 -C 18 alkyl.
[0089] In a preferred embodiment:
[0090] R 1 is optionally substituted C 10 -C 15 alkyl;
[0091] R 2 is H; and
[0092] R 3 is optionally substituted C 10 -C 15 alkyl.
[0093] In a preferred embodiment:
[0094] R 1 is optionally substituted C 3 -C 15 alkyl;
[0095] R 2 is optionally substituted C 3 -C 15 alkyl; and
[0096] R 3 is optionally substituted C 1 -C 5 alkyl, optionally wherein total number of carbon atoms in R 1 , R 2 and R 3 taken together is at least 10, or at least 15.
[0097] In a preferred embodiment:
[0098] R 1 is optionally substituted C 5 -C 10 alkyl;
[0099] R 2 is optionally substituted C 5 -C 10 alkyl; and
[0100] R 3 is optionally substituted C 1 -C 4 alkyl, optionally wherein total number of carbon atoms in R 1 , R 2 and R 3 taken together is at least 11, at least 12 or at least 15.
[0101] It may be preferable that one or more, e.g. each, of R 1 , R 2 and R 3 are unsubstituted.
[0102] The outer sphere extractant may include a P═O moiety. For example, the outer sphere extractant may include an organic phosphate, phosphonate or phosphinate (e.g. alkyl phosphate, alkyl phosphonate or alkyl phosphinate) or an organic phosphine oxide (e.g. alkyl phosphine oxide) moiety.
[0103] For example, the outer sphere extractant may be a compound according to Formula II below:
[0000]
[0000] wherein
each R 4 is independently selected from an optionally substituted C 3 -C 20 hydrocarbon moiety and —OR 5 , wherein each R 5 is an optionally substituted C 2 -C 20 hydrocarbon moiety.
[0104] It may be preferable that each R 4 is independently an optionally substituted C 3 -C 15 hydrocarbon moiety, e.g. an optionally substituted C 4 -C 15 hydrocarbon moiety or an optionally substituted C 5 -C 10 hydrocarbon moiety.
[0105] It may be preferable that each R 4 is independently —OR 5 , wherein each R 5 is an optionally substituted C 2 -C 20 hydrocarbon moiety, e.g. an optionally substituted C 3 -C 15 or C 3 -C 10 hydrocarbon moiety.
[0106] In a preferred embodiment, each R 4 is independently optionally substituted C 5 -C 10 alkyl, or is —OR 5 , wherein each R 5 is an optionally substituted C 3 -C 10 alkyl. In a particularly preferred embodiment, each R 4 is C 5 -C 10 alkyl.
[0107] In some embodiments, it is preferable that one or more, e.g. each R 4 and R 5 are unsubstituted.
[0108] In some embodiments, it may be preferable that the outer sphere extractant does not include an amine group.
[0109] The nature of the coordinating extractant is not particularly limited in the present invention. It includes a moiety capable of forming a covalent coordination bond with the metal atom of the labile metal species.
[0110] Preferably, the coordinating extractant includes a sulphur atom. For example, it may include one or more functional groups selected from the group consisting of thiol, thioether, thioketone, thioaldehyde, phosphine sulphide and thiophosphate. More preferably the coordinating extractant includes one or more functional groups selected from thioether and phosphine sulphide.
[0111] For example, the coordinating extractant may be a compound according to Formula III below:
[0000]
[0000] wherein each R 6 is independently selected from an optionally substituted C 2 -C 20 hydrocarbon moiety and —OR 7 , wherein each R 7 is an optionally substituted C 2 -C 20 hydrocarbon moiety.
[0112] It may be preferable that each R 6 is independently an optionally substituted C 2 -C 15 hydrocarbon moiety, e.g. an optionally substituted C 2 -C 15 hydrocarbon moiety or an optionally substituted C 3 -C 8 hydrocarbon moiety. For example, each R 6 may preferably be optionally substituted C 2 -C 15 alkyl, or more preferably optionally substituted C 3 -C 8 alkyl.
[0113] It may be preferable that each R 6 is independently —OR 7 , wherein each R 7 is an optionally substituted C 2 -C 20 hydrocarbon moiety, e.g. an optionally substituted C 2 -C 15 or C 3 -C 8 hydrocarbon moiety. For example, each R 7 may preferably be optionally substituted C 2 -C 15 alkyl, or more preferably optionally substituted C 3 -C 8 alkyl.
[0114] In some embodiments, it is preferable that one or more, e.g. each R 6 and R 7 are unsubstituted.
[0115] The coordinating extractant may be a compound according to Formula IV below:
[0000]
[0000] wherein R 8 is selected from H and an optionally substituted C 1 -C 20 hydrocarbon moiety, and R 9 is an optionally substituted C 1 -C 20 hydrocarbon moiety. R 8 may be selected from H and an optionally substituted C 3 -C 15 hydrocarbon moiety, more preferably an optionally substituted C 5 -C 10 hydrocarbon moiety. R 9 may be an optionally substituted C 3 -C 15 hydrocarbon moiety, more preferably an optionally substituted C 5 -C 10 hydrocarbon moiety. Preferably, R 8 is an optionally substituted hydrocarbon moiety. For example, both of R 8 and R 9 may be optionally substituted C 3 -C 15 alkyl, more preferably optionally substituted C 5 -C 10 alkyl. It may be preferred that the total number of carbon atoms in R 8 and R 9 taken together is at least 5, at least 6, at least 10, at least 12 or at least 16.
[0116] In some embodiments, it is preferable that R 8 and R 9 are unsubstituted.
[0117] As used herein, the term optionally substituted includes moieties in which one, two, three, four or more hydrogen atoms have been replaced with other functional groups. Suitable functional groups include —OH, —SH, —SR 11 , -Hal, —NR 11 R 11 , C(O)COR 11 , —OC(O)R 11 , —NR 11 C(O)R 11 and C(O)NR 11 R 11 , wherein each R 11 is independently H or C 1 to C 10 alkyl or alkenyl and wherein each -Hal is independently selected from —F, —Cl and —Br, e.g. —Cl. In the case of the outer sphere extractant, it may be preferable that the extractant does not include a sulphur atom and/or does not include an amine group. For example, suitable substituent functional groups include —OH, —OR 11 , -Hal, C(O)COR 11 , —OC(O)R 11 , —NR 11 C(O)R 11 and C(O)NR 11 R 11 , wherein each R 11 is independently H or C 1 to C 10 alkyl or alkenyl and wherein each -Hal is independently selected from —F, —Cl and —Br, e.g. —Cl.
[0118] As used herein, the term hydrocarbon moiety is intended to include alkyl (including cycloalkyl), alkenyl, alkynyl, aryl and alkaryl and aralkyl. The hydrocarbon moiety may be linear or branched. It is preferable that the hydrocarbon moiety is alkyl, aryl, alkaryl or aralkyl, more preferably alkyl, which may be linear or branched.
[0119] The organic phase typically includes a diluent in addition to the complexing extractant and the outer sphere extractant. A wide range of diluents are commonly used in solvent extraction processes, and the nature of the diluent is not particularly limited in the present invention. The complexing extractant and the outer sphere extractant should both be soluble in the diluent. Suitable diluents include aromatic petroleum solvents such as Solvesso 150 and Shellsol D70, or ketones such as 2,6-dimethyl-4-heptanone, but other organic solvents (such as aliphatic or aromatic hydrocarbon solvents and alcohols) are suitable. Typically, a diluent will be selected to give a convenient viscosity for processing, a high flash point and/or low volatility.
[0120] Typically, the coordinating extractant is present in the organic phase at a concentration of about 0.03 to 0.04 M. For example, the coordinating extractant may be present at a concentration of at least 0.01 M, at least 0.02 M or at least 0.03 M. There is no particular upper limit on the concentration of the coordinating extractant in the organic phase. The Examples below demonstrate that coordinating extractants may advantageously be used at low concentrations and still provide an excellent degree of extraction of the labile metal species. It may be preferable that the coordinating extractant is present at a concentration of 1 M or less, 0.2 M or less, or 0.1 M or less. The concentration of the coordinating extractant is typically selected to satisfy the coordination number of the labile metal species, and so may depend on the nature and concentration of the labile metal species in the aqueous acidic phase.
[0121] Typically, the outer sphere extractant is present in the organic phase at a concentration between 0.5 M and 2.5 M. For example, the outer sphere extractant may be present at a concentration of at least 0.1 M, 0.2 M or 0.3 M. There is no particular upper limit on the concentration of the outer sphere extractant, but it may be preferred that the outer sphere extractant is present in the organic phase at a concentration of 5 M or less, 3 M or less, or 1 M or less.
[0122] In some embodiments, particularly but not exclusively wherein the outer sphere extractant is a compound according to Formula II, (e.g. wherein each R 4 is independently —OR 5 ), it may be preferred that the outer sphere extractant is present at a concentration of at least 1 M, at least 1.2 M or at least 1.5 M. This may be preferable, for example, where the outer sphere extractant is tributyl phosphate.
[0123] The organic phase may also include solvent extraction modifiers, which can be employed for example to alter (e.g. lower) the viscosity of the organic phase, to enhance separation of the organic phase from the aqueous phase, and/or to suppress phase separation within the organic phase. The skilled person will be aware of suitable solvent extraction modifiers, which include for example alcohols, phenols or organic phosphates such as tributyl phosphate. Any solvent extraction modifiers are typically each present in the organic phase at a concentration of 0.9 M or less, preferably 0.7 M or less.
[0124] (As the skilled person will readily appreciate, the features of the organic phase discussed herein are equally applicable to the solvent extraction mixture of the second, third and fourth aspects of the invention.)
Separation Process
[0125] In step (a) of the methods of the present invention, the aqueous acidic phase is contacted with the organic phase, to extract the labile and non-labile metals into the organic phase. Typically, substantially all of the labile metal present in the aqueous acidic phase is extracted into the organic phase. For example, at least 95%, at least 99% or at least 99.5% is extracted. In some embodiments, a slightly lower proportion of non-labile metal is extracted into the organic phase. For example, at least 90%, at least 95%, at least 97% or at least 98% is extracted. The degree of extraction can be increased, for example by increasing the contact time and/or the number of contacts between the aqueous acidic phase and the organic phase, or by adjusting the acidity of the aqueous acidic feed as demonstrated in more detail below. One, two, three or more extraction steps may be included.
[0126] Following the extraction step, the organic phase may optionally be scrubbed. Typically, this is done by contacting the organic phase (after it has been contacted with the aqueous acidic phase) with an aqueous scrubbing solution, which preferably has a similar (e.g. the same) acidity as the aqueous acidic phase. Typically, the H + concentration of the aqueous scrubbing solution is within 1 M of the H + concentration of the aqueous acidic phase, more preferably within 0.5 M. Scrubbing advantageously allows any additional metals inadvertently extracted into the organic phase to be removed from the organic phase before the stripping step (step (b)). One, two, three or more scrubbing steps may be included. The scrubbing step may also help to remove entrained liquid from the organic phase. The scrubbing solution may comprise HCl.
[0127] In the selective stripping step of the present invention, the non-labile metal species is selectively stripped from the organic phase using water or an acidic aqueous stripping solution, to provide a first aqueous solution comprising non-labile metal species. Typically, the first aqueous solution includes substantially none of the labile metal species. For example, it may include 10 mg L −1 or less, 5 mg L −1 or less, or 2 mg L −1 or less of the labile metal species. The first aqueous solution may include 10 mg L −1 or less, 5 mg L −1 or less, or 2 mg L −1 or less of additional metal species. The concentrations are with respect to the mass of metal in the metal species.
[0128] Typically, the acidic aqueous stripping solution is less acidic than the aqueous acidic phase from which the labile and non-labile metal species are extracted. For example, the acidic aqueous stripping solution may have an H + concentration which is at least 1 M lower than the H + concentration of the aqueous acidic phase. For example, the H + concentration of the acidic aqueous stripping solution may typically be 4 M or less, 3 M or less, or 2 M or less. As demonstrated in the Examples, an H + concentration of about 1 M or 0.1 M may be particularly suitable. The stripping solution may comprise HCl.
[0129] Whether water or an acidic aqueous acidic phase is used to selectively strip the non-labile metal from the organic phase, it will typically have a pH of 7 or less. One, two, three or more stripping operations may be carried out, in order to maximise recovery of the non-labile metal.
[0130] Following the stripping step, the organic phase may optionally be washed with water. This can avoid transfer of any entrained acid from the organic phase into the solution used for selective stripping of the labile metal species. The water used for the wash may optionally be combined with the first aqueous solution, to maximise recovery of the non-labile metal.
[0131] In the selective stripping step of the present invention, the labile metal species is selectively stripped from the organic phase using an aqueous phase comprising a complexing reagent capable of complexing with the labile metal, to provide a second aqueous solution comprising labile metal species.
[0132] The complexing reagent includes a moiety capable of forming a covalent coordination bond with the metal atom of the labile metal species. Accordingly, it will be understood that the complexing reagent typically includes an atom having a lone pair capable of forming a covalent coordination bond with the metal atom of the labile metal species. For example, the moiety may comprise a nitrogen atom capable of forming a covalent coordination bond with the metal atom of the labile metal species. The moiety may comprise a sulphur atom capable of forming a covalent coordination bond with the metal atom of the labile metal species. The moiety may comprise an oxygen atom capable of forming a covalent coordination bond with the metal atom of the labile metal species. The moiety may comprise a phosphorus atom capable of forming a covalent coordination bond with the metal atom of the labile metal species. Particularly suitable complexing reagents include ammonia, compounds comprising an amine moiety (e.g. a primary or secondary amine), compounds comprising an oxime moiety, compounds comprising a —C═S moiety, compounds comprising a —S═O moiety and compounds comprising a —C═O moiety, and in particular include ammonia, compounds comprising an oxime moiety, compounds comprising a —C═S moiety, and compounds comprising a —S═O moiety. For example, the complexing reagent may be ammonia, an oxime (e.g. acetaldehyde oxime), a sulphite (e.g. ammonium sulphite) or thiourea.
[0133] The complexing reagent is water soluble, in order that it is capable of drawing the labile metal species into the second aqueous solution. Typically, the complexing reagent is present in the aqueous phase at a sufficiently high concentration that the equilibrium of the stripping reaction favours transfer of the labile metal to the aqueous phase. For example, the concentration of the complexing reagent in the aqueous phase is typically at least 1 M, at least 2 M or at least 3 M. A particularly suitable concentration is in the range from 3 M to 9 M.
[0134] Typically, the second aqueous solution includes substantially none of the non-labile metal species. For example, it may include 10 mg L −1 or less, 5 mg L −1 or less, or 2 mg L −1 or less of non-labile metal species. The second aqueous solution may include 10 mg L −1 or less, 5 mg L −1 or less, or 2 mg L −1 or less of additional metal species. The concentrations are with respect to the mass of metal in the metal species.
[0135] Typically the processes of the present invention are carried out at room temperature.
EXAMPLES
[0136] The following Examples demonstrate the efficacy of the invention for the combinations of extractants indicated in Table 1 below.
[0000]
TABLE 1
Ex-
am-
ple
Coordinating Extractant
Outer Sphere Extractant
1
2
3
4
Example 1
Preparation of Aqueous Feedstock Solution
[0137] An aqueous feedstock containing platinum group metals was prepared with concentrations as set out in Table 2 below:
[0000]
TABLE 2
Metal
Concentration/gL −1
Pt(IV)
100
Pd(II)
100
Ir(III)
5
Rh(III)
10
Ru(III)
30
[0138] This stock solution was diluted 100-fold for use in extraction experiments.
Preparation of Extractants
[0139] N-(iso-tridecyl))isotridecanamide was prepared by a process analogous to Example 1 of EP-B-0 210 004, which describes the synthesis of N-(n-propyl)-isohexadecamide.
[0140] (The content of EP-B-0 210 004 is incorporated herein by reference in its entirety and for all purposes, and in particular for the purpose of describing the synthesis of mono-N substituted amide extractants, and for the purposes of describing and defining extraction of precious metal species.)
[0141] Di-n-octyl sulphide (DOS) is commercially available from Alfa Aesar, A Johnson Matthey Company. Its CAS number is 2690-08-6.
Preparation of the Organic Phase
[0142] 1 L 0.5M N-(iso-tridecyl))isotridecanamide, 15% tributyl phosphate (TBP), 1% (w/v) DOS in Shellsol D70 was prepared by mixing 454 mL 50% (v/v) N-(iso-tridecyl))isotridecanamide in Shellsol D70, 150 g TBP, 10 g DOS and was made up to volume with Shellsol D70.
[0143] Shellsol D70 is commercially available from Shell Chemicals Limited, UK.
[0144] TBP is commercially available from Alfa Aesar, A Johnson Matthey Company. Its CAS number is 126-73-8.
Pt and Pd Extraction at Different Acidities
[0145] Extraction of platinum and palladium species from feeds with different acidities
[0146] The feeds were made up as set out in below, using feedstock solution prepared as described above:
[0147] 4 M HCl Feed:
[0148] 2 mL feedstock, 131 mL 6M HCl was made up to volume with deionised water (200 mL).
[0149] 8 M HCl Feed:
[0150] 2 mL feedstock and 138 mL conc. HCl were made up to volume with deionised water (200 mL).
[0151] 6 M HCl Feed:
[0152] 5 mL feedstock was made up to volume with 6 M HCl (500 mL).
[0153] The solvent extraction procedure for each of three feed acidities involved a single extraction of Pt and Pd from the feed into an equal volume of the organic phase by mixing for two minutes. The metal-containing organic phase was then subject to two scrub steps with equal volumes of fresh aqueous hydrochloric acid of the same concentration as the appropriate feed, again mixing for two minutes. The Pt was subsequently selectively stripped from the organic phase into an equal volume of dilute aqueous hydrochloric acid (0.1 M) by mixing for two minutes. The strip process was repeated. The organic phase was washed with an equal volume of clean water by mixing for two minutes. Pd was selectively stripped from the organic phase by mixing the organic phase with an equal volume of aqueous ammonium hydroxide (6 M).
[0154] The results for each of the aqueous solutions through the experiments at 4, 6 and 8 M HCl are provided in Tables 3, 4 and 5, respectively. The concentration of metal species was determined using Inductively Coupled Plasma Mass Spectroscopy (ICP analysis). This data shows that the extractants employed in this Example will selectively extract Pt and Pd from the other PGMs across a range of acidities. It also demonstrates that Pt may be selectively stripped from the organic phase, followed by selective stripping of Pd. The water wash could be combined with the Pt Strip solutions to maximise Pt recovery.
[0000]
TABLE 3
4M HCl feed
Concentration of metal species: mg L −1
Phase
Pd
Pt
Ir
Rh
Ru
Feed
1010
972
48
95
284
Raffinate
—
89
49
98
290
Scrub 1
—
67
1
—
2
Scrub 2
—
67
—
—
1
Pt Strip 1
—
696
—
—
—
Pt Strip 2
—
17
—
—
—
Water Wash
—
6
—
—
—
Pd Strip
938
2
—
—
—
Note:
“—” means less than detection limit of ICP
[0000]
TABLE 4
6M HCl feed
Concentration of metal species: mg L −1
Phase
Pd
Pt
Ir
Rh
Ru
Feed
1019
967
48
98
285
Raffinate
—
14
48
99
279
Scrub 1
—
11
—
1
1
Scrub 2
—
10
—
—
—
Pt Strip 1
—
812
—
—
5
Pt Strip 2
—
27
—
—
—
Water Wash
—
8
—
—
—
Pd Strip
941
3
—
—
—
Note:
“—” means less than detection limit of ICP
[0000]
TABLE 5
8M HCl feed
Concentration of metal species: mg L −1
Phase
Pd
Pt
Ir
Rh
Ru
Feed
1027
973
48
98
287
Raffinate
1
27
49
100
291
Scrub 1
—
30
1
2
4
Scrub 2
—
29
—
—
1
Pt Strip 1
—
687
—
—
2
Pt Strip 2
—
34
—
—
—
Water Wash
—
8
—
—
—
Pd Strip
959
7
—
—
—
Note:
“—” means less than detection limit of ICP
[0155] Table 6 and FIG. 1 show the distribution coefficients (calculated based on aqueous analysis), D A \ O , for Pt, Ir, Rh and Ru (Pd is excluded as its distribution coefficient is very large). The distribution coefficient is the concentration of the metal species in the organic phase divided by the concentration of the metal species in the aqueous phase. Concentrations in the organic phase have been calculated based on aqueous analysis. This demonstrates that maximum Pt extraction occurs at 6 M HCl. In all instances Ir, Rh and Ru extraction is very low, demonstrating selectivity for Pt and Pd.
[0000]
TABLE 6
Acid
Distribution Coefficient, D A \ O
Concentration
Pt
Pd
Ir
Rh
Ru
4
10
>1010
0
0
0
6
69
>1019
0
0
0
8
35
>1027
0
0
0
Pt Stripping at Different Acidities
[0156] Organic phase and 6 M HCl feed prepared as described above were used to investigate the most suitable acidity for Pt stripping.
[0157] A volume of the fresh organic solution was mixed with an equal quantity of feed solution at 6 M HCl concentration for two minutes. The organic phase was then scrubbed twice by mixing with an equal volume of fresh aqueous 6 M HCl. The results are presented in Table 7
[0000]
TABLE 7
Concentration of metal species: mg L −1
Phase
Pd
Pt
Ir
Rh
Ru
Feed
1031
997
49
101
288
Raffinate
—
13
50
101
278
Scrub 1
—
10
1
—
1
Scrub 2
—
10
—
—
1
Scrubbed organic
1031
964
—
—
8
(calc)
Note:
“—” means less than detection limit of ICP
[0158] The organic phase was split into portions to be subject to different Pt strip solutions: specifically water and HCl of 0.1, 0.5, 1.0 and 3.0 M concentration.
[0159] The concentration of Pt in each of the aqueous strip solutions for each of the strip conditions are tabulated in Table 8. The concentration of Pt remaining in the organic phase is shown in FIG. 3 . The concentrations were determined by ICP analysis. Concentrations in the organic phase have been calculated based on aqueous analysis. This data shows that Pt stripping is most effective in the first strip at low acidity.
[0000]
TABLE 8
Concentration of Pt in Solutions: mg L −1
3M HCl
1M HCl
0.5M HCl
0.1M HCl
Water
Scrubbed Organic
964
(calc)
1st Aqueous Pt
241
802
826
842
852
Strip solution
2nd Aqueous Pt
284
65
39
29
30
Strip solution
3rd Aqueous Pt
158
11
7
5
7
Strip solution
[0160] The distribution coefficients, D A \ O , for the first Pt strips into the different solutions are tabulated in Table 9 and shown in FIG. 2 . This data highlights that the best stripping (lowest D A \ O ) occurs under low acidities.
[0000]
TABLE 9
Acidity
D A \ O
3M HCl
3.00
1M HCl
0.20
0.5M HCl
0.17
0.1M HCl
0.14
0 (water)
0.13
[0161] The distribution coefficients were highest at 3 M HCl (3.00) indicating very poor stripping, whilst that into water was lowest (0.13) indicating good stripping. The distribution coefficients at 0, 0.1, 0.5 and 1.0 M HCl were very similar.
Example 2
Preparation of the Organic Phase
[0162] 25 g Cyanex 923 was weighed into a 100 mL volumetric flask and ˜50 mL Solvesso 150 added and mixed. 1 g DOS was added to the mixture and made up to 100 mL final volume with Solvesso 150.
[0163] Di-n-octyl sulphide (DOS) is commercially available from Alfa Aesar, A Johnson Matthey Company. Its CAS number is 2690-08-6.
[0164] Cyanex 923 is commercially available from Cytec. It is a mixture of hexyl and octyl phosphine oxides.
[0165] Solvesso 150 is commercially available from Brenntag. Its CAS number is 64742-94-5
Solvent Extraction Process
[0166] A feed was prepared by 100-fold dilution of an aqueous feedstock solution described in Example 1 with reference to Table 2.
[0167] The solvent extraction procedure involved a single extraction of Pt and Pd from the feed into an equal volume of the organic phase by mixing for two minutes. The metal-containing organic phase was then subject to two scrub steps with equal volumes of fresh aqueous hydrochloric acid of the same concentration as the feed (6 M HCl), again mixing for two minutes. The Pt was subsequently selectively stripped from the organic phase into an equal volume of dilute aqueous hydrochloric acid (0.1 M) by mixing for two minutes. The strip process was repeated. The organic phase was washed with an equal volume of clean water by mixing for two minutes. Pd was selectively stripped from the organic phase by mixing the organic phase with an equal volume of aqueous ammonium hydroxide (6 M). A third phase was encountered during the solvent extraction process.
[0168] The results of ICP analyses during the solvent extraction process are shown in Table 10 below.
[0000]
TABLE 10
Concentration of metal species: mg L −1
Ir
Pd
Pt
Rh
Ru
Feed
48
1042
983
100
286
Raffinate
47
—
4
100
259
Scrub 1
—
—
2
—
—
Scrub 2
—
—
1
—
—
0.1M HCl
—
—
1
—
1
0.1M HCl
—
—
20
—
5
Water
1
—
795
—
6
6M NH 3
—
505
11
—
5
Note:
“—” means less than detection limit of ICP
[0169] The Pt did not strip into low acid but into the water wash, indicating that either water or a very low acid concentration is required to effect the strip. This is believed to be due to the nature of the outer sphere extractant (Cyanex 923). The results show that it is preferable that this system is stripped directly into water rather than low acid. Pd stripping was not complete, but without wishing to be bound by theory, the inventors believe that this may be a result of excess Pt remaining in the organic after just one strip into water, as the Pt was not fully stripped by the single strip into water.
[0170] The results demonstrate that a mixture of Cyanex 923 and DOS will extract both Pt and Pd, and that the extracted Pt and Pd may be selectively stripped from the organic phase.
Example 3
Preparation of the Organic Phase
[0171] 50 g tributyl phosphate and 1 g Cyanex 471X solid were weighted into a 100 mL volumetric flask and made up to 100 mL volume with Solvesso 150.
[0172] Tributyl phosphate (TBP) is commercially available from Alfa Aesar, A Johnson Matthey Company. Its CAS number is 126-73-8.
[0173] Cyanex 471X is commercially available from Cytec.
[0174] Solvesso 150 is commercially available from Brenntag. Its CAS number is 64742-94-5
Solvent Extraction Process
[0175] A solvent extraction process was carried out using the procedure described in Example 2 above, using an organic phase comprising TBP and Cyanex 471X prepared as described above. The results of ICP analyses during the solvent extraction process are shown in Table 11 below.
[0000]
TABLE 11
Concentration of metal species: mg L −1
Ir
Pd
Pt
Rh
Ru
Feed
49
1048
958
101
288
Raffinate
52
17
197
107
304
Scrub 1
1
1
142
—
4
Scrub 2
—
1
110
—
2
0.1M HCl
—
—
478
—
2
0.1M HCl
—
—
15
—
—
Water
—
—
—
—
—
6M NH 3
—
1041
1
—
—
Note:
“—” means less than detection limit of ICP
[0176] The results demonstrate that a mixture of TBP and Cyanex471X will extract both Pt and Pd, and that the extracted Pt and Pd may be selectively stripped from the organic phase.
[0177] Significant Pt remained in the raffinate after extraction, but this could be addressed by including multiple extraction steps. Similarly, multiple extraction steps should reduce the amount of Pd remaining in the raffinate.
Example 4
Preparation of N,N-Dioctyl-Acetamide
[0178] Chloroform (150 mL) solution of di-n-octylamine (98%, 125.2 mL, 0.41 mol) and triethylamine (29.2 mL, 0.41 mol) were stirred in a three-neck flask over ice cold water. Acetyl chloride (>99%, 29.2 mL, 0.41 mol) in chloroform (50 mL) was added dropwise via a pressure-equalising funnel over 30 mins. The thick, creamy coloured, mixture was warmed to room temperature before being stirred at reflux for 2.5 hours. The resulting golden solution was concentrated by evaporation and diluted in n-hexane, filtered and washed with deionised water (300 mL), 6 M HCl (300 mL), deionised water (300 mL) and saturated aqueous sodium carbonate solution (300 mL). The organic phase was dried over magnesium sulfate, filtered and concentrated in vacuo. Yield: 81.3 g (70%).
Preparation of the Organic Phase
[0179] 14.15 g N,N-Dioctyl acetamide and 1 g di-n-hexyl sulfide (DHS) were weighed into a 100 mL volumetric flask and made up to 100 mL volume with Solvesso 150.
[0180] Di-n-hexyl sulphide is commercially available from Alfa Aesar, A Johnson Matthey Company.
[0181] Its CAS number is 6294-31-1.
[0182] Solvesso 150 is commercially available from Brenntag. Its CAS number is 64742-94-5
Solvent Extraction Process
[0183] A solvent extraction process was carried out using the procedure described in Example 2 above, using an organic phase comprising N,N-dioctyl acetamide and DHS, prepared as described above. The results of ICP analyses during the solvent extraction process are shown in Table 12 below.
[0000]
TABLE 12
Concentration of metal species: mg L −1
Ir
Pd
Pt
Rh
Ru
Feed
48
1049
986
100
291
Raffinate
49
—
26
100
280
Scrub 1
—
—
20
1
2
Scrub 2
—
—
19
—
1
0.1M HCl
—
—
754
—
10
0.1M HCl
—
—
16
—
—
Water
—
—
5
—
—
6M NH 3
—
924
40
—
—
Note:
“—” means less than detection limit of ICP
[0184] The results demonstrate that a mixture of N,N-dioctyl acetamide and DHS will extract both Pt and Pd, and that the extracted Pt and Pd may be selectively stripped from the organic phase.
Example 5
Preparation of the Organic Phase
[0185] 1 L 0.5 M N-(iso-tridecyl)isotridecanamide, 15% TBP 1% (w/v) DOS in Shellsol D70 was prepared by mixing 454 mL 50% (v/v) N-(iso-tridecyl)isotridecanamide in Shellsol D70, 150 g TBP, 10 g DOS and was made up to volume with Shellsol D70.
Preparation of the Aqueous Phase
[0186] A feed was prepared by 100-fold dilution of an aqueous feedstock solution described in Example 1 with reference to Table 2.
Solvent Extraction Process
[0187] The solvent extraction procedure involved a single extraction of Pt and Pd from the feed into an equal volume of the organic phase by mixing for two minutes. The metal-containing organic phase was then subject to two scrub steps with equal volumes of fresh aqueous hydrochloric acid of the same concentration as the appropriate feed, again mixing for two minutes. The Pt was subsequently selectively stripped from the organic phase into an equal volume of dilute aqueous hydrochloric acid by mixing for two minutes. The strip process was repeated twice. The organic phase was washed with an equal volume of clean water by mixing for two minutes. Pd was selectively stripped from the organic phase by mixing the organic phase with an equal volume of the various aqueous strip reagents detailed in Table 13
[0000]
TABLE 13
Concentration of
Percentage
Pd: mg L −1
Pd stripped
Pt Stripped Organic phase
1041
(Calc)
Organic phase after contact with:
Acetaldehyde Oxime (6M)
20
98
Ammonium Chloride
950
9
(Saturated)
Aqueous Ammonia (3M)
49
95
Aqueous Ammonia (6M)
24
98
Aqueous Ammonia (9M)
33
97
Ammonium Sulfite (6M)
15
99
Thiourea (Saturated)
1
100
[0188] This demonstrates that thiourea, ammonium sulfite and aqueous ammonia are suitable coordinating reagents for stripping Pd. It is believed that ammonium chloride is unsuitable as the ammonium ion does not have a lone pair for coordinating to Pd. The present inventors believe that it is the sulfite species which is acting as the coordinating reagent in the ammonium sulfite example.
Example 6
Preparation of Aqueous Solution
[0189] An aqueous feedstock containing gold (III) and iridium (IV) was prepared in hydrochloric acid (6 M) with Au and Ir concentrations as set out in Table 14 below:
[0000]
TABLE 14
Metal
Concentration/mgL −1
Au(III)
986
Ir(IV)
983
Preparation of the Organic Phase
[0190] 100 mL 50% (w/v) tributyl phosphate (TBP), 1% (w/v) di-n-octyl sulphide (DOS) in Multisolve 150 was prepared by mixing 50 g TBP, 1 g DOS and was made up to volume with Multisolve 150.
[0191] Multisolve 150 is commercially available from Brenntag.
[0192] TBP is commercially available from Alfa Aesar, A Johnson Matthey Company. Its CAS number is 126-73-8. DOS is commercially available from Alfa Aesar, A Johnson Matthey Company. Its CAS number is 2690-08-6.
Solvent Extraction Process
[0193] The solvent extraction procedure involved a single extraction of Au and Ir from the feed into an equal volume of the organic phase by mixing for four minutes. The metal-containing organic phase was then subject to two scrub steps with equal volumes of fresh aqueous hydrochloric acid of the same concentration as the appropriate feed, again mixing for four minutes. The Ir was subsequently selectively stripped from the organic phase into an equal volume of dilute aqueous hydrochloric acid (0.1 M) by mixing for four minutes. The strip process was repeated. Au was selectively stripped from the organic phase by mixing the organic phase with an equal volume of thiourea (1 M) in hydrochloric acid (1 M). This strip step was also repeated.
[0194] The results are provided in Table 15. The concentration of metal species was determined using Inductively Coupled Plasma Mass Spectroscopy (ICP analysis). This data shows that the extractants employed in this Example will co-extract Au and Ir. It also demonstrates that Ir may be selectively stripped from the organic phase, followed by selective stripping of Au.
[0000]
TABLE 15
Concentration of metal species: mg L −1
Phase
Au
Ir
Feed
986
983
Raffinate
—
135
Scrub 1
—
92
Scrub 2
—
80
Ir Strip 1
—
600
Ir Strip 2
—
13
Au Strip 1
698
—
Au Strip 2
180
—
Note:
“—” means less than detection limit of ICP
REFERENCES
[0000]
1. Gu Guobang et al, “Semi-industrial Test on Co-extraction Separation of Pt and Pd by Petroleum Sulfoxides”, Solvent Extraction in the Process Industries Volume 1, Proceedings of ISEC '93.
2. R. Grant; “Precious Metals Recovery and Refining”—Proc. Int. Prec. Met. Inst. 1989 | The invention relates to processes for separating metals, and in particular for separating precious metals such as platinum and palladium, by solvent extraction. The invention also provides novel solvent extraction mixtures useful in the processes of the invention. The inventors have found that by simultaneously employing different extraction mechanisms for the extraction of a plurality of different metals, a simple and convenient process for their separation can be achieved. In particular, the inventors have found that the use of different extraction mechanisms for simultaneously extracting metals from an aqueous acidic phase into an organic phase enables the extracted metals to be separated by selective stripping from the organic phase using simple and mild conditions. This process is particularly advantageous as it permits two or more metals to be separated following a single solvent extraction step, because of the ability to selectively strip the metals from the organic phase. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of the invention relates to container organizations, and more particularly pertains to a new and improved refuse recycling organizer container wherein the same utilizes compartments arranged to accommodate various catagories of recycling articles.
2. Description of the Prior Art
Contemporary society requires recycling of various components such as paper, aluminum cans, glass bottles, plastic and the like. These catagories of components are typically disposed of by conventional households in catagories such as 43 percent for paper, 18 percent for glass, 17 percent for polymerics, 12 percent for metals, and 10 percent for miscellaneous components such as fabric, fiberglass, organic wastes, and the like.
To accommodate these various components and to provide discrete storage for each of such components to permit recycling and disposal thereof, the instant invention attempts to overcome deficiencies of the prior art to provide compartments arranged in approximation of the percentage breakdown for the various components. Further inasmuch as such components may vary from household to household, the compartments devised by the instant invention are adjustable to accommodate variation of disposal of various items between households. Examples of prior art containers are set forth in U.S. Pat. No. 4,834,253 to CRINE for example wherein a recycling container unit utilizes a trio of generally pie shaped containers mounted within a central housing for disposal of various items therewithin.
U.S. Pat. No. 3,904,218 to KOSTIC sets forth a trash disposal unit with a platform movably mounted and supporting a series of four quadrant container chutes.
U.S. Pat. No. 4,739,894 to PENDER sets forth a compartmentalized container organization for trash disposal.
U.S. Pat. No. 4,646,628 to LADERMAN utilizes a cooking utensil illustrating the use of various removable chambers from within a central cooking pot.
U.S. Pat. No. 4,775,066 to KEPPELER sets forth an in ground trash receptacle for temporary storage of disposable and reclaimable items that is partially buried to prevent access to such components by scavengers, insects, and the like.
Accordingly, it may be appreciated that there continues to be a need for a new and improved refuse recycling organizer container as set forth by the instant invention which addresses both the problems of ease of use as well as effectiveness in construction in compartmentalizing and selectively providing adjustment for various components of recyclable refuse.
SUMMARY OF THE INVENTON
In view of the foregoing disadvantages inherent in the known types of refuse containers present in the prior art, the present invention provides a new and improved refuse recycling organizer container wherein the same utilizes selectively adjustable compartments within a central container to accommodate various catagories of refuse therewithin. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved refuse recycling organizer container which has all the advantages of the prior art refuse containers and none of the disadvantages.
To attain this, the refuse recycling organizer container of the instant invention includes container structure including spaced and parallel forward and rear walls and spaced and parallel side walls to define, a container with a lid removably mounted thereon. The forward and rear walls include spaced parallel slots to selectively receive divider walls therebetween. The organization is arranged to utilize castor wheels for mobility and optionally utilize adjustable wall portions for longitudinal division of the container.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention.
It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new and improved refuse recycling organizer container which has all the advantages of the prior art refuse containers and none of the disadvantages.
It is another object of the present invention to provide a new and improved refuse recycling organizer container which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved refuse recycling organizer container which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved refuse recycling organizer container which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such refuse recycling organizer containers economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved refuse recycling organizer container which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
Still another object of the present invention is to provide a new and improved refuse recycling organizer container which may be compactly stored when not being utilized.
Yet another object of the present invention is to provide a new and improved refuse recycling organizer container wherein the same provides adjustable compartments to accommodate variations of disposable refuse between various households in accordance with that household's needs for compartmentalizing various recyclable refuse components.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is an isometric illustration of a prior art refuse container.
FIG. 2 is a further example in isometric illustration of a refuse container or the prior art.
FIG. 3 is an isometric illustration of the instant invention.
FIG. 4 is an isometric illustration somewhat exploded of the instant invention.
FIG. 5 is an isometric illustration of a modified divider wall utilized by the instant invention.
FIG. 6 is an isometric illustration of a modified refuse container of the instant invention utilizing various latches and the like for support of component bags mounted within the container.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 to 6 thereof, a new and improved refuse recycling organizer container embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 and 10a will be described.
FIG. 1 illustrates a prior art refuse container 1 wherein a central container housing 2 includes a trio of pie shaped refuse container selectively receivable and removable from the container 2. FIG. 2 illustrates a further storage container 4 utilizing various compartments 5 of a fixed relationship interiorly of the container for temporary burial during a camping procedure and the like for temporary storage of refuse preventing access thereto by vermin, insects, and the like.
More specifically, the refuse recycling organizer container 10 of the instant invention comprises, a container defined by a forward wall 11 spaced from and parallel to a rear wall 12. A first side wall 13 is spaced from and parallel to a second side wall 14 with the walls orthogonally mounted to a floor 15 to define the rigid container. Castor wheels 16 are mounted at each corner of the floor to permit mobility of the organization. It is contemplated that the container as defined be dimensioned for positioning within a kitchen environment as a substitute for a trash compactor and the like to thereby provide organizational compartments for storage of various catagories of recyclable refuse. A lid 17 is illustrated utilizing spaced hinges 18 to mount the lid to the rear wall 12 but alternatively that it is contemplated that the lid be removable relative to the wall structure to permit access to the interior compartments of the container. Accordingly various members such as spring clamps or positioning pegs such as the pegs 17a as illustrated be utilized to provide registration of the lid relative to the container.
The interior surface of the forward wall 11 is defined by a series of slot groups defining a series of first slots 19 defined by a first width and a series of second slots 20 defined by a second width greater than that of the first width. The first and second slots are also formed to an interior surface of the rear wall 12 in alignment with corresponding first slots of the forward wall 11. The aligned slots permit reception of various divider panels in an adjustable manner interiorly of the container. Specifically, a first longitudinal panel 21 defined by a width equal to the second width is selectively receivable within one of the second pairs of aligned slots 20 formed within the forward and rear wall. A lateral panel 22 is orthogonally oriented relative to the second wall 14 and received within a corresponding longitudinal panel slot 21a aligned with a forward edge of the lateral panel 22. The lateral panel 22 is formed with further first slots 19a formed on each side of the lateral panel wherein each of the individual further first slots 19a are aligned with corresponding and confronting first slots 19 formed on the respective forward and rear walls 11 and 12 as illustrated to permit reception of first cross panel 28 selectively mounted between the forward wall 11 and the lateral panel 22 and a second cross panel 28a mounted between the lateral panel 22 and the rear wall 12. Further, as illustrated in FIG. 3, polymeric label strips 23 are provided adjacent each upper edge of each compartment defined by each of the panels within the wall structure of the container to permit convenient labeling of various catagories of recyclable refuse to be provided within each of the compartments.
Reference to FIG. 6 illustrates a modified container structure 10a wherein modified longitudinal panels 26 are utilized including a series of hooks 25 positioned within apertures 24 formed through each of the modified longitudinal panels 26 to assist in securement of various bag structures such as polymeric bags for reception of various catagories of refuse components as noted within each of the compartments. Further, a further longitudinal panel 29 (see FIG. 5) may be positioned between the modified longitudinal panel 26 and the second wall 14 as well as utilized in providing a panel for securement between spaced and aligned second slots 20.
The further longitudinal panel 29 is defined by a first planar apertured panel 30 including a matrix of rows and columns of apertures 33 therethrough spaced from and parallel to a second apertured panel 31 comprising a matrix of apertures 33 aligned with a matrix of apertures 33 within the first panel. Accordingly in this manner, plug members 34 are directed through selective apertures within a single column of apertures to provide an abutment surface for reception of a slide panel 32 complementarily received between the spaced first and second apertured panels 30 and 31. In this manner, the effective length of the further longuitudinal panel 29 is adjustable to accommodate various positions of the longitudinal panel 26 or 21 utilized within a container structure. The plug members 34 are of a relatively resilient construction to permit effective anchoring within an aligned pair of apertures defined between the first and second apertured panels 30 and 31 and including a shank portion 35 to be directed therethrough to proivde the abutment surface in the spacing between the first and second apertured panels 30 and 31.
As to the manner of usage and operation of the instant invention, the same should be apparent from the above disclosure and accordingly no further discussion relative to the manner of usage and operation of the instant invention shall be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | Container structure including spaced and parallel forward and rear walls and spaced and parallel side walls to define a container with a lid removably mounted thereon. The forward and rear walls include spaced parallel slots to selectively receive divider walls therebetween. The organization is arranged to utilize castor wheels for mobility and optionally utilize adjustable wall portions for longitudinal division of the container. | 8 |
BACKGROUND OF THE INVENTION AND RELATED ART STATEMENT
[0001] The present invention relates to a gasket clamped between two members fastened by fixtures to seal a sealing subject hole, and an engine with the gasket.
[0002] In order to improve fuel consumption, in a recent engine (internal combustion), both a cylinder block and a cylinder head are formed by a lighter material, for example, aluminum and the like, or a thickness is thinly formed and the like so as to be made lighter. As a result, both the cylinder block and the cylinder head have a low rigidity.
[0003] When such a cylinder block and cylinder head are tightened by a high head-bolt axial force by clamping the cylinder head gasket for sealing a combustion gas inside a cylinder bore, coolant water inside a water jacket, and lubricant oil, since a thickness of an upper face of the cylinder block is thin, there acts a force pulling up the cylinder block near an end of a head bolt. Also, at the same time, near the sealing subject hole such as the cylinder bore and the like, there also acts a force pushing down on the cylinder block by a surface pressure of the cylinder head gasket. As a result, a stress at a periphery of the water jacket or at a periphery of the cylinder bore increases locally, and there is a problem that the cylinder bore or a cylinder liner inserted into the cylinder bore is distorted or deformed.
[0004] Especially, in a case of a closed-deck-type cylinder block, the head bolt and the cylinder bore are connected without opening, so that the stress at the periphery of the water jacket or at the periphery of the cylinder bore of the relevant portion increases. Accordingly, a distortion or a deformation of the cylinder bore or the cylinder liner tends to occur.
[0005] If the cylinder bore or the cylinder liner is distorted or deformed, and is no longer capable of maintaining a circular shape, an unnecessary resistance is generated between the cylinder bore or the cylinder liner, and a piston carrying out a piston movement inside the cylinder bore; thereby the fuel consumption is deteriorated. Also, the lubricant oil flows into the cylinder bore, and the lubricant oil burns so as to cause adverse effects on an exhaust gas.
[0006] Here, a conventional cylinder head gasket will be explained with reference to FIG. 6 . A cylinder head gasket 10 X is the gasket clamped between a cylinder block 2 and a cylinder head 3 fastened by head bolts 1 , and sealing cylinder bores 4 , water jackets 5 , and a hole for the lubricant oil which is not shown in the figure. The cylinder head gasket 10 X is the gasket used for, i.e., the closed-deck-type cylinder block 2 wherein all upper faces of the water jackets 5 are not open.
[0007] The cylinder head gasket 10 X comprises cylinder-bore holes 12 , water holes 13 , and bolt holes 14 in a substrate 11 formed by laminating a plurality of metal plates. As shown in FIG. 7 , in respective circumferential edge portions thereof, there are provided cylinder-bore hole beads 15 , water hole beads 16 , and bolt hole beads 17 .
[0008] The cylinder head gasket 10 X is clamped between the cylinder block 2 and the cylinder head 3 , and the head bolts 1 are inserted and passed through the bolt holes 6 , 7 , and 14 so as to fasten the cylinder block 2 and the cylinder head 3 . At that time, the cylinder block 2 and the cylinder head 3 are fastened by the high head-bolt axial force to allow the cylinder head gasket 10 X to reliably seal the combustion gas inside the cylinder bores 4 , the coolant water inside the water jackets 5 , and the lubricant oil.
[0009] In a case of being fastened by the high head-bolt axial force in this manner, a fastening stress concentrates in areas (hereinafter, these portions are called fastening-stress concentration areas A) shown by A in the figure, and as mentioned above, the stress increases in these portions. Then, as a result, as shown in FIG. 7 , inner circumferential faces 4 a of the cylinder bores 4 are distorted, or the cylinder liner which is not shown in the figure is distorted.
[0010] With respect to the aforementioned problem, there is proposed a device wherein an end-surface pressure adjusting portion is provided in a gasket main body, which can press against a deck surface of the cylinder block and a deck surface of the cylinder head on an outside further than an end-portion bolt line connecting centers of a pair of bolt insertion holes lining up in a width direction of the engine at both end portions in a cylinder line direction, or in both end portions in the cylinder line direction (for example, see Japanese Patent Application Publication No. 2005-23773).
[0011] The aforementioned device can solve the problem that by the surface pressure receiving from the cylinder head gasket, the cylinder bore of each cylinder is deformed to bulge, so that if a surface pressure distribution is uneven, a deformation amount of the cylinder bore becomes also uneven so as to impair a circularity of the cylinder bore. Accordingly, the deformation of the cylinder bore relevant to the cylinder line direction can be controlled.
[0012] However, as mentioned above, when the cylinder block and the cylinder head are fastened, the fastening-stress concentration areas wherein the fastening stress thereof concentrates are generally disposed in a radial direction relative to the cylinder bore. Therefore, the deformation of the cylinder bore occurs not only in the cylinder line direction.
[0013] Also, the surface pressure distribution in a whole area of the gasket is made symmetrical in a right-and-left direction so as to control the deformation of the gasket cylinder bore in the cylinder line direction. However, there is no effect on the deformation of each cylinder bore due to the fastening stress in the fastening-stress concentration areas present in an outer circumference of each cylinder bore, and the distortion or the deformation of each cylinder bore cannot be controlled.
[0014] The present invention is made in view of the aforementioned problem, and an object of the present invention is to provide a gasket and a cylinder head gasket which can reduce the fastening stress generated when the two members are fastened by the fixture, and control the distortion, the deformation, or the like due to the fastening stress.
[0015] Further objects and advantages of the invention will be apparent from the following description of the invention.
SUMMARY OF THE INVENTION
[0016] In order to attain the above-mentioned object, a gasket of the present invention is clamped between two members fastened by fixtures, and seals a sealing subject hole. When the two members are fastened by the fixtures, in a fastening-stress concentration area wherein a fastening stress concentrates between a fixture hole, in which the fixture is inserted and passed through, and the sealing subject hole, the gasket of the present invention includes a fastening-stress reduction portion extending only in the fastening-stress concentration area.
[0017] According to the configuration, the fastening-stress reduction portion is formed in the fastening-stress concentration area where the fastening stress is generated when the two members are fastened by the fixture, the fastening stress thereof is reduced to control a distortion, a deformation, or the like of an inner circumference of the sealing subject hole. Thereby, without hindering a movement of a device or a fluid passing through the sealing subject hole, the sealing subject hole can be reliably sealed.
[0018] Incidentally, the gasket is a cylinder head gasket clamped between a cylinder block and a cylinder head, an intake-and-exhaust-system gasket provided in a joint line between a pipe arrangement and a pipe arrangement, and the like. Also, the term fastening-stress reduction portion extends only in the fastening-stress concentration area, and indicates beads except for seal beads provided around the sealing subject hole, or a shim. The fastening-stress reduction portion is configured so as not to block a surface pressure into the seal beads.
[0019] Also, in the aforementioned gasket, preferably, the fastening-stress concentration area is made as an area enclosed by two tangent lines of the fixture hole parallel to an axis line connecting a center of the fixture hole and a center of the sealing subject hole; an outer edge of the fixture hole; and an outer edge of the sealing subject hole so as to be effective.
[0020] Additionally, in the aforementioned gasket, preferably, the fastening-stress reduction portion is configured by fastening-stress reduction beads linearly formed, and also is disposed on the axis line connecting the center of the fixture hole and the center of the sealing subject hole so as to have an excellent working property.
[0021] Within a range of the fastening-stress concentration area, a cross-sectional shape thereof or the number of the fastening-stress reduction portion is not specially limited. However, preferably, there may be provided the fastening-stress reduction beads within the range of the fastening-stress concentration area, which extend radially relative to the sealing subject hole. More preferably, the fastening-stress reduction beads, whose cross-sectional shape is an arbitrary shape and which are formed in a linear shape, may be provided on the axis line connecting the center of the fixture hole and the center of the sealing subject hole.
[0022] Moreover, in the cylinder head gasket of the present invention for solving the aforementioned object, the aforementioned gasket is formed by a plurality of metal plates, and is configured by being clamped between the cylinder block and the cylinder head.
[0023] According to the structure, the fastening-stress reduction portion is provided within the range of the fastening-stress concentration area, so that in a case wherein the cylinder block and the cylinder head are fastened by a high head-bolt axial force, the fastening-stress reduction portion, provided between a head bolt (the fixture) and a cylinder bore (the sealing subject hole), becomes a resistance not allowing the cylinder block to be distorted. Thereby, the distortion or the deformation of the cylinder bore or a cylinder liner due to the fastening stress can be controlled.
[0024] In a case of the cylinder block having a lightweight and a low rigidity, when the cylinder block is fastened by the high head-bolt axial force, since a thickness of an upper surface is thin, there acts a force pulling up an inner circumferential surface of the cylinder block, and a stress at a periphery of a water jacket or at a periphery of the cylinder bore increases locally. Especially, in a case of a closed-deck-type cylinder block, the head bolt and the cylinder bore are connected so as to increase the stress of the relevant portion.
[0025] In the present invention, the stress at the periphery of the water jacket or at the periphery of the cylinder bore is reduced, so that the distortion or the deformation of the cylinder bore or the cylinder liner can be controlled. Thereby, a movement of a piston inside a cylinder due to the distortion or the deformation of the cylinder bore or the cylinder liner is not hindered so as to be capable of improving fuel consumption. Also, an inflow of lubricant oil or water into an inside of the cylinder bore can be prevented.
[0026] According to the present invention, the fastening stress generated when the two members are fastened by the fixture is reduced, and the distortion, the deformation, and the like due to the fastening stress can be controlled.
[0027] Especially, the fastening stress of the closed-deck-type cylinder block is reduced, and the distortion, the deformation, and the like of the cylinder bore can be controlled. Thereby, a shape of the cylinder bore and the cylinder liner is maintained, and an unnecessary resistance is not allowed to be generated in the cylinder bore and the cylinder so as to be capable of improving the fuel consumption.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is an exploded perspective view showing a cylinder head gasket of an embodiment according to the present invention, and an engine clamping the cylinder head gasket thereof between a cylinder block and a cylinder head;
[0029] FIG. 2 is an enlarged plan view showing fastening-stress concentration areas of the cylinder head gasket in FIG. 1 ;
[0030] FIGS. 3( a ) and 3 ( b ) are cross-sectional views taken along III-III in FIG. 2 ;
[0031] FIGS. 4( a ) to 4 ( d ) are enlarged views showing fastening-stress reduction beads of the cylinder head gasket in FIG. 1 , and show the fastening-stress reduction beads having respectively different shapes;
[0032] FIGS. 5( a ) and 5 ( b ) are plan views showing an intake-and-exhaust-system gasket of the embodiment according to the present invention, and show the intake-and-exhaust-system gasket having respectively different shapes;
[0033] FIG. 6 is an exploded perspective view showing a conventional cylinder head gasket, and an engine wherein the cylinder head gasket thereof is clamped between the cylinder block and the cylinder head; and
[0034] FIG. 7 is an enlarged plan view showing an area where a fastening stress of the cylinder head gasket in FIG. 6 concentrates.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0035] Hereinafter, a gasket and a cylinder head gasket of an embodiment according to the present invention will be explained with reference to drawings. Incidentally, in FIGS. 1 to 7 , sizes are changed for the sake of explanation of a configuration, and sizes of a dimension of a cylinder-bore hole, a water hole, a thickness of beads, a shape, and the like do not necessarily correspond to a ratio of actual manufactured ones.
[0036] Also, as the embodiment, FIGS. 1 to 4( d ) explain the cylinder head gasket used for an in-line four-cylinder engine as an example. However, as for an engine to which the present invention can be applied, the number of cylinders and an array thereof are not limited. Also, in the present invention, especially a closed-deck type wherein a water jacket portion is not all open exerts the most effect. However, the present invention can be applied to an open-deck type as well.
[0037] Moreover, for the embodiment, FIGS. 5( a ) and 5 ( b ) explain an intake-and-exhaust-system gasket as an example. The term intake-and-exhaust-system gasket here indicates a gasket which is provided in a joint line between a pipe arrangement and a pipe arrangement of a muffler, a manifold, and the like.
[0038] A cylinder head gasket 10 of the embodiment according to the present invention will be explained with reference to FIGS. 1 to 4( d ). The cylinder head gasket 10 is formed in a configuration of a conventional cylinder head gasket 10 X shown in FIG. 6 . As shown in FIG. 1 , when a cylinder block 2 and a cylinder head 3 (two members) are fastened by head bolts (fixtures) 1 , in fastening-stress concentration areas A wherein a fastening stress concentrates between bolt holes (fixture holes) 14 , through which the head bolts 1 pass, and cylinder-bore holes (sealing subject holes) 12 , there are provided fastening-stress reduction beads (fastening-stress reduction portions) 18 extending only in the fastening-stress concentration areas A.
[0039] Here, the fastening-stress concentration areas A will be explained. As shown in FIG. 2 , the fastening-stress concentration areas A are areas wherein the fastening stress concentrates when the cylinder block 2 and the cylinder head 3 are fastened by the head bolts 1 . Specifically, the fastening-stress concentration areas A are the areas between the cylinder-bore holes 12 and the bolt holes 14 , and are the areas enclosed by two bolt-hole tangent lines L 2 of the bolt hole 14 parallel to a head-bolt axis line L 1 connecting a center (the center of a cylinder bore 4 ) O of the cylinder-bore hole 12 , and a center P of the bolt hole 14 ; an outer circumferential edge (in a case of the embodiment, indicating cylinder-bore hole beads 15 ) of the cylinder-bore hole 12 ; and an outer circumferential edge (in the case of the embodiment, indicating bolt hole beads 17 ) of the bolt hole 14 .
[0040] Generally, around each cylinder bore 4 provided in the cylinder block 2 , there is provided a plurality of bolt holes 6 . In the embodiment, there are provided four bolt holes 6 relative to one cylinder bore 4 . Therefore, each cylinder-bore hole 12 is enclosed by four fastening-stress concentration areas A, and when the cylinder block 2 and the cylinder head 3 are fastened by the head bolts 1 , stresses at a periphery of water jackets 5 and at a periphery of the cylinder bores 4 increase locally in the respective four fastening-stress concentration areas A.
[0041] In the present invention, in order to control a distortion or a deformation of each cylinder bore 4 , there are provided the fastening-stress reduction beads 18 in all respective fastening-stress concentration areas A (in the embodiment, since there are four fastening-stress concentration areas A relative to one cylinder bore, there are sixteen fastening-stress concentration areas A).
[0042] The fastening-stress reduction beads 18 are the beads except for seal beads such as the cylinder-bore hole beads 15 ; water hole beads 16 ; the bolt hole beads 17 ; and the like, and are the beads extending only inside the fastening-stress concentration areas A. In the fastening-stress reduction beads 18 , a cross-sectional shape thereof or a shape in a plan view are not specially limited. Also, the fastening-stress reduction beads 18 do not contribute to the cylinder-bore hole beads 15 provided around the cylinder-bore hole 12 ; the water hole beads 16 provided around the water hole 13 ; and the bolt hole beads 17 provided around the bolt hole 14 , and are configured not to block a surface pressure of each of the beads 15 to 17 .
[0043] In the embodiment, as shown in FIG. 3( a ), as the fastening-stress reduction portions, there are provided the fastening-stress reduction beads 18 formed in a convex type toward the cylinder head 3 , and the fastening stress of the fastening-stress concentration areas A is reduced. However, in place of the fastening-stress reduction beads 18 , for example, as shown in FIG. 3( b ), on a substrate 11 formed by a plurality of metal plates, there may be provided a fastening-stress reduction shim 19 which can press against the cylinder head 3 when the cylinder block 2 and the cylinder head 3 are fastened by the head bolts 1 .
[0044] Also, the cross-sectional shape, and the shape in the plan view of the fastening-stress reduction beads 18 , the number of the fastening-stress reduction beads 18 provided in one fastening-stress concentration area A, and the like are not specially limited. For example, as fastening-stress reduction beads 21 in FIG. 4( a ), the fastening-stress reduction beads 21 may be provided by displacing the fastening-stress reduction beads 21 from the head-bolt axis line L 1 . In that case, relative to the head-bolt axis line L 1 , the fastening-stress reduction beads 21 are disposed to have a predetermined angle, or may be disposed not to intersect with the head-bolt axis line L 1 . Also, as fastening-stress reduction beads 22 in FIG. 4( b ), the fastening-stress reduction beads 22 may be formed in a polygonal shape, and may be formed in various shapes such as a circular shape, an oval shape, and the like besides the polygonal shape.
[0045] Additionally, as fastening-stress reduction beads 23 in FIG. 4( c ), the fastening-stress reduction beads 23 may not be arranged linearly in the plan view, and may be meandered in a W shape, an S shape, or the like. Moreover, as fastening-stress reduction beads 24 and 25 shown in FIG. 4( d ), a plurality of the fastening-stress reduction beads 18 may be provided in one fastening-stress concentration area A.
[0046] As mentioned above, the fastening-stress reduction portions can be formed in the beads or shims having various shapes, and be disposed in the fastening-stress concentration area A. However, preferably, for example, as shown in FIG. 1 , each fastening-stress reduction beads 18 may be arranged radially relative to the cylinder-bore hole 12 . More preferably, as shown in FIG. 2 , the fastening-stress reduction beads 18 , whose cross-sectional shape is an arbitrary shape and which are formed in a linear shape in the plan view, may be disposed on the head-bolt axis line L 1 connecting the center O of the cylinder-bore hole 12 and the center P of the bolt hole 14 .
[0047] If the fastening-stress reduction beads 18 formed linearly are disposed on the head-bolt axis line L 1 , they can be easily manufactured, and have a great effect reducing the fastening stress as well. Incidentally, in the embodiment, four bolt holes 6 are provided relative to one cylinder bore 4 , so that the head-bolt axis line L 1 connecting the center O of the cylinder-bore hole 12 and the center P of the bolt hole 14 exactly becomes a diagonal line of a polygonal shape which has the center P of each bolt hole 14 enclosing one cylinder-bore hole 12 at the top. The fastening-stress reduction beads 18 are provided on the diagonal line thereof so as to reduce the fastening stress generated between all the bolt holes 14 and the cylinder-bore holes 12 provided around the cylinder-bore holes 12 .
[0048] On the other hand, the fastening-stress reduction beads 18 can not block the surface pressure of the cylinder-bore hole beads 15 , the water hole beads 16 , and the bolt hole beads 17 , so that, for example, as shown in FIG. 4( a ), if the fastening-stress reduction beads 21 are provided by displacing the fastening-stress reduction beads 21 from the head-bolt axis line L 1 , a clearance between the cylinder-bore hole beads 15 , the water hole beads 16 , and the bolt hole beads 17 can be obtained so as to be capable of preventing the surface pressure from being blocked.
[0049] According to the aforementioned configuration, in the fastening-stress concentration areas A of the cylinder head gasket 10 clamped between the cylinder block 2 and the cylinder head 3 , there is provided the fastening-stress reduction beads 18 to become a resistance when the cylinder block 2 and the cylinder head 3 are fastened by the head bolts 1 , and the fastening stress when the cylinder block 2 and the cylinder head 3 are fastened by the head bolts 1 is reduced so as to be capable of controlling the distortion or the deformation of the cylinder bore 4 , or a cylinder liner which is not shown in the figures due to the fastening stress.
[0050] Especially, as explained in the aforementioned embodiment, the fastening stress of the closed-deck-type cylinder block 2 is reduced, and the distortion, the deformation, or the like of the cylinder bore 4 or the cylinder liner can be controlled, so that the shape of a cylinder is maintained, and an unnecessary resistance is not allowed to be generated in the cylinder bore 4 and a piston (not shown in the figures) inside the cylinder so as to be capable of improving fuel consumption.
[0051] Incidentally, a material of the metal plates forming the substrate 11 of the cylinder head gasket 10 , and the number of the metal plates are not limited, and for example, the metal plates forming the substrate 11 may be configured by one sheet of the metal plate instead of a plural number.
[0052] Next, an intake-and-exhaust-system gasket 30 of the embodiment according to the present invention will be explained with reference to FIGS. 5( a ) and 5 ( b ). As shown in FIG. 5( a ), the intake-and-exhaust-system gasket 30 comprises an exhaust-gas hole 32 and bolt holes 33 in a substrate 31 formed by one sheet or a plurality of the metal plates, and exhaust-gas hole beads 34 and bolt hole beads 35 are respectively provided in circumferential edge portions thereof.
[0053] Then, in fastening-stress concentration areas B that are enclosed by two bolt-hole tangent lines L 4 of the bolt hole 33 parallel to a head-bolt axis line L 3 connecting a center Q of the exhaust-gas hole 32 and a center R of the bolt hole 33 ; an outer circumferential edge (in the case of the embodiment, indicating the exhaust-gas hole beads 34 ) of the exhaust-gas hole 32 ; and an outer circumferential edge (in the case of the embodiment, indicating the bolt hole beads 35 ) of the bolt hole 33 , fastening-stress reduction beads 36 are formed.
[0054] The fastening-stress reduction beads 36 provided in the fastening-stress concentration areas B are formed in the shape explained in the fastening-stress reduction beads 18 provided in the fastening-stress concentration areas A of the first embodiment, and the like. The fastening-stress reduction beads 36 do not block the surface pressure of the exhaust-gas hole beads 34 , and the bolt hole beads 35 so as to be capable of reducing the fastening stress in the fastening-stress concentration areas B.
[0055] In the embodiment, there have been illustrated an example, as shown in FIG. 5( a ), wherein three bolt holes 33 are provided, and the substrate 31 is formed in a triangle shape, or an example, as shown in FIG. 5( b ), wherein two bolt holes 33 are provided, and the substrate 31 is formed in a rhombus shape. However, in the present invention, the shape of the substrate 31 or the number of the bolt holes 33 are not limited.
[0056] Incidentally, as for the embodiment of the present invention, there have been explained the cylinder head gasket 10 and the intake-and-exhaust-system gasket 30 as an example. However, the present invention can be applied provided that the gasket is a gasket clamped between two members fastened by a fixture such as a bolt and the like. For example, the present invention can be applied to a transmission, a gasket for a clutch cover, and the like.
[0057] The gasket of the present invention reduces the fastening stress generated when the two members are fastened by the fixture, and can control the distortion, the deformation, and the like due to the fastening stress so as to be capable of being used for sealing a closed-deck-type engine, wherein the cylinder bore is going to be distorted due to the fastening stress especially when the two members are fastened.
[0058] The disclosure of Japanese Patent Application No. 2012-268199, filed on Dec. 7, 2012, is incorporated in the application.
[0059] While the invention has been explained with reference to the specific embodiments of the invention, the explanation is illustrative and the invention is limited only by the appended claims. | A gasket clamped between two members fastened by a fixture, includes first and second metal plates laminated together to form the gasket, fixture holes formed in the first and second metal plates for inserting the fixture therein, sealing subject holes formed in the first and second metal plates, fastening-stress concentration areas located on the first and second metal plates between the fixture holes and the sealing subject holes where a fastening stress concentrates when the two members are fastened by the fixture, and a linear bead formed on the first metal plate only at the fastening-stress concentration area to reduce the fastening stress when the two members are fastened. The linear bead projects to a side opposite to the second metal plate, and is disposed on an axis line connecting a center of the fixture hole and a center of the sealing subject hole in the first metal plate. | 5 |
FIELD OF THE INVENTION
The field of this invention relates to downhole packers and bridge plugs which contain principally nonmetallic components so that the packer or plug structure can be easily drilled out.
BACKGROUND OF THE INVENTION
In many applications where a packer or bridge plug is to be used, there exists a need at some point in time for subsequent removal of the plug. Packers or plugs made primarily from metallic substructures which involve resilient seals, which are compressed in a sealing relationship with the wellbore, generally take a long time to drill or mill out. Accordingly, a need has developed in the past to construct a packer of materials which are more easily drilled out than the traditional metallic structural components of packers and bridge plugs. Accordingly, bridge plugs have been made with wooden mandrels and metallic slips, as illustrated in U.S. Pat. No. 1,684,266. Other designs have featured nonmetallic mandrels and/or slips. These designs are illustrated in U.S. Pat. Nos. 5,224,540; 5,390,737; 5,540,279; 5,271,468; and 5,701,959. Other designs have simply featured softer materials or other design components so as to make the overall packer or bridge plug easy to drill out. These packers include those disclosed in U.S. Pat. Nos. 2,589,506; 4,151,875; and 4,708,202. Additionally, wiper plugs used primarily in cementing have been made of nonmetallic materials to facilitate rapid drill-out. An example of a nonrotating plug of this nature is illustrated in U.S. Pat. No. 4,858,687.
When trying to use as few metallic components as possible in a packer or bridge plug, problems develop which are not normally dealt with when constructing a mostly metallic packer. One of the difficulties is the mechanism to hold the set once the packer or bridge plug is set. Accordingly, one of the objectives of the present invention is to simplify the locking mechanism for a packer or bridge plug having primarily nonmetallic components. Another problem with composite bridge plugs or packers is to guard against extrusion of the sealing element using as few components as possible, yet providing sufficient structural strength on either side of the element to retain it in proper set position without significant extrusion due to pressure differential. Accordingly, another object of the present invention is to provide a simple, functional design which will minimize relative axial travel required to make functional the backup assemblies that retain the sealing element against extrusion. Guiding systems for slips are an important feature in a composite packer, and one of the objectives of the present invention is to provide an improved system for guiding the slips from the retracted to the set position. Composite packers will still be run into the well on a setting tool which is metallic. One of the objectives of the present invention is to provide a design which removes the components of the setting tool left behind in prior designs as a result of setting a composite packer. Thus, the objective is to retrieve metallic components of the setting tool after the set, so that subsequent milling will not be lengthened by having to mill through the residual component of the setting tool after the packer or bridge plug is set.
In another objective of the present invention, each of the composite plugs has a clutching feature or an extending tab on at least one of the top and bottom. Thus, when there are multiple composite bridge plugs set in the wellbore and they need to be drilled out, they can be pushed against one another to interlock to facilitate the milling of the top most packer or bridge plug while it is held to a lower plug which is still set. These and other features will become apparent to those of skill in the art from a description of the preferred embodiment below.
SUMMARY OF THE INVENTION
A composite packer or bridge plug is disclosed. The design features substantially all nonmetallic components. The design allows the setting tool metallic components to be retrieved after the bridge plug is set. The slips contain flats with mating flats on the cones which extend to one end of the cones and guides for the slips to facilitate proper slip movement into engagement with the wellbore. A lock ring rides on the nonmetallic mandrel and secures the set, using a buttress-type thread to engage into the mandrel body. Alternative designs are revealed for backup to the sealing elements to prevent extrusion. In one design, split rings are axially compressed so that they grow in radial dimension to act as extrusion barriers. In another design, tapered scored rings are rotationally locked against each other and are axially compressed so that they bend into contact with the wellbore to act as extrusion barriers. Axial travel to obtain an extrusion barrier is minimized. The slips are made of a cohesive component and separate from each other upon advancement with respect to the cone. Mandrels of different plugs can lock together end-to-end to facilitate mill-out in multi-plug installations.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 a-c illustrate the preferred embodiment of the composite packer of the present invention.
FIG. 2 is a perspective view of the cone which guides the slips.
FIG. 3 is a section view through the slip assembly showing all the slips retained to each other.
FIG. 4 is a view of FIG. 3 showing the slip ring in an end view.
FIG. 5 is section view through the lock ring.
FIG. 6 is a detail of the engaging thread on the lock ring which engages the mandrel.
FIGS. 7, 8 and 9 are section views of an assembly of rings which act as backup and deter extrusion of the sealing element with the ring of FIG. 7 being closest to the sealing element, FIG. 8 between FIGS. 7 and 9 when fully assembled, as shown in FIG. 1 b.
FIGS. 10 and 11 are, respectively, section and end views of an alternative embodiment which is preferred for the sealing element backup assembly showing slotted beveled rings being used.
FIG. 12 shows in two different positions the overlapping rings which are scored and rotationally locked in the run-in position and the set position.
FIG. 13 is the view of FIG. 12 looking at a side view.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The packer or bridge plug, which will be referred to as plug P, is shown in the assembly drawing of FIGS. 1 a-c , a known setting tool 10 which can be a metallic structure. The setting tool 10 has a setting sleeve 12 which bears down on spacer washer 14 . Spacer washer 14 is preferably made of a fiber glass/epoxy laminate. Mandrel 16 , which is preferably made of fabric laminated fiber glass or filament wound with high-temperature epoxy resin, supports the slip molding 18 . Slip molding 18 is made preferably of glass-reinforced phenolic moulding compound such as Fiberite® FM 8130E. The slip molding 18 is shown in more detail in FIGS. 3 and 4. As can be seen in FIGS. 3 and 4, the slip molding 18 is a unitary ring featuring individual slips 20 held together by tabs 22 . Each of the slips 20 has a flat portion 24 which rides on a flat 26 of the cone 28 shown in FIG. 2 . Cone 28 has a plurality of guides 30 which guide edges such as 32 and 34 , as shown in FIG. 3 and is made from filament-wound or fabric-laminated epoxy. Referring to FIGS. 1 b and 1 c , slip molding 18 is in the lower position while slip molding 36 is oppositely oriented in the upper position. The mandrel 16 has a shoulder 38 which supports the slip molding 18 . Cone 28 is shown in the lower position adjacent slip molding 18 , while cone 40 is in the upper position adjacent slip molding 36 . The cones 28 and 40 are identical but mounted in opposite directions. Slip moldings 18 and 36 are also identical but mounted in opposite directions.
Referring now to FIG. 3, the slip molding 18 and slip molding 36 each contain inserts 42 which preferably are of a serrated design, as shown in FIG. 3, and made of a hard carbon steel. Alternative metallics or nonmetallics can be inserted as the insert 42 without departing from the spirit of the invention. Each insert 42 which appears on each slip 20 has serrations 44 to help with getting a bite into the casing when the plug P is set. Those of skill in the art will appreciate that the tabs 22 , shown in FIG. 4, will all break as the slip molding 18 or 36 is advanced on its respective cone 28 or 40 because the slips 20 will move away from each other and radially outwardly as they are ramped with flats 24 sliding on flats 26 . By making the slip molding 18 in a single piece, it is easier to produce. Additionally, the design is preferred to using individual slips and holding them in position with a band spring as in the prior art. The use of tabs such as 22 fixes the position of all the slips to each other, plus facilitates assembly of the plug P for run in.
Referring again to FIGS. 1 a-c , a lock ring 48 , which is made preferably of aluminum with a maximum yield strength of 35,000 psi, is retained by sleeve 50 , which can be of the same material as the lock ring 48 or a nonmetallic component, such as the material used for mandrel 16 . The unique features of the lock ring 48 and its interaction with the mandrel 16 can be better seen by an examination of FIGS. 5 and 6. The lock ring 48 is longitudinally split and has an internal serration, preferably in the form of a buttress thread 52 . It is preferred that the pitch be fairly long in the order of at least about eight threads per inch. The profile of the thread which is machined into the ring is shown in FIG. 6 . It is further preferred that the relaxed diameter of the split lock ring 48 internally, as represented by the dimension between opposing ridges 54 , be somewhat smaller than the diameter of the mandrel 16 on which the lock ring 48 is assembled so that a preload of stress of about 200-500 psi is seen by the lock ring 48 in its installed position within sleeve 50 upon assembly. The details of the buttress thread 52 can be seen in FIG. 6 . Extending from ridge 54 is preferably a surface 56 which is preferably perpendicular to surface 58 . Surface 58 is parallel to the longitudinal axis 60 . Surface 62 is sloped preferably at about 20°. Ridge point 54 is defined by surfaces 56 and 62 , respectively, and the length of surface 56 is the depth of the ridge 54 , which indicates the maximum penetration of ridge 54 into the mandrel 16 when the plug P is set. The preferred length of surface 56 is in the order of about 0.015-0.020″ for a plug to fit through a 3½″ O.D. opening.
Referring to FIG. 1 b , it can be seen that the serration or thread 52 rides on a smooth surface 64 of mandrel 16 and penetrates surface 64 to hold the set.
Referring again to the setting tool 10 , there is an upper tension mandrel 66 to which is connected a tension mandrel sleeve 68 . A release stud 70 connects the upper tension mandrel 66 to the lower tension mandrel 72 . An upper sleeve 74 is secured to mandrel 16 . Upper sleeve 74 is preferably made of fabric-laminated fiberglass with high-temperature epoxy or filament-wound fiberglass with high-temperature epoxy. It is secured to the mandrel 16 by high-temperature adhesive and shear pins 76 which are preferably fiberglass rod. The same pins that hold the upper sleeve 74 also retain the plug 78 to seal off bore 80 in mandrel 16 . Plug 78 can be blown clear by breaking pins 76 to equalize plug P before it is milled out. Alternatively, plug 78 can simply be drilled out to equalize the plug P. Plug 78 is preferably made of carbon-filled PEEK or other reinforced composite materials and is secured within bore 80 of mandrel 16 in a sealing relationship due to rings 82 and 84 . Connected to lower tension mandrel 72 are collet fingers 86 which are trapped by tension mandrel sleeve 68 in the position shown in FIG. 1 b . Thus, the lower tension mandrel 72 is held to the upper sleeve 74 when the collets 86 are trapped to the upper sleeve 74 . The collets 86 are released from sleeve 74 to allow retrieval of the setting tool 10 . When the setting tool 10 operates, a tensile force is exerted on release stud 70 , causing it to shear at the necked down portion 88 . At the same time, the setting sleeve 12 bears down on spacer washer 14 , with a net result of setting the packer due to relative movement. In the course of this operation, the release stud 70 breaks to allow the setting tool 10 to be retrieved. Upward movement on the setting tool 10 allows shoulder 90 on tension mandrel sleeve 68 to engage shoulder 92 on lower tension mandrel 72 so as to retrieve the lower tension mandrel 72 and that portion of the release stud 70 which is affixed to it. Accordingly, one of the advantages of the present invention is that the metallic portions of the setting tool are retrieved from above the plug P when the setting tool 10 is removed after set, as opposed to prior art designs which left metallic components of the setting tool above the nonmetallic packer or plug as a result of setting such a device.
Referring now to FIGS. 1 b and c , a sealing element 94 is shown retained by an anti-extrusion assembly comprising a beveled packing element retainer ring 96 , which is seen in greater detail in FIG. 7 . It is a complete ring and preferably has no longitudinal split. Stacked behind the retainer ring 96 , which is preferably made of a phenolic composite material called Resinoid 1382, is a packing ring 98 , as seen in FIG. 8 . This ring is longitudinally split and is shaped to accept in a nested manner the cone ring 100 , which is shown in FIG. 9 . The packing ring 98 and cone ring 100 are preferably made of Amodel 1001 HS, a high-performance thermoplastic material. The longitudinal splits in the packing ring 98 and cone ring 100 are offset. Accordingly, when there is relative longitudinal compression, such as when the setting tool 10 is actuated, spacer washer 14 moves closer to shoulder 38 . This longitudinal compression radially expands packing ring 98 and cone ring 100 so as to allow them to reach the casing and guard against extrusion of the element 94 . The sealing element 94 has similar assemblies above and below, as illustrated in FIGS. 1 b and 1 c . In an alternative and preferred design of an anti-extrusion assembly illustrated in FIGS. 10 - 13 , the assembly of rings 96 , 98 , and 100 are replaced with a plurality of overlapping beveled rings such as 102 and 104 , shown in FIG. 12 . These rings 102 and 104 are slotted radially, with a plurality of spaced-apart slots 106 , which are also shown in FIG. 10 . On the other side of each of the rings and spaced between the slots 106 are tabs 108 , also best seen in FIGS. 10 and 11. It can be seen that the tabs 108 of one ring extend into the slots 106 of the adjacent ring such that the slots are offset in the run-in position shown on the left-hand side of FIG. 12 . The extension of the tabs 108 into the slots 106 prevents relative rotation between rings such as 102 and 104 . As shown in the right-hand side of FIG. 12, when exposed to axial compression, the slots 106 spread apart as the beveled rings are moved toward a flattened position so that the outside diameter of each of the rings grows until it makes contact with the tubing or casing 110 . The same effect is shown in a side view in FIG. 13 . Two or more rings such as 102 and 104 can be used without departing from the spirit of the invention. The operation of rings 102 and 104 is distinctly different from the assembly of rings 96 , 98 , and 100 described and shown in FIGS. 7, 8 , and 9 . In the design employing the rings 96 , 98 , and 100 , a greater degree of axial travel is necessary to open up the longitudinal splits in rings 98 and 100 sufficiently far to encounter the tubing or casing 110 . On the other hand, using two or more of the slotted rings, such as 102 or 104 , S allows such rings to contact the tubing or casing 110 with a far lesser amount of axial relative movement during the setting process. This occurs because the rings 102 and 104 are actually bent toward a flattened position due to relative axial movement by an angular bending which opens up the slots 106 , as shown in FIGS. 12 and 13 in the right-hand portion. Thus, the bending in rings 102 and 104 occurs about the center of the rings and down toward a plane perpendicular to the centerline of those rings, as opposed to the rings 98 and 100 which must be spread radially until contact with the casing or tubing 110 . In many situations with available running tools or setting tools 10 , the amount of relative axial movement is limited, thus creating a distinct advantage for the anti-extrusion back-up system illustrated by using the radially slotted rings such as 102 and 104 .
In another feature of the present invention, the plug P has at least one of top and bottom end clutching feature which is shown in FIG. 1 c , for example, at the bottom of the plug P as item 112 . In an installation involving multiple packers or plugs P, they can be pushed one against the other and interlocked due to the conforming mating shapes which prevent relative rotation. Thus, one plug P which has been released can fall and be engaged by the next lower plug P in a manner where no relative rotation can occur to facilitate the further milling of the plug P in the wellbore. The clutching or nonrotation feature can be accomplished in a variety of ways, including matching slanted tapers or other types of lug arrangements.
Those skilled in the art will now appreciate that there are several advantages to the plug P as described above. One of the features is the ability to engage the remaining portions of the setting tool 10 below the tensile failure so that they can be retrieved after the plug P is set. By actuation of the setting tool 10 , the mandrel 16 is brought up with respect to the spacer washer 14 and the lock ring 48 holds the set position between the mandrel 16 and the sleeve 50 . The outer sloping surface 114 (see FIG. 5) of the lock ring 48 engages a mating sloping surface internally on sleeve 50 to further assist the ridge 54 of the buttress thread 52 to dig into the smooth surface 64 of mandrel 16 . Thus, the locking device is simple in its operation and is easily drilled out, being made of a relatively soft aluminum material which can interact with the smooth surface 64 of the mandrel 16 to hold the set of the plug P. At the same time, the removal of the setting tool 10 entails the recapture of the severed component parts so that subsequent milling out of the plug P is facilitated by the absence of durable metallic parts left over from the setting operation. The alternative designs which have been depicted for extrusion resistance of the element 94 allow expansion so that rings 98 and 100 extend fully against the casing or tubular 110 . In the alternative preferred embodiment, using the beveled rings with radial slots 106 , the feature of full bore protection against extrusion is accomplished with far less relative longitudinal movement than it takes to set the rings 98 and 100 against the tubing or casing 110 .
The interaction between the individual slips 20 and the flat surface 26 on the cone 28 , for example, allows a greater flexibility in manufacturing of the slip molding 18 and a broader versatility in size ranges as the slips 20 can cover a greater extension due to the interaction of the flat surface 24 on the slips 20 with the corresponding surface 26 on the cone such as 28 . The design is to be contrasted with cones of prior designs where the flat segments on the cones come to a point whereas in cone 28 , for example, the flat segments 26 are cut clean to the end, assuring a more uniform contact with each of the slips 20 and the tubing or casing 110 . Depending on the downhole environment, the slip molding 18 can be made from Fiberite FM 8130 or 5083, or E7302 Resinoid 1382X. Finally, the clutching feature, in a multiple installation, allows taking advantage of the fact that the lowermost plugs P are still fixed to ease in the milling of those plugs P which are above due to the ability of one plug P to interconnect with an adjacent plug in a manner preventing relative rotation.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made without departing from the spirit of the invention. | A composite packer or bridge plug includes substantially all nonmetallic components. The design allows the setting tool metallic components to be retrieved after the bridge plug is set. The slips contain flats with mating flats on the cones which extend to one end of the cones and guides for the slips to facilitate proper slip movement into engagement with the wellbore. A lock ring rides on the nonmetallic mandrel and secures the set, using a buttress-type thread to engage into the mandrel body. Alternative designs are revealed for backup to the sealing elements to prevent extrusion. In one design, split rings are axially compressed so that they grow in radial dimension to act as extrusion barriers. In another design, tapered scored rings are rotationally locked against each other and are axially compressed so that they bend into contact with the wellbore to act as extrusion barriers. Axial travel to obtain an extrusion barrier is minimized. The slips are made of a cohesive component and separate from each other upon advancement with respect to the cone. Mandrels of different plugs can lock together to facilitate mill-out in multi-plug installations. | 4 |
BACKGROUND
1. Field of the Disclosure
This disclosure relates generally to wellbore systems, including multilateral wellbore systems that inhibit flow of particles over a certain size from one wellbore to another wellbore.
2. Background of the Art
Wells or wellbores are drilled in subsurface formations for the production of hydrocarbons (oil and gas). In some cases, multilateral wells are formed, wherein one or more wells are formed from a main wellbore. Sometimes lateral wellbores are also formed from one or more of the other lateral wellbores. Such a wellbore system is generally referred to a “multilateral wellbore” or a “multilateral wellbore system.” Typically, the main wellbore is a cased wellbore, in that, it is lined with a metal casing (typically a jointed metallic tubular). In some cases the lateral wellbore is not lined with a casing, i.e., it is left as an open hole. Sand control and other flow control devices are installed at locations from which the formation fluid is extracted into the lateral wellbore. However, in open hole lateral wellbores, the junction between the main wellbore and the lateral wellbore includes no sand control devices that prevent the flow of particles, such as sand, from entering into the main wellbore from the lateral wellbore. Excessive sand production is detrimental to the equipment in the wellbores. This problem can be exacerbated when the open hole is formed in an unconsolidated formation, as such formations can produce excessive amounts of sand.
The disclosure herein provides wellbore systems that include sand control apparatus that inhibit or prevent flow of particles above a certain size from the junctions and the lateral wellbores into the main wellbore and methods of installing such apparatus.
SUMMARY
In one aspect, a wellbore system is disclosed that in one non-limiting embodiment includes a first wellbore capable of producing a fluid from a first formation, a second wellbore intersecting the first wellbore at a junction, wherein the second wellbore is an open hole and capable of producing a fluid from a second formation and a sand screen at the junction configured to inhibit particles larger than a selected size from flowing from the second wellbore and the juncture into the first wellbore.
In another aspect, a method of forming a wellbore is disclosed that in one non-limiting embodiment includes: forming a first wellbore capable of producing a fluid from a first formation; forming a second wellbore from a junction in the first wellbore; and placing a sand screen at or proximate to the junction to inhibit and/or prevent particles larger than a selected size from flowing from the second wellbore and the junction into the first wellbore.
Examples of the more important features of the apparatus and methods of the disclosure have been summarized rather broadly in order that the detailed description thereof that follows may be better understood, and in order that the contributions to the art may be appreciated. There are, of course, additional features that will be described hereinafter and which will form the subject of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a detailed understanding of the apparatus and methods disclosed herein, reference should be made to the accompanying drawing and the detailed description thereof, wherein:
The FIGURE is a schematic diagram of a non-limiting production multilateral wellbore system showing a cased main wellbore an open hole lateral wellbore and a sand screen at the junction of the main wellbore and the lateral wellbore for preventing flow of particles above a selected size from the junction into the main wellbore, according to one embodiment of the disclosure.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
The FIGURE is a schematic diagram of a non-limiting production multilateral wellbore system 100 showing a main wellbore and a lateral wellbore with a screen at the junction of the main wellbore and the lateral wellbore for preventing flow of particles above a selected size from the junction, according to one embodiment of the disclosure. The system 100 is shown to include a main well or wellbore 110 formed in a formation 102 for producing fluid 118 from formation 102 . The main wellbore 110 is shown as a cased wellbore that may be lined with a casing 104 , which may be any suitable liner, including, but not limited to, a pipe made from joining pipe sections or another metallic liner. The wellbore 101 is shown to include cement 106 in the annulus 108 between the wellbore 110 and the casing 104 . The casing 104 is shown to include a window 120 through which a lateral wellbore 180 has been formed to a depth 182 . In the particular embodiment of the FIGURE, the lateral wellbore 180 is shown as an open hole, i.e., it is not lined with a casing, such as casing 104 in the main wellbore 110 . For the purpose of this disclosure an open hole is at least partially not lined with a casing or liner. The lateral wellbore 180 and the main wellbore 110 form a junction 130 at the window 120 . In the particular embodiment of system 100 , the junction 130 between the main wellbore 110 and the lateral wellbore 180 is not sealed and thus fluid 132 from the formation 102 can flow from the formation 102 into the main wellbore 110 via the junction 130 as shown by arrows 133 . For illustration purposes and not as a limitation, the wellbore system 100 is shown to include a single lateral wellbore 180 . It will be understood that there may be more than one lateral wellbore formed from the main wellbore and/or from one of or more lateral wellbores. Furthermore, for the purpose of this disclosure, any or all such lateral wellbores may be open hole or cased-hole wellbores.
The lateral wellbore 180 includes inflow devices, such as a sand screen 184 and other devices, such as flow control devices (valves, pressure drop devices, etc. known in the art), collectively referred to by numeral 186 . Fluid 188 from a production zone 190 may flow into the lateral wellbore 180 via devices 184 and 186 , as shown by arrows 188 a . The fluid 188 flows into the wellbore 180 and then into the main wellbore 110 at the junction 130 , as shown by arrows 188 b . As noted earlier, fluid 132 from the formation proximate the junction 130 also may flow into the main wellbore 110 as shown by arrows 133 . In one non-limiting embodiment, a lateral liner 140 (sometimes referred to in the industry as “lateral hook liner”) extends from a location 140 a in the main wellbore 110 uphole (or above) of the junction 130 to a location 140 b downhole (or below) of the junction 130 proximate to the screen 184 in the lateral well bore 180 . The lateral liner 140 includes a through passage 144 that provides a through opening in the main wellbore 110 across the junction 130 . The fluid 132 from the junction 130 flows or is directed to flow into the main wellbore 110 via fluid path 134 between the lateral liner 140 and the casing 104 . The fluid 188 , however, will generally flow into the main wellbore 110 from inside of the lateral liner 140 , as shown by arrows 188 b . Alternatively, the lateral liner may be located at any other suitable location in the wellbore system 100 so as to direct the fluid 132 from the junction toward the sand screen 160 .
Still referring to the FIGURE, the main wellbore 110 is shown to include a production string 112 having a production tubing 114 that includes a window or opening 150 that in one embodiment may extend across the window 120 , such as from a location 150 a above the window 120 to a location 150 b below the window 120 . Seals, such as packers 134 a and 134 b are respectively placed between the tubing 114 and the casing 104 above and below the window 120 to cause the fluid 188 b to flow from the lateral wellbore 180 into the production tubing 114 and to cause fluid 132 to flow into the production tubing via fluid path 136 .
In one non-limiting embodiment, a flow control device, such as a sand screen 160 of sufficient length and size is placed in the production tubular 114 to inhibit or prevent flow of solid particles above a certain (selected) size in the fluid 132 and fluid 188 b from entering the production tubing 114 . In one aspect, the sand screen 160 may extend from a location 160 a above the junction 130 to a location 160 b below the junction 130 . In one non-limiting embodiment, the sand screen 160 may be placed in a tubing 170 and placed inside the production tubing 114 . Alternatively, the sand screen 160 may be placed in the lateral wellbore 180 or partially in the main wellbore 101 and partially in the lateral wellbore 180 , each such screen adapted to or configured to inhibit or prevent solid particles above a size from entering the flow of the fluid toward the surface. In one non-limiting embodiment, the production tubing 114 includes an inward profile (also referred as indentations) 116 and the tubing 170 includes a collet 172 that is configured to engage with (mate with) the profile 116 , so that when the collet 172 engages with the profile 116 , the tubing 170 will securely hang inside the production tubing 114 . In one embodiment, the tubing 170 also included another profile 176 . To install or place the screen 160 in front of the junction 130 , collet 175 a on a run-in tool 175 is engaged with the profile 176 on the tubing 170 at the surface. The run-in tool 175 carrying the tubing 170 and the sand screen 160 is moved into the production tubing 114 until the collet 172 engages with the profile 116 . In aspects, the force (pull force) required to dislodge the collet 172 from the profile 116 is greater than the pull force required to dislodge the collet 175 a from the profile 176 and thus the run-in tool 175 from the profile 116 . Once the tubing 170 has been placed in the production tubing 114 , the run-in tool 175 is pulled out of the tubing 114 , leaving the sand screen 160 in front of the junction 130 . Seals 162 a and 162 b are provided between the tubing 170 and the production tubing 114 to prevent flow of the fluid from the lateral wellbore 180 or the junction 130 to bypass the sand screen 160 . In other aspects, devices in addition to the sand screen may also be placed outside the screen ( 198 ) r inside the screen ( 189 ). For example, a flow control device, such as sliding sleeve valve, may be placed inside the sand screen 160 to control the flow of the fluid from the lateral wellbore 180 . In another aspect, a flow control device that discriminates flow of one type of fluid against another type of fluid may be placed inside the sand screen 160 . Such devices are known in the art and may include, but are not limited to, device having a tortuous fluid flow path; a device that inhibits flow of water compared to the flow of oil or gas; and a flow that created a greater pressure drop for water compared to oil or gas. Also, the sand screen may be any suitable sand screen.
The foregoing disclosure is directed to certain exemplary embodiments and methods. Various modifications will be apparent to those skilled in the art. It is intended that all such modifications within the scope of the appended claims be embraced by the foregoing disclosure. The words “comprising” and “comprises” as used in the claims are to be interpreted to mean “including but not limited to”. Also, the abstract is not to be used to limit the scope of the claims. | In one aspect, a wellbore system is disclosed that in one non-limiting embodiment includes a first wellbore capable of producing a fluid from a first formation, a second wellbore intersecting the first wellbore at a junction, wherein the second wellbore is an open hole and capable of producing a fluid from a second formation and a sand screen at the junction configured to inhibit particles larger than a selected size from flowing from the second wellbore and the junction into the first wellbore. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a positive displacement machine.
Positive displacement machines have been widely used in practice. Such positive displacement machines as piston pumps or rotary pumps are composed of a great number of separate parts, and for this reason they are very expensive and bulky. Relatively simple gear pumps which are used when it is necessary to provide a high pressure, are even more expensive inasmuch as voluminous sealing elements are provided on the side surfaces of the gears. They are not always satisfactory in operation, and the construction costs of high pressure gear pumps are great.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a positive displacement machine which avoids the disadvantages of the prior art.
More particularly, it is an object of the present invention to provide a positive displacement machine which has a simple construction and is very small, and at the same time is applicable for high pressure operations.
Another feature of the present invention is to provide a positive displacement machine which has an uncomplicated and weight-saving construction, and for this reason is especially applicable for the utilization in hydraulic systems of automobiles and airplanes.
In keeping with these objects, and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a positive displacement machine having a flat displaceable part-circular received in a compartment of the housing and subdividing the same into a pressure chamber and a suction chamber, which displacement element has a recess formed in a periphery thereof and bounded by two edges which are spaced circumferentially of the periphery, and drive means for imparting to the element a translatory displacement and for superposing on the translatory displacement an angular movement such that during displacement of the element between two opposite dead center positions the pressure and suction chambers are temporarily placed in communication by the recess so as to permit displacement of a fluid from one to the other chamber.
The thus-constructed positive displacement machine has a simple construction and small dimensions, and at the same time is suitable for high pressure operations. It is especially suitable for utilization in hydraulic systems of automobiles and airplanes.
Another feature of the present invention is that the displaceable element may be composed of two or more separate displaceable members located in a common plane and jointly displaceable in the compartment of the housing by the drive means. When the displaceable element includes two such separate displaceable members, the latter during the translatory displacement move angularly in opposite directions relative to one another. In the case when the displaceable element is composed of several displaceable members, pressure equilibrium and a very small pulsation of flow of the working fluid is provided.
Still another feature of the present invention is that the displaceable element has a second recess forming an outlet passage and operative for temporarily placing the pressure chamber in communication with the pressure port during displacement of the displaceable element so as to permit displacement of the fluid from the pressure chamber. The first recess provided in the displaceable member may be substantially lenticular, whereas the second recess may be substantially triangular and may have a rounded base corner. The first mentioned recess may also be formed as a curved groove or an angle groove.
A further feature of the present invention is that the first and second recesses may be formed as surface recesses in a side wall of the displaceable element or through-going openings in the displaceable element. The recesses may be spaced from one another in a circumferential direction of the displaceable element preferably by an angular distance substantially equal to 130° of arc.
A still further feature of the present invention is that the elongated compartment of the housing may have two end portions which are rounded in accordance with a contour of the periphery of the displaceable element. On the other hand, the housing may have a straight wall bounding the elongated compartment in the region of the pressure chamber, and the displaceable element may have a flattened portion which faces toward the pressure chamber and is adapted to be located parallel to the straight wall of the compartment when the displaceable element is in its upper dead center position.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a pump in accordance with the present invention;
FIG. 2 is a view showing an axial section of the pump shown in FIG. 1;
FIG. 3 is a schematic view showing a displaceable element of the pump in accordance with the present invention in a position in which a pressure chamber of the pump communicates with a suction chamber thereof;
FIG. 4 is a schematic view showing a displaceable element of the pump in accordance with the present invention in a position in which the pressure chamber does not communicate with the suction chamber of the pump;
FIG. 5 is a plan view of a pump in accordance with another embodiment of the present invention;
FIG. 6 is a view showing an axial section of the pump shown in FIG. 5;
FIG. 7 is a view showing a displaceable element in accordance with a further embodiment of the present invention;
FIG. 8 is a view showing the displaceable element in accordance with a still further embodiment of the present invention;
FIG. 9 is a view showing the displaceable element in accordance with an additional embodiment of the present invention;
FIG. 10 is a view showing the displaceable element in accordance with still an additional embodiment of the present invention; and
FIG. 11 is a view showing a partial cross-section of a pump in accordance with another embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
A positive displacement machine in accordance with the invention is here shown as a pump. The pump has a housing 10 which is closed at its opposite sides by covers 11 and 12. The housing 10 has an elongated opening 13 whose longitudinal sides are connected with one another by arcuate sections 13' and 13".
The cover 11 is connected with a part of motor means 14, for instance with a sliding ring bearing of a three-phase-current generator. A ball bearing 15 is mounted in the part 14 and supports a driving shaft 16. The driving shaft 16 has an eccentric pin 17 which is received in a bushing 18. The bushing 18 is arranged in a bore 19 of a disc-shaped piston 20 which forms a displaceable element of the pump. The bore 19 is provided close to an outer periphery of the piston 2, that is with a great eccentricity.
The diameter of the piston 20 substantially corresponds to the width of the opening 13 or, in other words, to the distance between the longitudinal sides of the opening 13. The piston 20 is located between the longitudinal sides of the opening 13 with a very small play. When the driving shaft 16 rotates in the clockwise direction, the piston 20, due to the eccentric location of the bore 19, is displaced in a translatory movement and a partially rotational movement, that is the piston 12 moves lengthwise the longitudinal opening 13 between the arcuate sections 13' and 13" and at the same time is somewhat angularly displaced. The positions in which the piston 20 is located near the arcuate sections 13' and 13" are an upper dead center position and a lower dead center position, respectively.
Two recesses 21 and 22 are formed in a side surface of the piston 2 facing toward the cover 12. The recess 22 is lenticular and substantially smaller than the recess 21. An upper boundary of the recess 22 with the periphery of the piston forms an edge 23. The recess 22 faces toward the left straight wall of the opening 13.
The recess 21 is circumferentially spaced from the recess 22 by an angular distance equal to substantially between 120° and 130° of arc. The recess 21 moves in the region adjacent to the right portion of the arcuate wall 13' of the opening 13. The recess 21 has a substantially triangular form with a rounded base corner and with an edge 24 at the left side facing toward the opening 22.
The piston 20 subdivides the opening 13 into a suction chamber 25, which is located in a lower region in FIG. 1, that is adjacent to the arcuate section 13", and a pressure chamber 26 located opposite to the suction chamber 25. A bore 27 is open into the suction chamber 25 and connected with a not shown conduit which is connected, in turn, with a source of a pressure medium. A bore 28 is opened into the pressure chamber 26 which is connected through a connecting bore 29 with a not shown conduit communicating with a consumer. As shown in FIG. 2, the recess 21 has a depth which is substantially equal to two thirds of the thickness of the piston 20. The same is true for the recess 22. The piston 20 has a periphery exceeding over somewhat more than 180° of arc. The cover 11 is centered relative to the part 14 of the motor means by an intermediate member 30 located in a bore 31. A sealing member 32 facing toward the pump, is arranged in the intermediate member 30.
When the piston 20 moves from the upper dead center position downwardly and turns in the clockwise direction, as shown in FIG. 3, the recess 22 moves away of the left side of the opening 13 and thereby the suction chamber 25 communicates with the pressure chamber 26 so that the pressure medium flows from the former into the latter. When the piston 20 moves upwardly and turns in the counterclockwise direction as shown in FIG. 4, the edge 23 of the recess 22 interrupts the communication between the suction chamber 25 and the pressure chamber 26. The pressure medium located in the pressure chamber 26 is compressed inasmuch as this chamber is smaller, and therefore is displaced through the recess 21 into the bore 28. The communication from the pressure chamber 26 and the recess 21 to the bore 28 is performed by the edge 24 of the recess 21. When the edge 24 during the partial angular movement of the piston 20 is so located that the recess 21 communicates with the bore 28, the pressure medium is discharged to the consumer. Simultaneously, the pressure medium is sucked into the increased suction chamber 25.
Controlling of the discharge can also be performed by a check valve 35 located in an outlet opening 36, as shown in FIG. 11. In dependence upon desirable dynamic behavior by smaller or greater partial opening through the recess 22, it is possible to select the closing or opening angle.
In the pump shown in FIGS. 5 and 6 the displaceable element is composed of two pistons 40 and 41. The pistons 40 and 41 are located in a common plane and move in an opening 42 which is similar to the opening 13 but is somewhat longer than the latter. A driving shaft 43 is located directly in a housing cover 44. An eccentric pin 45 is received in bores 46 and 47 of the pistons 40 and 41, respectively, and surface recesses 40' and 41' are formed in the regions of the pistons wherein the latter contact one another. Thus, the pistons are located in the same plane. All other parts of the pump shown in FIGS. 5 and 6 are similar to those shown in FIGS. 1 and 2.
The operation of the pump shown in FIGS. 5 and 6 is easy to understand. However, the pistons 40 and 41 operates in opposite directions. An advantage of such operation is that the pump is fully balanced. This is because the pressure chambers 49 and 50 are located opposite to one another, whereas the suction chambers 51 and 52 are located in the central region of the longitudinal side of the opening 42.
FIGS. 7-10 show various displacement elements and the openings for receiving the displacement elements therein. In the embodiment shown in FIG. 5, the control passage from the suction chamber to the pressure chamber is formed in a different manner, that is this passage is curved and identified by reference numeral 55. Since the discharge control is performed by the check valve 35, the recess 21 similar to that shown in FIG. 1 is not needed. It is only necessary to provide a communication from the suction chamber to the pressure chamber. The same is true for the embodiments shown in FIGS. 6, 7 and 8.
In the embodiment shown in FIG. 8 the piston is not formed as a full disc, but, instead, is a partially circular disc with a cut-off upper portion. It has a periphery exceeding 180° of arc so that in various angular positions of the piston the suction chamber is separated from the pressure chamber. Because of a flattened edge 56, the pressure chamber 57 is also flattened and in the upper dead center position is located parallel to the flat edge 56 of the piston. In the embodiment shown in FIG. 9, a piston 59 has reduced weight due to provision of openings 60, and a connecting passage 61 has a shape somewhat differing from the shape of the passage in accordance with the embodiment shown in FIG. 6.
The piston in accordance with the embodiment shown in FIG. 10 is again round and has a connection at the suction side which is similar to that shown in FIG. 7. The operation of the pump in all the above cases are similar to that described with respect to FIGS. 1-4.
The pump in accordance with the embodiment shown in FIGS. 5 and 6 has an advantage that it provides for a uniform flow of the pressure medium. It is also possible to form the piston composed of four, six or eight piston members so as to increase the flow of the pressure medium. In these cases a crankshaft and corresponding ports on the disc shaped piston are necessary. It is also possible to form the recesses 21 and 22 in accordance with FIG. 1 not as surface openings, but, instead, as through-going openings.
Positive control which is performed by the pump in accordance with the present invention constitutes an essential simplification of the pump control. In this case it is possible to provide an advancement with greater number of revolutions. Various volumes can be simply obtained by varying of the width of the piston. The diameter of the pump is not increased in this case, but, instead, it becomes somewhat thicker. Simple parts can be used for manufacturing the pump, for instance, a section of a rod can be used as a piston. The displacement is fully independent on the number of revolutions, whereby the operation of the pump is comparatively quiet.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions, differing from the types described above.
While the invention has been illustrated and described as embodied in a positive displacement machine, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | A positive displacement machine has a housing bounding an elongated interior compartment, a flat displaceable part-circular element in said compartment subdividing the latter into a pressure chamber and a suction chamber and having a recess in a periphery thereof bounded by two edges which are spaced circumferentially of the periphery, and drive elements for imparting to the displaceable element a translatory displacement and for superposing on the translatory displacement an angular movement such that during displacement of the element between two opposite dead center positions, the pressure and suction chambers are temporarily placed in communication by the recess of the displaceable element so as to permit displacement of a fluid from one to the other chamber. The displaceable element has a periphery exceeding over more than 180° of arc and a diameter corresponding to the width of the interior compartment of the housing in a direction transverse to the elongation of the compartment. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of application Ser. No. 951,085 filed Oct. 13, 1978, now abandoned, which was a continuation of application Ser. No. 842,177 filed on Oct. 14, 1977, now abandoned, which was a continuation of application Ser. No. 706,067 filed July 9, 1976, now abandoned, which, in turn, was a continuation application of application Ser. No. 495,834 filed Aug. 6, 1974, now abandoned.
FIELD OF INVENTION
The invention is directed to protective arrangements against projectiles, particularly so-called hollow explosive charge projectiles.
BACKGROUND INFORMATION AND PRIOR ART
It has previously been proposed to provide a protective arrangement against the destructive force of projectiles, including hollow explosive charge projectiles. According to this prior art proposal, explosive charges are accommodated in a series of interconnected or communicating hollow bodies which are arranged adjacent or on a base plate which may constitute the very surface to be protected. These explosive charge-containing bodies are thus arranged in the immediate vicinity of the base plate. The hollow bodies referred to, and which contain the explosive charges, are formed by two, intersecting ribbed strip-like members and resistant, relatively thick-walled plates which constitute those boundaries of the hollow bodies which face away from the base plate. At the broad sides of these thick-walled plates which face the explosive charges, fuse or detonator needles or pins are arranged, which extend perpendicular to the plates. The plates are connected to the associated, adjacent ribbed sections by screwing or the like with the interposition of flexible or elastic seals or packing. Upon the impact of a projectile on the associated, resistant plate and due to the yieldable construction of the seals, each of these fuse needles moves together with the plate in the direction toward the associated explosive charge. The explosive charge is then caused to detonate when contact is established. The result of such a detonation is a movement of the respective resistant plates in a direction away from the base plate in order to counteract and minimize the damaging projectile effect on the base plate, the base plate--as mentioned above--usually or sometimes constituting the surface to be protected.
The prior art arrangement briefly described above has numerous disadvantages and drawbacks, some of which are of a serious nature. These drawbacks and disadvantages may be enumerated as follows: firstly, the arrangement is relatively complicated and cumbersome. In view thereof, experience has indicated that the construction oftentimes malfunctions and no detonation of the explosive charges take place. Further, due to the complexity of the arrangement, the production costs are relatively high. Moreover the prior art arrangement is bulky, space-consuming and relatively heavy, disadvantages which are particularly detrimental if the objects to be protected are vehicles, since the bulkiness and weight of the protective arrangement significantly and negatively influences the maneuverability of the vehicles. It should also be considered that due to the particular construction and arrangement of the resistant plates, the ribbed members, the packing or seals between these structural members and the detonator or fuse needles, detonation of the associated explosive charges most frequently fails to take place when the projectiles strike the resistant plates in an oblique or slanted manner. In this context it should be appreciated that, in practice, projectiles customarily and most frequently impinge onto the resistant plates in an angular manner and not in a direction which extends exactly perpendicular to the surface of the plates. The prior art arrangement is particularly unsuitable for such oblique impact of the projectiles. This is so because that component of the impact or shock force which is effective in the direction of the fuse or detonator needle or pin is no longer sufficient in order to move the fuse or detonator needle into the required contact with the associated explosive charge of the protective arrangement. However, even when the impact of the projectile is exactly perpendicular or approximately perpendicular to one of the resistant plate surfaces, the prior art protective arrangement, which is usually referred to as a "dynamic protective arrangement" does not offer sufficient protection if the impinging projectile is of the hollow explosive charge type. Such hollow explosive charge projectiles are, however, used predominantly in modern warfare due to their superior penetrating effect against strongly armored objectives. The prior art protective arrangement is unsuitable to protect against such hollow explosive charge projectiles because, as is known, at the instant of impact of the projectile and due to the detonation of the hollow explosive charge released thereby, an energy-rich thorn or jet is formed from the lining material of the hollow explosive charge. This thorn which travels along a path toward the base plate will have penetrated the resistant plate of the prior art protective arrangement long before such plate--under the pressure effect of the detonated explosive charge of the protective device--starts its counter directed movement. In this connection it should be appreciated that the velocity of the thorn is several thousand meters per second while by contrast the movement of the plate which is caused by the pressure resulting from the detonation of the explosive charge is relatively slow. Thus the intended barrier formed by the protective arrangement is, from a practical point of view, not effective at all, since the barrier is penetrated by the thorn before any effective counter measures can be taken. It follows that the prior art protective arrangement does not in fact form an effective defense or protection against projectiles of this kind.
SUMMARY OF THE INVENTION
It is the primary object of the present invention to overcome the disadvantages and drawbacks of the prior art protective arrangement and to provide a protective arrangement which is superiorly effective against all kinds of projectiles including hollow explosive charge projectiles.
It is also an object of the present invention to provide a protective arrangement of the indicated kind which is relatively inexpensive to manufacture, is reliable, not bulky and relatively light.
It is also an object of the invention to provide a protective arrangement of the indicated kind which has an exceedingly simple structural composition and can be readily assembled and installed.
Briefly and in accordance with the invention, the protective arrangement comprises a wall structure which has the explosive wall layer being covered by a wall layer of inert material. The term "inert" as used herein is deemed to refer to a non-explosive material which does not react with itself or with other materials. Such inert materials are most of the metals, plastics and natural substances, such as, for example, wood. For the purposes of this invention, it is of particular advantage to use an "inert" wall layer in which the inert material is made of steel or simply iron. The latter metal is suitable if cost is of the essence and an average density value is sufficient. However, if the emphasis is on light weight constructions, then the non-explosive "inert" wall layer may be made of or consist of aluminum or plastics. For military purposes, heavy metals, such as copper, can be suitably used. Such metals, of course, are more expensive, but due to their high specific weight they assure a more intensively destructive influence on the thorn. In one embodiment of the invention both faces of the explosive wall layer are covered with an inert wall layer.
A large variety of explosive materials may be used for the explosive wall layer. The following examples are given by way of illustration but not by way of limitation:
Hydrogen, octogen, nitropenta, tentryl, TNT or mixtures of such explosives.
Such a mixture, for example, is the known "Composition B" which consists of 60% by weight of hexogen, 39% by weight of TNT and 1% by weight of wax. Another suitable explosive mixture consists of 90% by weight of nitropenta and 10% by weight of wax.
For weight reasons, it is within the scope of this invention to dimension the entire wall structure in an exceedingly thin manner of, for example, only about 0.5 mm. If an extremely thin protective wall structure is to be constructed, the explosive layer is advantageously made of nitropenta having a grain size of below 100 μmm. For example, if an armored vehicle having a total surface of 20-30 square meters is to be protected by the protective arrangement of the invention, the wall structure is applied to the exterior surfaces of the vehicle or the wall structure is applied in the manner of roofing tiles to the walls of the vehicle. If the protective arrangement has a thickness of about 0.5 mm, then the total protective arrangement with the dimensions previously mentioned and with an average specific weight of the protective arrangement of, for example, 6 (30 m2×6×0.0005) three layers being applied=0.27 ton=270 kg. It follows that it is suitable to keep the protective structures very thin in order not unduly to increase the weight of the armored vehicles and thus to have to reduce the military load which the vehicle can carry.
In addition to its exceedingly simple construction, the inventive protective arrangement is distinguished by its light-weight and compact construction as differentiated from the heavy, bulky constructions of the prior art arrangements. Further, and as will be demonstrated hereinbelow, the inventive protective arrangement is exceedingly effective against projectiles which impinge on the protective device in an oblique manner, even if the projectile is of the hollow explosive charge type. This is clearly in contrast to the inferior protective effect of the prior art arrangements which are essentially useless for protecting against hollow explosive charge projectiles impinging in oblique manner.
As previously stated, it is well recognized that in hollow explosive charge projectiles the detonation of the lined hollow charge results in the instantaneous formation of an extremely energy-rich thorn or jet member. This thorn is capable of penetrating into or through steel plates for a distance which is six to eight times as large as the base diameter of the hollow explosive charge lining. This applies also to steel plates of great tensile strength. This extremely high penetration effect of the hollow explosive charge thorn is generally attributed by the experts in this field to the extremely high peak speeds of the thorn which oftentimes reach values of several thousand meters per second. These peak speeds in turn result in the generation of very high pressure heads in the target material which in turn cause the target material to be displaced away from the thorn axis without consideration of the strength characteristics of the target material. If the point of such a highly energetic thorn impinges on the wall layer of explosive material of the inventive arrangement, the impact force causes detonation of the explosive wall layer. This detonation effect will somewhat interfere with the point of the thorn in maintaining its original travel direction. However, this detonation effect, taken alone, is not sufficient in order to cause a significant performance loss or loss in effect of the entire thorn. Such loss, however, is caused by the additional wall layer of non-explosive material which is provided on at least one of the faces of the explosive material wall layer. Thus when the explosive wall layer detonates, the additional, non-explosive, inert wall layer is caused to move away in a direction perpendicular or approximately perpendicular to the explosive wall layer. This additional inert wall layer, dependent on whether it is provided on the front or rear face of the explosive wall layer, thus moves opposite to or in the same direction as the thorn. The movement of this additional wall layer is, in respect of its speed, dependent both on the composition and thickness of the explosive wall layer and also on the composition and thickness of the inert wall material. This inert wall movement--particularly if the normal of the wall structure includes with the longitudinal axis of the impinging projectile or thorn an angle of at least 30°, preferably 45° to 70°--makes sure that continuously fresh inert wall material is moved into the path of travel of the thorn with sufficient speed. The positive consequence, of course, is that the thorn is rapidly spent or consumed at the areas where this fresh wall material cuts into the thorn. These cutting areas on the thorn thus constantly change in respect to the longitudinal extension of the thorn. The consumption of the thorn is, of course, particularly effective and rapid if the inert wall material has a relatively high density.
As previously stated, in one embodiment of the invention, both the front face and the rear face of the wall layer of explosive material are covered with wall layers of inert material. The inert wall layers are advantageously made of material of high density. The use of high density wall layers to cover the wall layer of explosive material has the following advantage: when the explosive wall layer is detonated, the inert wall layer which covers the front face of the explosive wall layer will be moved in a direction opposite to that of the thorn while the inert wall layer which covers the rear face of the explosive wall layer moves in the same direction as the thorn. This means that if a situation should occur in which the amount of inert material of the front wall layer which comes into impeding or cutting contact with the thorn is insufficient to neutralize the penetrating action of the thorn, so that the thorn reaches the rear wall layer of inert material, the amount of inert material of this rear wall layer which comes into cutting contact with the thorn will be sufficient to cut up or consume the thorn. This is particularly so since this rear wall layer moves in the same direction as the thorn and thus the material of this rear wall layer repeatedly intersects the thorn path and thus cuts up and spends the thorn. Experiments have indicated that this constructively very simple wall structure, effectively minimizes the penetrating effect of the thorn. Thus it has been found that in many instances the original penetration effect is reduced to one-twentieth.
According to a further feature of the invention, the explosive material used for the explosive wall layer should be of the kind which is relatively insensitive to detonation and is capable of detonation at shockwave pressures of at least ten kilobar only and which have or can reach detonation velocities of at least 2,000 meters per second. Explosive materials which exhibit such characteristics are preferred for the inventive purposes because premature, unintentional and thus undesired explosion of the explosive wall layer is effectively prevented. Further, the inventive protective arrangement which makes use of such explosive materials will then, of course, not respond, that is the explosive wall layer will not be detonated, if projectiles impinge on the arrangement which have insufficient impact or penetration force to cause the detonation of the explosive wall layer. Thus, for example, if the protective arrangement should be subject to small arms fire and the impinging projectiles do not cause the required shockwave pressure values, no explosion of the explosive wall layer will take place. In other words if the inventive protective arrangement is fired upon with ammunition which is not capable of penetrating conventional armor, the detonation of such ammunition will be sufficiently neutralized by the covering lateral wall layer or wall layers of inert material. The protective effect of the wall structure against such relatively innocuous ammunition is thus sufficient to reduce the speed of the projectile or thorn to a value at which no detonation of the explosive wall layer takes place.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing:
FIG. 1 is a fragmentary sectional view of a protective arrangement embodying the invention and indicating a hollow explosive charge projectile just prior to impact on the inventive protective arrangement; and
FIG. 2 is a view corresponding to FIG. 1, however, indicating the conditions after the detonation of the explosive wall layer of the wall structure caused by the impact of the projectile.
DETAILED DESCRIPTION OF THE INVENTION
The wall structure of the inventive protective arrangement of FIGS. 1 and 2 is generally indicated by reference numeral 1 and is depicted as a cross-sectional fragment. The wall structure consists of three wall layers which are united without spacing to form the structural unit 1. The wall structure unit 1 thus comprises layers 2, 3 and 4. The central layer 3 consists of an explosive material of the kind which detonates at shockwave pressures of about ten to 200 kilobar and which has detonation speeds of at least 2,000 meters per second. Wall layer 2, hereinafter referred to as the front wall layer, is made of non-explosive inert material of high density, for example a suitable metal. Wall layer 4, hereinafter referred to as the rear wall layer, is also made of inert, high density material such as metal and may be made of the same material as wall layer 2. As shown in FIG. 1, wall layers 2 and 4 thus sandwich and contact the opposite faces of the wall layer 3 of explosive material.
As stated above, a large variety of inert material, such as metals, plastics and material substances, can be used for the layers 2 and/or 4. This includes materials of high density and, for example, copper. Though natural materials, such as wood, have a low density, that is, a density below 1, they are also suitable. It will be appreciated that materials with high densities are more favorable if considered from the viewpoint of military effectiveness because the destruction or at least the destructive influence on the hollow charge thorn is more intense by a heavy metal. This would appear to be obvious. However, this individual specific effectiveness of a material of high density is negated by the substantially higher weight of such materials. For this reason, compromise solutions are oftentimes resorted to in which the high destructive effect of a high density material is compromised with a less expensive lower density material. A protective wall structure including or made of plastics material may be advantageous considering the light weight of such structures.
A wide variety of explosive material may be used for the wall layer 3. As mentioned above, some of the explosive materials which may be used are hexogen, octogen, nitropenta, tetryl, TNT or mixtures of these materials.
The individual layers of the protective wall structure may be adhesively connected to each other. However, there are other ways of forming the protective wall structure. Thus, for example, and referring to FIG. 1 of the drawings, the explosive layer 3 may be applied to an inert layer 2 in liquid condition, and a second inert layer 4 is subsequently applied on the other side of the explosive layer 3. Upon solidification, the three layers are rigidly connected to each other to form the uniform wall structure. Another possibility is to place the three layers in solid condition one upon the other and then to insert the superimposed structure into a heating furnace at a temperature which is slightly above the melting temperature of the explosive material so that the three layers fuse to form the uniform structure. A still further possibility is to cast the explosive layer 3 between the two inert layers 2 and 4 in a suitable mold.
The drawings, in addition to the inventive protective structure, also shows a projectile of the hollow explosive charge kind generally indicated by reference numeral 5. In FIG. 1 the projectile 5 is shown at the instant of impact with the front metal layer 2 just prior to detonation of the hollow explosive charge 6 of the projectile 5. By contrast, in FIG. 2 the projectile 5 is shown after the detonation of its hollow explosive charge 6 which, in turn, resulted in the detonation of the explosive wall layer 3 of the protective arrangement 1. The projectile 5 is of well-known construction and consists, in addition to the mentioned hollow explosive charge 6, of a lined recessed portion 7, a contact hood 8 which serves as a spacer and a casing or projectile sleeve 9 which combines and holds together the members 6, 7 and 8 as a single unit. The angle which the projectile longitudinal axis 10 includes, at the instant of impact with the normal 11 of the front metal layer 2, is indicated by reference numeral 12 and amounts in the present example to about 60 degrees. As previously stated, projectiles customarily strike at an oblique angle relative to the impact surface.
The mode of operation or effect of the projective arrangement of FIGS. 1 and 2 is as follows: at the instant of impact of the hollow explosive charge projectile 5 on the front metal layer 2, the hollow charge 6 is detonated by means of an igniting mechanism (not shown) which does not pertain to the invention and is well-known in the art. Accordingly this igniting mechanism has not been shown or described. The detonation of the projectile 5 causes the formation of a highly energetic thorn or jet which is formed by the lining material 7 of the projectile 5, the thorn being indicated by reference numeral 13. The formation of such thorns or pointed penetration members is well-known in the art. The point of this thorn 13 impinges with a speed of 2,000 to 12,000 meters per second on the explosive wall layer 3 of the protective arrangement and thus causes this explosive wall layer to detonate. The explosive wall layer is composed in such a manner that thorn speeds of at least 1,000 meters per second are required to cause detonation. The detonation of the explosive wall layer 3, slightly interferes with the point of the thorn 13 without, however, seriously interferring with the travel of the thorn. The detonation pressure caused by the detonation, in turn, sets into motion the front wall layer 2 and the rear wall layer 4. These wall layers 2 and 4 are thus moved perpendicular or almost perpendicular relative to the surface of the detonated explosive wall layer 3, the front wall layer 2 moving in a direction opposite to the direction of the thorn 13 while the rear wall layer 4 moves in the same general direction as the thorn 13. Due to these movements of the wall layers 2 and 4 which in the present embodiment consist of an inert high density metal, new metal material is continuously moved into the path of the high speed thorn 13 thus causing consumption or cutting up of the thorn at the areas of intersection with the inert material. The speed of movement of the wall layers 2 and 4 is dependent on the nature and quantity of the explosive material in the explosive wall layer 3 and also on the nature and quantity of the inert material of the wall layers 2 and 4. Dependent on these factors, the wall layers 2 and 4 move with speeds of, for example, 500 to 2,000 meters per second, speeds which thus are sufficient to cause continuously new inert metal material to come into contact with portions of the thorn 13, thereby consuming or destroying the thorn. Any thorn remnants, indicated by reference numberal 14, which penetrate through the front wall layer 2 and continue to move toward the rear wall layer 4 are effectively absorbed and cut up by the moving rear wall layer 4 which, as stated, moves in an opposite direction.
A distinction should be made between the inherent detonation velocity of at least 2000 m per second of the explosive layer 3 and the initiating velocity of this layer. The explosive layer 3, in order to be initiated or activated, requires thorn speeds of at least 1000 m per second. As previously indicated, the point of the hollow charge thorn penetrates, for example, with a penetration speed of 2000 m per second. Of course, it could also happen that the point of the thorn penetrates at a higher speed. This, of course, would be sufficient to initiate the explosive action of the layer 3 which, however, in such a case would then detonate at a higher speed.
The wall structure unit 1 shown in the drawing finds particular use or application for the protection of armored land vehicles. However, it is also within the scope of this invention to use the proposed protective arrangement on sea-going vehicles, such as ships, and also for aircraft. Thus, for example, the protective arrangement may be used for the protection of gun emplacements, certain particularly sensitive areas of ships and aircraft, cell walls and the like. Moreover, the protective arrangement can be suitably used for stationary installations. The walls of rockets or other flying bodies should also be mentioned. It is thus feasible to construct the walls of rockets of protective wall structures of the invention.
While a specific embodiment of the invention has 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. | A protective arrangement against projectiles is a wall structure formed f a wall layer of explosive material, and at least one additional wall layer covering at least one face of the wall layer of explosive material. The additional wall layer is made of a non-explosive, inert high-density material such as metal. In one embodiment both faces of the explosive wall layer are covered with a layer of inert, non-explosive high-density material such as metal. The protective arrangement is particularly suitable for protection against the destructive force of hollow explosive charge projectiles. | 8 |
FIELD OF THE INVENTION
This invention relates in general to centrifugal pump stages, and in particular to a method of attaching radial and axial support bearing elements.
BACKGROUND OF THE INVENTION
Centrifugal pumps for petroleum production are made up of a large number of stages. Each stage has an impeller that is rotated by a shaft driven by an electrical motor. Each impeller is located within a stationary diffuser. Each diffuser has passages that extend downstream and radially inward toward the shaft for receiving fluid from an upstream impeller and delivering the fluid to a downstream impeller. Each impeller has a central inlet and passages that extend outward in a downstream direction for delivering well fluid to a downstream diffuser.
The rotation of the impeller causes down thrust. Typically, each impeller is free to float axially on the shaft, and transmits the down thrust to its mating diffuser. Furthermore, thrust washers are located between the mating surfaces for handling the rotating sliding engagement between the impeller and the diffuser.
One type of thrust washer is made of phenolic material, which is not particularly hard. Another type, which is used for abrasive well fluid conditions, is of a hard, wear resistant metal such as tungsten carbide. The diffuser and impeller are cast of a metal such as Ni-Resist. Normally, the thrust washer is attached to the impeller for rotation therewith, such as by adhesive or by an interference fit. One problem with adhesive is that the bonding surface of the impeller must be very clean and free of oil. Also, the adhesive has to have time to cure. Further, in high temperature wells, the temperature may exceed that of the adhesive, causing it to deteriorate. If the thrust washer begins to spin relative to the impeller, damage to the impeller may occur.
An interference fit requires a high tolerance for the mating components. Also, it may not be as reliable as the adhesive because variations in the force fit installation. The differences in the coefficient of expansion of the impeller and a tungsten carbide thrust washer could cause the thrust washer to become loose at high temperatures. An interference fit required to hold a tungsten carbide thrust washer at high temperatures may be so large that the thrust washer fractures during assembly.
The diffuser has an internal bearing support that receives a bearing sleeve for engaging the rotating shaft. The bearing sleeve is typically installed in the bearing support by heat shrink and force fit techniques. In high temperature operations, the differences in thermal expansion of the bearing sleeve can cause the bearing sleeve to become loose and fall out or to spin in the bearing holder of the diffuser. Force fits may not be successful when the plastic deformation of the bearing holder material of the diffuser causes the bearing to become loose at high temperatures. An interference fit required to hold the bearing sleeve at high temperatures may be so large that the bearing fractures during assembly.
SUMMARY OF THE INVENTION
The bearing element for a centrifugal pump assembly is installed in a receptacle of a bearing holder, which may be a portion of an impeller or a portion of a diffuser. The receptacle has a retaining wall located adjacent the bearing element. The retaining wall is permanently deformed against the bearing element to prevent rotation.
The mechanical deformation involves staking or bending portions of the retaining wall inward. These deformed portions are spaced circumferentially apart from each other around the retaining wall. Recesses may be provided on the outer diameter of the bearing element for receiving the deflected portions of the retaining wall therein. The recesses may be flats that are circumferentially spaced around the bearing element. The flats may be in axial planes or, they may be inclined bevels located at the intersection of the sidewall with an end of the bearing element.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial sectional view of a portion of a pump stage constructed in accordance with this invention.
FIG. 2 is an axial sectional view of the impeller of the pump stage of FIG. 1 .
FIG. 3 is a bottom view of the impeller of FIG. 1 .
FIG. 4 is a top view of a die used for staking the thrust washer to the impeller of FIG. 2 .
FIG. 5 is an axial sectional view of a die assembly that utilizes the die of FIG. 4 .
FIG. 6 is an enlarged sectional view of a portion of the assembly of FIG. 5 , showing the staking operation being performed with the die assembly of FIG. 5 .
FIG. 7 is a sectional view of an alternate embodiment of a pump stage constructed in accordance with this invention.
FIG. 8 is a plan view of one of the thrust washers of the pump stage of FIG. 7 .
FIG. 9 is a partial sectional view of the pump stage of FIG. 7 .
FIG. 10 is a sectional view of the pump stage of FIG. 11 , taken along the line 10 — 10 of FIG. 11 .
FIG. 11 is a sectional view of a third embodiment of a pump stage constructed in accordance with this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , pump stage 11 is part of a centrifugal pump stage of a pump that is particularly used for petroleum production. Normally, such a pump has a large number of pump stages 11 , each having an impeller 13 that has a hub 15 mounted to a shaft 17 for rotation therewith. In most pumps, impeller 13 is free to move small distances in axial directions on shaft 17 . Impeller 13 has a plurality of passages 19 that extend from an upstream inlet outward to the periphery of impeller 13 . A skirt 21 surrounds the central inlet and depends downward or in upstream direction. A retaining wall 23 extends downward from the lower or upstream side of impeller 13 concentric with the axis and spaced radially outward from skirt 21 .
Skirt 21 and retaining wall 23 define an annular receptacle for receiving an outer thrust washer 25 . A second or inner thrust washer 27 may be located on impeller 13 . Thrust washers 25 , 27 are both secured in receptacles in a manner to cause them to rotate with impeller 13 . Because of the greater distance from the axis of shaft 17 , outer thrust washer 25 encounters more torque than inner thrust washer 27 .
Impeller 13 is rotatably carried within a diffuser 29 that is stationarily mounted in a housing (not shown). Diffuser 29 has fluid passages 31 that extend inward in a downstream direction for delivering fluid to the inlet of impeller 13 within skirt 21 . Skirt 21 slidingly engages the outlet of diffuser 29 . Diffuser 29 has an outer thrust surface 33 and an inner thrust surface 35 , both on the downstream end. Thrust surface 33 engages thrust washer 25 , while thrust surface 35 engages inner thrust washer 27 .
Referring to FIG. 3 , retaining wall 23 has an inner side 37 and an outer side 39 that are joined by a rim 41 . Rim 41 is typically in a plane perpendicular to the axis of rotation of impeller 13 . After thrust washer 25 is placed in the receptacle next to retaining wall 23 , a plurality of deformed portions 43 are made in rim 41 . As can be seen in FIG. 3 , deformed portions 43 enlarge the wall thickness of retaining wall 23 between inner side 37 and outer side 39 . Deformed portions 43 are spaced circumferentially around retaining wall 23 to mechanically stake or secure outer thrust washer 25 in place. Inner thrust washer 27 could be installed by the same manner, or it could be installed in a conventional manner, such as by adhesive.
Referring to FIG. 5 , die assembly 45 is suitable for making the deformed portions 43 (FIG. 3 ), although other devices could also perform the staking operation. Die assembly 45 has a lower body 47 that rigidly supports an annular die 49 . Die 49 has a plurality of staking projections 51 , as shown in FIG. 4 , which is a top view of die 49 . Each projection 51 is a sharp tooth-like member protruding from the upper surface of die 49 .
A lower support 53 is reciprocally carried within lower body 47 . Lower support 53 has a central cavity 54 and an annular upward facing rim 55 . Rim 55 is located radially inward a slight distance from die 49 for engaging thrust washer 25 . A plurality of coiled springs 57 bias lower support 53 upward. A fastener 59 extends axially through lower support 53 for retaining lower support 53 with lower body 47 , but allowing axial movement of lower support 53 relative to lower body 47 . A plunger 61 is located above or opposite lower body 47 . Plunger 61 is adapted to engage the downstream end of impeller 13 and may be hydraulically or mechanical driven. Plunger 61 has central passage 63 for receiving hub 15 of impeller 13 .
In the operation of die assembly 45 , impeller 13 is placed on die 49 with its wall 23 in contact with projections 51 and its skirt 21 located within cavity 54 . Lower support 53 will be in contact with outer thrust washer 25 . Plunger 61 is placed against the downstream end of impeller 13 with hub 15 located in passage 63 . Plunger 61 is stroked toward body 47 . As illustrated in FIG. 6 , this causes projections 51 to embed into retaining wall rim 41 , radially deforming inner and outer sides 37 , 39 (FIG. 3 ). This deformation also causes some deformation of thrust washer 25 , creating an interference fit. Springs 57 allow lower support 53 to move downward slightly as plunger 61 moves impeller 13 further toward die 49 . If a staking procedure is to be used with inner thrust washer 27 , a different die assembly would be required as it would need to pass through skirt 21 and engage the retaining wall surrounding inner thrust washer 27 .
FIG. 7 illustrates an alternate embodiment. Pump stage 65 is particularly to be used in abrasive applications, such as where well fluid has an appreciable content of sand. Impeller 67 rotates within diffuser 69 . An impeller thrust washer 71 is mounted to impeller 67 for transferring downward thrust to a diffuser thrust washer 73 that is stationarily mounted to diffuser 69 . Both thrust washers 71 , 73 are preferably formed of a hard wear resistant material such as tungsten carbide. Thrust washers 71 , 73 engage each other in rotating sliding contact.
Referring to FIG. 9 , thrust washers 71 , 73 are identical in this embodiment, each having an outer diameter containing a radially extending lip 75 . Also, lip 75 of each thrust washer 71 , 73 has a plurality of flats 77 . In this embodiment, three flats 77 are shown spaced 120° from each other. Each flat 77 extends in an axial plane that is parallel with an axial plane that passes through the axis of thrust washer 71 or 73 . Lip 75 has a smaller radial dimension at each flat 77 , and if desired, could be substantially eliminated at each flat 77 . Impeller 67 as a cylindrical retaining wall 79 that receives lip 75 of thrust washer 71 . A skirt 81 depends from impeller 67 , surrounds the inlet of impeller 67 , and slidingly engages an outlet portion of diffuser 69 .
Deformed portions 83 are formed in the rim of retaining wall 79 adjacent each flat 77 . Deformed portions 83 bear against each flat 77 to prevent rotation of thrust washer 71 . Flats 77 avoid having to deform any portion of the tungsten carbide washer 71 to create an interference fit. The staking operation for deformed portions 83 may be as described in connection with the first embodiment. The plan view of FIG. 8 discloses shallow recesses 87 formed in the mating surface of impeller thrust washer 71 . These recesses assist in lubrication and do not form a part of this invention.
Similarly, diffuser 69 has a retaining wall 85 that closely receives the lip of diffuser thrust washer 73 . It has deformed portions also that engage flats on the outer diameter of diffuser thrust washer 73 . The same procedure as described in connection with the first embodiment may be used for performing the staking operation.
Referring to FIG. 11 , portions of two pump stages 89 are shown, these stages being a third alternate embodiment. Impellers 91 , 93 are located within diffusers 95 , 96 , respectively. Each diffuser 95 , 96 has an outer wall or shell 97 that is stationarily mounted within a housing (not shown). Each diffuser has a central hub 99 that provides radial support for one of the impellers 91 , 93 . Central hub 99 also receives down thrust from one of the impellers 91 , 93 . Each diffuser 95 , 96 has passages 101 that extend downstream and inward to an intake of one of the impellers 91 , 93 . A central cavity 103 is formed within outer shell 97 . Fluid from upstream impeller 91 flows through central cavity 103 to diffuser passages 101 of downstream diffuser 96 .
Each diffuser 95 , 96 also has an integral bearing support 107 formed in central cavity 103 . Bearing support 107 has an axial bore that serves as a receptacle to receive a stationary bearing sleeve 109 . Bearing sleeve 109 is fixed to bearing support 107 and receives within it a rotating bushing 111 that is mounted to shaft 112 . In an abrasion resistant pump, bearing sleeve 109 and bushing 111 may be made of a hard wear resistant material such as tungsten carbide.
To retain bearing sleeve 109 stationarily within bearing holder 107 , a plurality of flats or bevels 113 are formed on one end of bearing sleeve 109 , as shown in FIG. 10 , and spaced circumferentially around the outer diameter of bearing sleeve 109 . Each bevel 113 is a flat surface that is inclined relative to an axial plane parallel to an axial plane passing through the axis of shaft 112 . Each bevel 113 joins an end surface 115 with an outer diameter 117 of bearing sleeve 111 . A plurality of circumferentially spaced-apart deformations 118 are located in one of the end surfaces 115 of bearing holder 107 , preferably the downstream end. Deformations 118 permanently deform a portion of bearing holder 107 into engagement with one of the bevels 113 . Deformations 118 may be formed generally in the same manner as described in connection with the first embodiment. Because of bevels 113 , no deformation of bearing sleeve 109 is required. Thrust washers 119 may be attached conventionally with adhesive, or they may be installed in a mechanical staking operation as in the other embodiments.
The invention has significant advantages. The mechanical staking operations avoids having to clean all oil from the impeller prior to securing a thrust washer. It avoids having to delay further manufacturing operations to allow the adhesive to cure. The circumferentially spaced apart deformations do not require high tolerances of the outer diameter of the thrust washer, unlike conventional force fits. As no glue is required, high temperature operations will not cause the adhesive to deteriorate. Mechanical staking also avoids the disadvantage of interference fits between two different materials that have different coefficients of expansion.
While the invention has been shown in only three of its forms. It should be apparent to those skilled in the art that it is not so limited but is susceptible to various changes without departing from the scope of the invention. | A method of installing an annular bearing element within a centrifugal pump utilizes a mechanical staking operation. The bearing element locates within a receptacle of a pump stage that is surrounded by a retaining wall. Once the bearing element is located within the retaining wall, the retaining wall is permanently deformed at various points against the bearing element. The bearing element, if of a hard wear resistant metal, may have flats for the circumferentially spaced apart deformations to locate within. The bearing element may be a thrust washer for transmitting downward thrust, or it may be a radial support bearing sleeve. | 8 |
BACKGROUND
[0001] 1. Field of Invention
[0002] The device described herein relates generally to wellhead assemblies, and in particular to provide a pressure seal for use with a wellhead assembly.
[0003] 2. Description of Related Art
[0004] Wellheads used in the production of hydrocarbons extracted from subterranean formations typically comprise a wellhead assembly. Wellhead assemblies are attached at the opening of wellbores that intersect hydrocarbon producing formations. Wellhead assemblies also provide support for casing inserted into the wellbore. The casing lines the wellbore, thereby isolating the wellbore from the surrounding formation. Tubing typically lies concentric within the casing and provides a conduit for producing the hydrocarbons entrained within the formation. Wellhead assemblies also typically include production trees that connect to the upper end of the tubing and distribute the produced fluids. The tubing may be supported by a tubing hanger in the wellhead housing or in the production tree.
[0005] Hardware within the wellheads for suspending the tubing and casing is arranged in a concentric arrangement. If the hanger is in the wellhead housing an isolation sub extends between the tubing hanger and a production bore in the production tree. Various seals are employed between the sub and its mating parts.
SUMMARY OF INVENTION
[0006] The present disclosure includes a wellhead assembly comprising, a housing, a tubular within the housing, a support shoulder, and a seal assembly disposed between the tubular and the housing where the seal assembly is configured to engage the shoulder. The seal assembly comprises an annular seal having a lower portion, an upper portion an inner side wall and an outer side wall, wherein a portion of the outer surface of the seal is inverted. One of the lower portion or upper portion may be inverted. The wellhead assembly may further comprise a lower support ring formed for mating engagement with the lower portion and an upper support ring for mating engagement with the upper portion. The support rings may include raised portions for engagement with the inverted contours of the portions. Optionally, a vent may be formed through a wall of the annular seal and solid particles may be included in the annular seal. The annular seal is energized into sealing engagement between the tubular and housing in response to pressure applied to its outer surface. The annular seal may be a metal face seal.
[0007] Also disclosed herein is a pressure energized seal assembly for sealing between a tubular and a corresponding member. In this embodiment the seal comprises an annular element configured to circumscribe the tubular member, the annular element having an upper portion, a lower inverted portion, and side walls, wherein the lower inverted portion is formed for pressure communication with a pressure source, and wherein pressure applied to the lower inverted portion urges the side walls into sealing engagement with the tubular and the corresponding member, and a supporting shoulder formed for compressive engagement with the upper portion.
[0008] A method of sealing between a tubular and a housing in a wellhead assembly is further included herein, the method comprising, forming a shoulder within the wellhead assembly, wherein the shoulder circumscribes the tubular, disposing a seal assembly adjacent the shoulder, wherein the seal assembly comprises an annular sealing element circumscribing the tubular having an axis, an upper portion, an inner side wall, an outer side wall, a lower portion wherein the lower portion is inverted towards the axis, and putting a pressure source in pressure communication with the lower portion thereby imparting a compressive force onto the annular sealing element that outwardly urges the inner side wall into sealing engagement with the tubular and the outer side wall into sealing engagement with the housing.
BRIEF DESCRIPTION OF DRAWINGS
[0009] Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
[0010] FIG. 1 is a side cross sectional view of an embodiment of a wellhead assembly having a pressure energized seal.
[0011] FIG. 2 is a side cross sectional view of an embodiment of a pressure energized seal.
[0012] FIG. 3 is a side cross sectional view of another embodiment of a pressure energized seal.
[0013] While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
[0014] The present invention will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
[0015] Referring now to FIG. 1 , one embodiment of a wellhead assembly having a pressure activated sealing element is provided. FIG. 1 shows a cross sectional view of a wellhead assembly 5 comprising a production tree 7 mounted atop a wellhead housing 9 . A production bore 11 is formed within the production tree 7 that provides fluid communication with a production flow outlet 15 extending from the production tree 7 . In the embodiment shown, a portion of the production bore 11 extends laterally within the production tree 7 to the production flowline 15 . Control valves 13 are provided in the primary portion of the production bore 11 and also on the production outlet 15 . Selectively opening and closing the control valves 13 selectively allows wellbore fluid flow through the production outlet 15 .
[0016] The wellhead housing 9 is attached to the production tree 7 by an external connector 17 . Included within the housing 9 are production tubing 22 , a tubing hanger 21 , and a casing hanger 23 . In the embodiment shown, the casing hanger 23 , which is a generally annular member, is coaxially secured within a portion of the housing 9 and supports a string of casing cemented in the well. Packoffs 19 (also referred to as casing hanger seals) are disposed between the outer circumference of the casing hanger 23 in a portion of the inner circumference of the housing 9 . An inner groove is shown formed within the casing hanger 23 formed to receive the annular tubing hanger 21 . Production tubing 22 extends downward from the tubing hanger 21 into the wellbore 3 from within the housing 9 .
[0017] An annular isolation sleeve 27 coaxially resides within a portion of the production tree 7 on its upper end and extends downward terminating within the upper portion of the tubing hanger 21 . Wellbore flow from the production tubing 22 reaches the production bore 11 through the isolation sleeve 27 . Examples of seal assemblies 30 are shown circumscribing the isolation sleeve 27 on the sleeve 27 upper end and sleeve 27 lower end. For the purposes of reference and clarity, the term “upper” generally refers to a position closer to the top of the production tree 7 , and the term “lower” generally refers to a position closer to the bottom of the wellbore 5 .
[0018] The seal assembly 30 on the sleeve 27 upper end resides in an upper pocket 26 formed in the sleeve 27 . The seal assembly 30 on the sleeve 27 lower end is in a lower pocket 28 formed in the sleeve 27 . In the embodiment of FIG. 1 , seal assembly 30 provides a sealing function between the outer circumference of the isolation sleeve 27 and surrounding concentric hardware. Optionally the seal assembly 30 can be positioned in other concentric members of the wellhead assembly 5 or multiple seal assemblies 30 may be included within the wellhead assembly 5 .
[0019] FIG. 2 illustrates one cross-sectional view of an embodiment of a seal assembly 30 for use within a wellhead assembly 5 . In this embodiment, the seal element 34 is in a pocket 26 formed by an upward facing shoulder 31 formed on the isolation sleeve 27 and a downward facing shoulder 36 on a threaded retainer ring 29 . Optionally and as noted above, the pocket 26 may be formed in any one of a number of the concentric members making up the wellhead assembly 5 . The seal assembly 30 of FIG. 2 comprises a seal element 34 in the annular space between a pair of concentric wellhead assembly elements. In the embodiment shown, the seal element 34 is an annular member comprising a metal, elastically deformable outer wall 39 circumscribing an inner hollow space 43 . The hollow space 43 does not have to be sealed. The wall 39 forms a pressure barrier around the hollow space 43 whereby applying a force at a first location on the outer surface of the wall 39 causes an outward bulge on the wall 39 at a second location. The wall 39 may be formed from a pliable and elastic metal allowing it to deform under applied force and in some situations return to its original un-deformed shape. Optionally the seal element 34 may be a metal faced seal.
[0020] With reference to the specific embodiment illustrated in FIG. 2 , the seal element 34 comprises an upper portion 40 , a lower portion 42 , an outer sidewall 46 , and an inner sidewall 44 . The outer sidewall 46 is shown in contacting engagement with a wall of the tree production bore 11 . The inner wall of the pocket 26 in this embodiment is the isolation sleeve 27 , thus, the inner sidewall 44 is illustrated in contact with a cylindrical exterior surface of the isolation sleeve 27 . The upper and lower portions 40 , 42 of the seal element 34 of FIG. 2 are inverted wherein the mid section of these portions 40 , 42 bows inward toward the axis of the seal element 34 . Inverting each of the upper and lower portions 40 , 42 creates a “W” shaped cross section of these respective portions 40 , 42 . Inverting the upper and lower portions 40 , 42 fashions an inwardly protruding space on the outside of the wall 39 at the upper and lower portions 40 , 42 .
[0021] Thus in one example of use applying a distributed force, such as pressure, at the outer wall 39 where the lower portion 42 is inverted, the upward force on the inverted portion flexes the sidewalls 40 , 46 radially inward and outward into contacting and sealing engagement with the respective walls of the pocket 26 between the wall of the tree production bore 11 and the wall of the isolation sleeve 27 . In use, normally the upper portion 40 of the seal 34 will be exposed to internal pressure in the tubing 22 via the clearance existing between the end of the isolation sleeve 27 and the tree production bore 11 . Since wellbore pressure normally exceeds ambient pressure existing below the seal assembly 30 , a pressure differential will form between the lower portion 42 and the upper portion 40 . The resulting pressure differential results in a force distribution that energizes the seal assembly 30 into sealing engagement between the isolation sleeve 27 and the tree production bore 11 . If a higher pressure occurred on the exterior of the isolastion sleeve 27 , the reverse would occur with pressure being exerted in the lower seal portion 42 .
[0022] Optionally the seal assembly 30 may further comprise annular rigid conformed members 32 on top. FIGS. 2 and 3 provide a cross sectional view of the conformed members 32 . The conformed members comprise a base 33 , wherein the base is shown roughly perpendicular to the axis of the wellhead assembly 5 . Perpendicularly extending from roughly the middle of the base 33 is a cylindrical vertical member 35 giving each member 32 a “T” shape in cross section. The members 32 include a cylindrical portion that inserts into one of the inverted portions and a cap that contacts one of the shoulders 31 or 36 . Conforming members 32 prevent the inverted portion from deflecting excessively when under pressure.
[0023] In one optional embodiment, individual solid particles 38 may be included within the inner annulus of the seal 34 . These particles 38 provide a structural support to the seal element 34 without hindering the distribution of or transfer of pressure forces throughout the seal element 34 , thereby energizing the seal element 34 . The diameter of the particles 38 can vary or be substantially homogenous. In one embodiment, the particles 38 comprise a multitude of glass beads. Optionally the particles may comprise fine particles such as talc. The particles 38 would not completely fill all void space within the seal element 34 , rather room is left between the particles to allow inward and outward flexing of the seal element 34 .
[0024] Another optional embodiment of the seal assembly 30 a is provided in cross sectional view in FIG. 3 . In this embodiment, a pressure vent 37 is shown formed through the wall 39 a. The pressure vent allows equalization of the pressure within the seal element 34 a and the surrounding area. This may be useful in situations when the area surrounding the seal element 34 a may experience a pressure increase during use. If the pressure in the seal element 34 a is substantially lower than its surrounding environment, the unequal pressure distribution may prevent it from expanding into sealing engagement as needed.
[0025] The seal element 34 may be formed by combining together two metal W seals, the W seals may be seam welded along their edges at a line of symmetry. Additionally, the apex of the corresponding upper and lower portions 40 , 42 may include added support for accommodating the presence of the ring members 32 .
[0026] The member 32 may comprise other embodiments. For example, the cross section may resemble that of a triangle having rounded edges as well as a semi-circular member, where the apex of the semi-circle protrudes into the inverted portion of the seal 34 . In order to ensure proper sealing engagement of the seal member 34 , the design of the seal 34 should maintain an axial clearance between the apex of the inverted portions, even under related conditions.
[0027] It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. For example, the seal element 34 may have a single side that is inverted and not both sides. Additionally, the inverted space may comprise a generally rectangular cross section and be positioned at any radial location on the outer surface of the wall 39 . The seal may be used in many other applications other than on an isolation sleeve of a wellhead assembly. In the drawings and specification, there have been disclosed illustrative embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation. Accordingly, the invention is therefore to be limited only by the scope of the appended claims. | A seal for use in sealing on a wellhead assembly, where the seal is pressure energized and comprises an annular element having an inverted portion on its outer portion along its length. The seal may further include upper and lower ring members sandwiching the element between the ring members. The seal is formable by adjoining the open surfaces of two “W” shaped annular seals along their edges thereby forming an element responsive to pressure. | 4 |
FIELD OF THE INVENTION
The field of the invention relates to sealing technology, particularly those seals used in downhole tools for sealing annular chambers.
BACKGROUND OF THE INVENTION
In the past, tubing strings have employed various devices which have needed pressure chambers for actuation of various components. In some of these layouts, a separate connection outside the tubing string is provided for hydraulic control pressure. This pressure is used to selectively actuate a subsurface safety valve, depending on the configuration. Occasionally, the control components in the hydraulic circuit, for actuation of such downhole components as a subsurface safety valve, fail. For example, the hydraulic piston that is actuated by the control circuit, which is in fluid communication with an annular chamber, occasionally sticks or experiences seal failure. When this occurs, it is not possible to use the hydraulic forces in the control circuit to actuate the subsurface safety valve, or some other downhole component as required. When these circumstances occur, it is desirable to lower a substituted component through the tubing and position it appropriately to accomplish the task of the part rendered inoperative due to control circuit failure. At the same time, it is desirable to use the hydraulic control pressure to actuate this newly inserted component in the tubing or wellbore.
When these situations occur, it has become desirable to lower a penetrating tool to the desired depth and bore laterally into the hydraulic control circuit chamber. In order to facilitate the fluid communication into the control circuit, an annular chamber is provided so that upon reaching the proper depth, radial puncture in any direction will assure fluid communication into the annular chamber. Stated differently, if the control circuit flowpath extending within the tubular were strictly longitudinal, the puncture device would have to be properly oriented so that when it was actuated to perform a radial puncture, it would be in alignment with the longitudinal flowpath of the control circuit.
In the past, sealing annular control circuit chambers has been and continues to be of concern. Prior designs have employed resilient seals on at least one side of the chamber. These resilient seals suffered from difficulty in assembly and reduced reliability.
Accordingly, one of the objects of the present invention is to provide an annular chamber, such as those used in control circuits where the annular chamber extends in the tubular goods and is sealed internally and externally by metal-to-metal seals. It is a further object of this invention to eliminate resilient seals for sealing annular chambers used in control circuits or other application in tubular goods for downhole use.
SUMMARY OF THE INVENTION
Internal and external metal-to-metal radially interfering seals are provided for an annular chamber. Typically, an annular chamber is used in tubular goods to be part of the hydraulic control circuitry, such as for operating subsurface equipment such as a subsurface safety valve. Resilient seals are eliminated and sealing reliability is enhanced by a design which features metal-to-metal seals internally and externally, preferably assembled by an external two-step thread. The radial interference seal, which is internally disposed, is constructed so as to be incapable of experiencing tensile loads. This reinforces joint integrity by minimizing stresses on thin components.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an sectional elevational view showing the annular chamber with a sealing assembly using resilient seals.
FIG. 2 is a sectional elevational view of the apparatus of the present invention showing the annular pressurized chamber with internal and external metal seals.
FIG. 3 shows the operation with an insert valve installed after penetration into the chamber.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates the annular chamber with a sealing assembly. There, an annular chamber 10 is internally sealed by resilient seals 12 and 14. A connection 16 is provided to allow introduction of control hydraulic pressure. The hydraulic pressure enters chamber 10 and flows through passage 18 until it reaches piston 20. The movement of piston 20 can be used to actuate a downhole component, such as a subsurface safety valve. Threads 22 and 24 in conjunction with sealing surfaces 28 and 30 have been used for external seals for chamber 10. This two-step thread employed a torque shoulder 26 and opposed scaling surfaces 28 and 30.
The apparatus of the present invention, as shown in FIG. 2, still has the connection 16 leading into the chamber 10. Chamber 10 is in flow communication with passage 18 for actuation of subsurface component, such as a subsurface safety valve, by pressure applied to connection 16. The internal seals for chamber 10 comprise opposed surfaces 32 and 34. In a preferred embodiment, there is radial interference between the pin 36 and the box 38. The upper end 40 of pin 36, due to the absence of threads, is incapable of being subjected to tensile loads. This is significant because upper end 40 is a thin-walled component of pin 36 and could be subject to fracture under tensile loads following radial puncture. In order to provide the interference force that keeps mating surfaces 32 and 34 together, a two-step thread 42 and 44 is employed. The two-step thread 42 and 44 has a form known to those skilled in the art and further comprises a pair of sealing surfaces 46 and 48. A torque shoulder 50 assists in the makeup of the two-step thread 42 and 44. The thread form of threads 42 and 44 can be overhung so that, in conjunction with the torque shoulder 50, the sealing surfaces 46 and 48 are drawn to their opposed surface. There is a preferably slight interference fit radially for the paired surfaces 46 and 48. In the preferred embodiment, the sealing surfaces 32, 34, 46, and 48 are slightly tapered in the range of 0°-20° from the longitudinal axis of the pin 36 and box 38.
Another feature of the apparatus of the present invention is the configuration of chamber 10. Chamber 10 has a thin-walled section 52. This facilitates the radial puncture procedure by providing a thin wall 52 for the puncture apparatus. As a result, the puncture procedure can be concluded more quickly since there is less metal to penetrate. At the same time, the inner wall of the pin 36 has sufficient structural rigidity to withstand the desired interference fit radially at mating surfaces 32 and 34, as well as the expected internal pressures in chamber 10.
Referring now to FIG. 3, an insert valve 60 is lowered into bore 54. Valve 60 latches on to bore 54 in the customary manner such as using locking collets in a manner well-known in the art. With chamber 10 punctured to create port 56, the insert valve 60 may be operated by applying pressure at inlet 16, which flows through a channel 62 to a piston 64. Seals 66 seal off the lower end of passage 62. Additionally, seals 68 seal off passage 62 at the upper end. Accordingly, pressure applied to inlet 16 is communicated against piston 64 to actuate its movements so that the valve 60 can continue to operate using the control circuit pressure communicated through chamber 10. The insert valve 60 takes the place of subsurface safety valve 70, which is pushed out of the way upon insertion of the insert valve 60.
Normally, the subsurface components are actuated by a control circuit pressure applied at connection 16. Typically, the applied pressure at port 16 actuates a piston which in turn ties into the final controlled component (not shown). However, if for any reason, the piston (such as 20 shown in FIG. 1) fails to operate and another replacement component is inserted through the bore 54, it is desirable to redirect the pressure in the control circuit from chamber 10 directly into the newly installed component. Those skilled in the art will appreciate that the replacement component inserted through the bore 54 has its own actuating mechanisms responsive to hydraulic pressure. At that point in time with thin wall 52 having been penetrated by a penetrating tool, the control circuit pressure in chamber 10 is redirected into the replacement component. The replacement component (not shown) straddles the opening 56 which is placed there as a result of the operation of the penetrating tool. Thereafter, the replacement downhole component can be actuated using pressure applied at port 16. Now, instead of directing the pressure downwardly through passage 18, the pressure is redirected through opening 56 into the replacement subsurface component so that it can be actuated and operations resumed.
It can be seen that internal pressure applied in bore 54 also urges the sealing surfaces 32 and 34 into greater contact, thus promoting the internal seal of chamber 10.
The elimination of the flexible seals is a significant improvement in reliability of these critical joints that are part of the hydraulic circuit for key downhole components. Unreliability in the sealing of the joints in the control circuit, such as at chamber 10, can adversely effect the longevity of the control system. By virtue of the addition of the internal and external metal seals, reliability has been approved. Assembly has also been facilitated since in the past the resilient seals, such as cup-shaped seals, were extremely difficult to install without doing damage to the seals during assembly. With the metal-to-metal seals internally and externally, assembly has been greatly facilitated as it is now guided by the two-step thread 42 and 44.
In another feature of the present invention, a method has been developed to create a pin 36 and box 38 arrangement so that an annular cavity is created, with the annular space sealed internally and externally with metal-to-metal seals. The method of the present invention overcomes the prior problem in attempting to build such an apparatus because there previously did not exist the means of economically controlling the needed metal-to-metal interferences so that the seals could be reliably created internally and externally to the annular chamber. The proper amount of interference is important to ensure sealing integrity. However, too much interference can tend to create galling and prevent the easy assembly of the joint. Due to the close manufacturing tolerances required, construction of annular chambers with metal-to-metal internal and external seals have not been commercially available in the past. The threaded connection 42 and 44 has a center locating shoulder 50 which carries the torque of the made-up connection. The shoulder 50 also positions the contacting surface 32 and 34 on the pin nose 40 and the mating opposed surfaces in the box, as well as on the other end involving the contacting surfaces 46 and 48 on the box nose and its mating surface on the pin. In the preferred embodiment, the pin and box are made so as to have radial interference of about 0.0025 inch per inch of diameter. It has generally been found that lesser degrees of interference do not provide for an adequate seal, while substantially greater interference presents a hazard of galling. The pin 36 and box 38 are designed such that the pin nose is thin-walled but abuts the relatively thick main section of the box 38. Therefore, internal pressures in bore 54 actually promote internal sealing, while the substantial thickness of box 38 adjacent pin nose 40 provides the structural rigidity for the internal sealing. The same concept applies on the external joint at sealing surfaces 46 and 48. While the box nose is relatively a thin-walled member, it is mounted opposite the thick-walled portion of the pin. Accordingly, external pressures in the annulus applied to the pin 36 and box 38 promote sealing externally at sealing surfaces 46 and 48.
The method of the present invention applies a technique wherein the pin and box are manufactured using the same baseline dimensions. The manufacturing baseline dimension is taken from the torque shoulder 50 on both the pin and box. Based on this starting dimension, the extension portion is developed which includes sealing surfaces 32 and 34. Since the base dimension is taken from shoulder 50, the exact location of mating surfaces 32 and 34 can be positioned with the desired amount of interference in a manufacturing process that allows for specific control of the tolerances. This ensures that the proper amount of the desired radial interference is built into the pin 36 and the box 38 such that when they are put together, there will be sufficient force to ensure the seal yet an interference amount short of a situation where galling can occur. The pin nose 40 is not manufactured with a torque shoulder due to the difficulty in manufacturing tolerances of having two torque shoulders seat simultaneously. The torque shoulder 50, along with precise control of the dimensions of the pin nose 40 and the mating portions of box 38, removes the need for an internal torque shoulder or threads. However, the base reference technique using torque shoulder 50 or another starting reference point can be employed to optionally produce a pin/box joint involving an annular space in between, with an internal as well as external torque shoulder. Through the use of a common reference point, the particular interference range at the pin nose is accomplished by dimensional control of the surfaces adjacent the pin nose. Since a common reference point is used for the mating surfaces adjacent the pin nose, the tolerance spread of mating surfaces 32 and 34 can be controlled to within the same tolerance as the mating surfaces 46 and 48.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made without departing from the spirit of the invention. | Internal and external metal-to-metal radially interfering seals are provided for an annular chamber. Typically, an annular chamber is used in tubular goods to be part of the hydraulic control circuitry, such as for operating subsurface equipment such as a subsurface safety valve. Resilient seals are eliminated and sealing reliability is enhanced by a design which features metal-to-metal seals internally and externally, preferably assembled by an external two-step thread. The radial interference seal, which is internally disposed, is constructed so as to be incapable of experiencing tensile loads. This reinforces joint integrity by minimizing stresses on thin components. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an information reproducing method for reading information out from an information recording medium such as an optical card or an optical disk and an information recording method for writing information in the recording medium, and more particularly, to an information reproducing or recording method for an information reproducing or recording apparatus applied when track jump is unsuccessful in a seek operation on the information recording medium.
2. Related Background Art
The information recording media conventionally known include optical disks and optical cards for optically recording and reproducing information, fixed magnetic disks and floppy disks for magnetically recording and reproducing information, and magneto-optical disks, optical cards, etc. for optically and magnetically recording and reproducing information.
Generally, these information recording media have tracks consisting of a plurality of sectors. The tracks are provided with address information (hereinafter referred to as track numbers) indicating their positions in the information recording medium when the information recording medium is produced or formatted. Then, a desired track position is sought for, based on the track number, and recording or reproduction is carried out at that position. The information reproducing apparatus for reproducing the information in the recording medium is equipped with a memory for storing data of one or more tracks, and the cache technique is used upon reproduction of a desired sector in order to store data of all sectors including the desired sector in the track and decrease the number of track scans.
An example of operation of the conventional reproducing apparatus is next explained referring to the flowchart of FIG. 1. First, a host computer sends a logical address of an information reproducing portion together with a reproducing instruction to the reproducing apparatus. The reproducing apparatus having a memory for storing a part of data previously searched checks whether there is data of the logical address in the memory (step S11). If there is data, the reproducing apparatus transmits the data of the address in the memory to the host computer (step S15). If the data is absent, the apparatus obtains a physical address from the logical address, calculates a target track number corresponding to the physical address, and tries moving to the target track (step S12). Here, the apparatus scans the track to identify the track number, and checks whether the movement to the target track was unsuccessful (step S13). If unsuccessful, the apparatus again tries moving to the target track (step S12). If the movement to the target track was successful, data of the track is stored in the memory (step S14), and data of the desired sector is transferred to the host computer (step S15).
There is a limit to the capacity of the memory mounted in the reproducing apparatus. Thus, as to a method for abandoning stored data, a variety of proposals have been given; for example, first-in first-out abandonment, abandonment taking into account frequency of data reproduction address instruction, first-in last-out abandonment, etc.
An example of operation of a conventional recording apparatus is next explained referring to the flowchart of FIG. 2. First, receiving a recording instruction of data from the host computer (not shown), the recording apparatus (hereinafter referred to as a drive) moves a recording head to a target track corresponding thereto to look for a non-recorded area of an information recording unit (except for those registered as defective areas) (step S11). Since the track number cannot be identified without scanning the track, the recording head first scans the track to determine whether movement to the target track was successful (step S12). If the track is not the target track, the apparatus again looks for the target track (step S11). If it is the target track, recording and verification of data are carried out by scanning (steps S13, S14). Then, it is checked whether verification was successfully done (step S15). If there is an anomaly in verification, the apparatus performs altering processing, for example, preparation of movement to a next track (step S16). If the operation is normally ended, the recording processing is completed.
The above conventional example, however, had such a defect that the track scanning time for fault movement was wasted, because whether the movement to the desired track, instructed by the host computer, was unsuccessful was not able to be determined without scanning the track to which the head had moved.
SUMMARY OF THE INVENTION
The invention has been made so as to solve the above mentioned problem. That is, the object of the invention is to provide an information recording/reproducing apparatus in which even if an optical head failed to access a desired track, a time spent for scanning of a track thereupon is never wasted.
Specifically, the above object can be achieved by the following constitutions.
The object can be achieved by an information reproducing apparatus for reproducing information from a recording medium having a plurality of tracks with respective addresses, comprising:
a reproducing head;
a moving mechanism for relatively moving the reproducing head relative to the recording medium in order to let the reproducing head make access to a target track;
a memory for storing information having been reproduced in the past by the reproducing head; and
controlling means arranged in such a manner that when, in making the access, the reproducing head reaches another track as failing to make access to the target track, the controlling means reads information of the other track reached and stores the information in the memory.
The above object can also be achieved by an information reproducing method for reproducing information, using a reproducing head, from a recording medium having a plurality of tracks with respective addresses and storing information having been reproduced in the past in a memory, comprising:
a step of letting the reproducing head make access to a target track; and
a step of, when in making the access the reproducing head reaches another track as failing to make access to the target track, reading information of the other track reached and storing the information in the memory.
Further, the above object can also be achieved by an information recording apparatus for recording information in a recording medium having a plurality of tracks with respective addresses, comprising:
a recording head;
a moving mechanism for relatively moving the recording head relative to the recording medium in order to let the recording head make access to a target track; and
controlling means arranged in such a manner that when in making the access the recording head reaches another track as failing to make access to the target track, the controlling means writes information in the other track reached.
Further, the above object can also be achieved by an information recording method for recording information, using a recording head, in a recording medium having a plurality of tracks with respective addresses, comprising:
a step of letting the recording head make access to a target track; and
a step of, when in making the access the recording head reaches another track as failing to make access to the target track, writing information in the other track reached.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flowchart to show a flow of processing in the conventional information reproducing method;
FIG. 2 is a flowchart to show a flow of processing in the conventional information recording method;
FIG. 3 is a drawing to show an example of a setup of the information recording/reproducing apparatus used in the information reproducing or recording method of the present invention;
FIG. 4 is a schematic drawing of a recording surface of an optical card in which data is recorded, which is used in explaining the information reproducing method of the present invention;
FIG. 5 is a flowchart to show a flow of processing of the information reproducing method of the present invention;
FIG. 6 is a flowchart to show a flow of processing of a second embodiment of the information reproducing method of the present invention;
FIG. 7 is a schematic drawing of a recording surface of an optical card used in the information recording method of the present invention;
FIG. 8 is a flowchart to show a flow of processing in the information recording method of a third embodiment of the present invention;
FIG. 9 is a flowchart to show a flow of processing in the information recording method of a fourth embodiment of the present invention;
FIG. 10 is a flowchart to show a flow of processing for reproducing data recorded by the information recording method of the present invention; and
FIG. 11 is a defect list table concerning data recorded in the third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment!
The embodiments of the present invention will be explained in detail with reference to the drawings. FIG. 3 is a block diagram to show an example of the setup of the information recording/reproducing apparatus used in the information reproducing method of the present invention. In FIG. 3, reference numeral 1 designates an optical card, 31 the recording/reproducing apparatus (hereinafter referred to as a drive), and a host computer 32 of a host control unit is connected to the drive 31. Numeral 37 denotes a motor for driving the optical card, which introduces the optical card 1 through an unrepresented carrying mechanism into the drive 31, translationally moves the optical card 1 in directions R by a predetermined drive, and further discharges the optical card out of the apparatus (through a discharging mechanism not shown). Numeral 38 represents an optical beam irradiation optical system including a light source, which forms an optical beam spot on the optical card 1 upon recording of information and upon reproduction of information. Numeral 39 stands for a photodetector, which can receive reflected light of the optical beam spot on the above optical card 1. Numeral 40 denotes an AF actuator for performing autofocusing servo (AF) by driving a part of the optical beam irradiation optical system 38 to move the focus position of the optical beam spot on the surface of optical card 1 in the Z-direction, that is, in a direction perpendicular to the surface of optical card 1, and numeral 41 an AT actuator for performing autotracking servo (AT) by driving a part of the optical beam irradiation optical system 38 to move the optical beam spot on the surface of optical card 1 in the Y-direction (that is, in a direction perpendicular to both the R-direction and the Z-direction).
The optical head 50 is formed as including the above optical beam irradiation optical system 38, photodetector 39, AF actuator 40, and AT actuator 41. Further, numeral 36 designates a drive motor for moving the optical head 50 in the Y-direction to effect access of the optical beam spot to a desired track on the optical card 1. The arrangement for access of the optical beam spot may be replaced by an arrangement for moving the optical card 1 in the Y-direction.
MPU 33 is a microcomputer, including memories of ROM and RAM, which controls the card feed motor 37 and the head feed motor 36 and which performs communication, control, etc. of data with the host computer 32 under control thereof. Receiving a signal from the photodetector 39, an AT/AF control circuit 34 drives the AF actuator 40 and AT actuator 41. The output signal from the above photodetector 39 is input into the AT/AF control circuit 34 and, based on this output signal, the AT/AF control circuit 34 executes AF and AT as controlling the above AF actuator 40 and AT actuator 41. The output from the above photodetector 39 is also output to a modulation-demodulation circuit 35, where demodulation of read information is carried out. A demodulated signal is sent to the above MPU 33, which forms desired data therefrom and outputs the data to the host computer 32.
The modulation-demodulation circuit 35 modulates an information signal sent from the above MPU 33, drives the above optical beam irradiation optical system 38 in accordance with the modulation signal to execute information recording, and demodulates data, based on the signal from the photodetector 39, upon reproduction. The host computer 32 performs transmission of data to and from the drive 31, and executes a recording/reproducing operation of information for every data track. Generally, the optical card 1 has a high error rate because of the properties of the recording medium, and requires an error correcting means in applications necessitating information with high reliability.
FIG. 4 is a drawing to show a recording surface of the optical card used in the information reproducing method of the present embodiment, in which reference numeral 1 denotes the optical card, 50, the optical head located at the home position, S0 to S15 sectors, TN track numbers recorded with the same numbers at the left and right edges of the optical card 1, TR0 to TRn tracks, and HP the home position of the optical head. When the optical card 1 is inserted into the drive 31, the optical head 50 is first located at the home position HP after the optical card 1 is loaded. The following description is given assuming the reproducing apparatus is equipped with a sufficient memory in the present embodiment.
FIG. 5 is a flowchart to show processing procedures of a first algorithm of the present invention, and the next description is given according thereto. Let us suppose the host computer 32 issued a reproducing instruction, for example, of sector S10 shown in FIG. 4 to the drive 31. At this time, the MPU 33 checks whether the data of sector S10 is present or not in the memory (step S1). If the data is present in the memory, the flow goes to step S5 to transfer the data in the memory in the MPU 33 to the host computer 32 and finish the processing; but, assuming the data is absent in the memory in the present embodiment, the flow goes to step S2. Since the sector S10 exists in track TR2 in the optical card 1, the MPU 33 uses the drive motor 36 to move the optical head 50 to the track TR2 (step S2). However, whether a track to which the optical head 50 was moved is actually the track TR2 cannot be determined unless the optical head scans the track to detect the track number TN.
Suppose the movement was unsuccessful in the present embodiment, so that the optical head 50 is located at the track TR3. Then, the MPU 33 drives the card feed motor 37 to perform track scanning with the optical head 50. Then, data S12 to S15 is stored in the memory (step S3). If the movement to the target track was successful, the data of sector S10 is transferred to the host computer 32 via step S4 (at step S5) to end the processing, but the MPU goes via step S4 to step S2 because the movement to the target track was unsuccessful in the present embodiment. At step S2, the drive tries moving to the target track TR2 on the opposite side in the longitudinal direction of track to the home position HP, and again performs scanning. The track number TN is read by this scanning and data of four sectors is stored in the memory irrespective of whether the track number TN is 2 (step S3). After it was determined here that the movement to the target track was successful by reading the sector S10 (step S4), the MPU transfers the data of sector S10 to the host computer 32 (step S5), and completes the reproducing processing.
Next, suppose the host computer 32 issues a reproducing instruction of sector S11 to the drive 31. The MPU 33 checks whether the memory has data of the sector S1 (step S1), and, because the data of S11 is present in the memory among the sectors S8 to S11 in the above scanning of track TR2, the drive transfers the data of sector S11 to the host computer 32 (step S5).
Next, suppose the host computer 32 issues a reproducing instruction of sector S12 to the drive 31. The MPU 33 checks whether the data of sector S12 is present in the buffer memory (step S1). Since the data of sector S12 was already read into the buffer memory when the track TR3 was scanned on the occasion of fault movement as described previously, the data of sector S12 in the buffer memory is transferred to the host computer without scanning (step S5).
As described above, the memory in the MPU 33 is assumed to memorize data of sectors scanned together with sector numbers irrespective of whether scanning was unsuccessful, and to have a memory capacity sufficient to memorize it. In such a case, the memory is assumed to store all data in the track scanned. In the above algorithm, if the information recording/reproducing apparatus has a sufficient capacity of memory, the memory stores all sector information of the track scanned, thus fully demonstrating the function of so-called cache memory accordingly.
Second Embodiment!
The first embodiment was arranged in such a manner that the apparatus was equipped with a sufficient memory and the data was always stored in the memory even if the movement to the target track was unsuccessful. However, some reproducing apparatus may not have a sufficient memory capacity because of issues of cost or packaging space. In the case where there is a limit to the capacity of the memory, it can be conceivably determined based on a predetermined algorithm whether scanned data should be stored or not in the case of failure in movement to the target track. The operation according to this predetermined algorithm can save the memory transfer time for storing data in the memory and can simplify the algorithm for abandoning the data stored in the memory. FIG. 6 shows the flowchart to illustrate procedures of processing in the present embodiment. The procedures will be explained in the following.
The host computer 32 gives a reproducing instruction of a sector to the drive 31. At this time the MPU 33 checks whether the data of the sector requested is present in the memory (step S21). If the data is present in the memory, the MPU goes to step S27 to transfer the data in the memory of MPU 33 to the host computer 32 and to end the processing. On the other hand, supposing the data is absent in the memory in the present embodiment, the MPU goes to step S22.
Then, the MPU 33 uses the drive motor 36 to move the optical head 50 to a track where the sector is present (step S22). However, whether the track to which the optical head 50 was moved is actually the desired track or not cannot be determined unless the optical head scans the track to detect the track number TN and further to scan all sectors S in the track number TN to detect a target sector number. If the movement was unsuccessful, the MPU goes to step S24. Here, the MPU determines, based on a predetermined condition, whether the data of the track to which the head moved by the unsuccessful movement to the target track should be stored in the memory or not. Of course, if the movement to the target track was successful at step S23, the data obtained by track scanning is stored in the memory (step S26), and the MPU transfers the data to the host computer (step S27).
In the present embodiment, the predetermined algorithm is explained with three examples. It is assumed in the following description that a read instruction from the host computer 32 is issued in a sector unit.
A first algorithm is such that if the movement to the target track was unsuccessful and if data scanned is not present in the memory then the data is stored in the memory.
Next, a second algorithm is explained referring to FIG. 4 and FIG. 5 used in the first embodiment. Since the elements in the drawings were already described, the description thereof is omitted herein. The second algorithm is such that, presuming that the host computer 32 makes access to sector addresses in order from the smallest, data is stored in the memory only if the head unsuccessfully moved to a track with a larger address than the address of the target track.
Generally, when computers read an external memory device, reading is often carried out in block units (where a block is an assembly of sectors of consecutive addresses). In this case, data is read in order from the sector of the first address in the block. For example, let us consider a case where the computer reads eight sectors at the addresses of sector S4 to sector S11 in order.
Specifically explaining, the host computer 32 first selects the sector S4 closest to the home position HP in the block and gives a read instruction of sector S4. The drive 31 moves the optical head 50 to the track TR1. Since the memory in the MPU 33 preliminarily stores the track numbers TN and sector numbers therein in a table form, presence or absence of sector S4 can be determined by reading the track number TN1 of this track TR1. Judging that the movement was successful, the data of track TR1 is stored in the memory in the MPU. Then, the MPU transfers the data of sector S4 to the host computer 32. Next, since the data is present in the memory to read instructions for sector S5 to sector S7, the data is transferred to the host computer 32 without performing movement of the optical head.
Next, the host computer 32 gives a read instruction of sector S8 and the MPU 33 tries moving the optical head 50 to the track TR2 in which the sector S8 is present. However, supposing the movement to the target track was unsuccessful and the optical head moved, for example, to the track TR0, the data of sectors S0 to S3 in the track TR0 is not stored in the memory. Namely, if the optical head moved to a track not having the sector instructed, the data of the sectors in the erroneous track is not stored in the memory.
A third algorithm is next explained. This algorithm is such that whether data should be stored or not is determined from a relation between a remaining capacity of memory for storing data and the address of the track reached after unsuccessful movement. In detail, only if the address of the track reached after unsuccessful movement is greater than the address of the target track and only if a quantity of data from the target track to the track reached after unsuccessful movement is not more than the remaining capacity of the memory, the data of the track reached is stored in the memory.
The third algorithm is explained in more detail. Let us suppose here that the memory for storing data has a capacity for storing data of five tracks.
First, the algorithm is explained assuming that the memory already stores data of the two tracks. It is assumed that when the host computer 32 issued a read instruction of sector S0, movement to the target track was unsuccessful and the optical head moved to the track TR3. At this time, the remaining capacity of memory is of three tracks. However, the data quantity from track TR0 including the sector S0 to the track TR3 is of four tracks. The data of track TR3 is not stored in the memory accordingly.
The effect of this algorithm is next described. If the optical head were moved three times toward the track TR0 and all the data of the respective tracks TR1, TR2, TR3 were stored in the memory, the memory would be filled with the data of the tracks reached after unsuccessful movement. Even if the optical head were next successfully moved to the target track TR2, some data must be abandoned according to a predetermined abandonment algorithm because of no vacancy in the memory. Use of the third algorithm can obviate this abandoning processing.
As explained above, first, if there is a limit to the capacity of the memory, data is stored in the memory taking account whether data of sectors in the track reached or data of the track can be stored or not. When the optical head reaches the target track, the data thereof is, of course, stored in the memory. Even if the movement were unsuccessful, the computer would give a next instruction to request data of the unsuccessful track with high probability, and then the data requested by the host computer would be able to be quickly transferred thereto in that case.
As explained above, the first embodiment effectively utilizes the track scanning in the case of unsuccessful movement to the target track, whereby the reproducing speed can be maintained at the same level even with unsuccessful movement to the target track as those of the conventional apparatus.
If the memory of the reproducing apparatus is not sufficient as shown in the second embodiment and if the movement to the target track was unsuccessful, simplification of processing becomes possible by employing an appropriate algorithm to determine whether the data of the track should be stored or not in the memory.
It is noted that the positions in the recording medium were recognized by the addresses given in track units in the first and second embodiments, but the effect of the present invention can be maintained when the positions in the recording medium are recognized by the addresses given in sector units.
Third Embodiment!
The third embodiment of the present invention is next explained in detail with reference to the drawings. The apparatus used in the present embodiment is the same as shown in FIG. 3, and the description thereof is omitted herein.
FIG. 7 is a drawing to show a recording surface of the optical card used in the information recording method of the present embodiment, in which reference numeral 10 designates the optical card, T0 to Tn track numbers, P0, P1, . . . physical addresses of sectors, L0, L1, . . . logical addresses of sectors in which data is recorded, X, Y data recording directions, P, Q directory recording directions, and HP the home position of the optical head 50. The description to follow is based on the structural drawing of the optical card 10 in FIG. 7 and the flowchart of FIG. 8.
First, the host 32 gives a recording instruction of logical address L0 to the drive apparatus 31. Then, the MPU 33 moves the optical head 50 to a track including a sector in which no data is recorded (step S31). This state to move to the target track is described in further detail. When the optical card 10 is initially loaded in the apparatus, the optical head 50 is located at the home position HP and then the drive motor 36 moves the optical head in the Y-direction toward the target track. There are a variety of methods proposed for accurately moving the optical head to the target track on the optical card 10, but it cannot be determined in practice whether a track reached is the target track or not unless the track is scanned in the card scanning direction (in the X-direction or a direction opposite to the X-direction) to read the track number.
Then, the MPU 33 feeds the optical card 10 in the direction opposite to the X-direction by the card feed motor 37. As a result, the optical head 50 scans the track in the X-direction. When the track number is read, it is determined whether there is a recording-possible region (step S32). If there is no recording-possible region, movement to the target track is again carried out (step S31). If there is a recording-possible region, the track is scanned in the X-direction to record data therein (step S33). Further, the sector in which the data was recorded is again scanned in the X-direction to read the data for verification (step S34). In the present embodiment, the host computer 32 gave recording instructions of from L0 to L5 to the drive apparatus 31 and track movement, and recording was normally ended. However, when the host computer gave a recording instruction of L6, the movement of the optical head 50 of the drive apparatus 31 was unsuccessful. Namely, the optical head was originally intended to move to the target track T1, but actually moved to the track T2. Since the track T2 is a recording-possible region, recording of L6 is carried out in the physical sector P12. The physical sectors P6 to P12 are memorized as defect sectors in the RAM memory in the MPU 33 and the processing is completed.
Next explained is the case where the host computer 32 makes access to the data recorded as described above by designating the logical address to the drive apparatus 31. FIG. 11 shows a defect list stored in the RAM memory in the MPU 33, which includes a record of defect list numbers, defect start addresses, and numbers of consecutive defects. FIG. 10 is a flowchart to show procedures for reading data as converting a logical address into a physical address, using the defect list. FIG. 10 is explained with an example of reproduction of data at the logical address 6 in FIG. 7.
Step S51 is arranged to initialize defect counter Cnt for counting defect sectors to 0 and defect list number Ptr to 1. Step S52 checks whether the number of consecutive defects in the defect list number Ptr is 0 or not, and if it is 0, then the processing proceeds to step S56 as determining that there is no defect in the list. If the number is not 0, then step S53 is executed as judging that there is a defect list. At step S53, the defect counter Cnt (=0) is subtracted from the defect start address (=6) in the defect list, and the result is compared with the logical sector address La6 given. Here, because the logical sector address La6 given is not smaller than the right side (the resultant of subtraction of Cnt from the defect start address in the defect list number 1), the processing goes to step S54. At step S54, the number of consecutive defects N (Ptr) (=6) in the defect list number 1 is added to the defect counter Cnt. At step S55 the defect list number Ptr is given an increment (Ptr+1).
Further, step S52 is executed. Since the defect list number 2 includes 0 in the number of consecutive defects, step S56 is carried out.
The physical address is calculated at step S56. Since Cnt=6 and the logical address given La=6, the physical address Pa obtained is 12; that is, sector P12.
In this manner the information corresponding to the sector L6 of the logical address is recorded in the sector P12 of the physical address Pa. If over tracking is made by a track and if the track reached after jumping is a track in which no data is recorded, the information instructed is recorded in the track and jumped tracks are dealt with as defect tracks; more precisely, sectors in the track are dealt with as defect sectors, thus resulting in presenting a great effect of decreasing the recording period. Since some thousand tracks are expected as information recording tracks in one optical card, the time reduction during operation is more advantageous even with allowing to jump one track or several tracks.
Fourth Embodiment!
The third embodiment showed an example in which the Y-directional movement of the optical head 50 missed only one track, whereas the present embodiment is an example in which the optical head misses some ten or even some hundred tracks because of runaway or the like of the drive motor 36, which is explained using the flowchart of FIG. 9. After the drive apparatus 31 receives a recording instruction of data from the host computer 32, movement of the optical head 50 is started to the target track (step S41). Scanning the track number, it is determined whether a difference between the target track and the scanned track falls within a predetermined condition (step S42). The determination standard changes system by system depending upon the total number of tracks in the optical card, the altering processing method, or the like. In the present embodiment, the difference is determined as to be large for ten or more tracks, but as to be small for 9 or fewer tracks. If the difference between the target track and the track reached after jump is ten or more, the optical head 50 is again moved to the target track. If the difference is less than 10, the processing proceeds to step S43. Step S43 is to determine whether a recording-possible region exists in the track scanned, and if no recording-possible region exists, then the processing goes to step S41. If a recording possible region exists, then the processing proceeds to step S44 to record data sent from the host 32 in the recording-possible region. Step S45 is to perform the verification operation for checking whether the data recorded is normally recorded or not. If there is an anomaly in the verification, the altering processing is carried out at step S47. If the verification is normal, the recording operation of the recording instruction from the host 3 is ended.
Since the method for reading the data recorded in the present embodiment is the same as in the first embodiment, the description thereof is omitted herein.
The above embodiment is so arranged that the MPU 33 sets a track with a region of no record as the target track by arithmetic to find it from the number of record-including logical sectors having been stored in the RAM before the current recording instruction, and if the optical head 50 moves from the home position HP to the target track as counting zero-cross points in the tracking error signal, it rarely passes some ten tracks as described above. In that case, the above event is peculiar. In the case of such an event, the operation according to the flowchart shown in FIG. 9 is extremely effective.
The information recording medium was explained with the example of the optical card in the above embodiments, but the information recording medium may be any one of those shaped as a disk, card, tape, or the like. Further, the recording method is not limited to the optical method, but may be another method, such as the magneto-optical method or the magnetic method. For example, in the case of the disk medium, because the disk is rotating, the optical head reaches the target track by counting the tracks. If the track reached is not the target track, but if there is a recordless region, the recording operation is immediately started to record data therein. This can achieve the recording operation within a short time.
As explained above, even if movement of the optical head to the target track was unsuccessful, but if recording is possible in the track, the data is recorded therein, whereby the recording time can be decreased.
If the difference is large between the address of the target track and the track address of the track to which the optical head actually moved, movement to the target track is again tried without performing recording of data, which provides a system with a decreased number of redundant tracks (defect sectors) decreases the recording time. | When information is reproduced from a recording medium having a plurality of tracks with respective addresses, a head is moved relative to the recording medium in order to let the head make access to a target track. A memory is provided for storing information having been reproduced in the past by the head. When, in making the access, the head reaches another track as failing to make access to the target track, a controlling unit reads information of the other track reached and stores the information in the memory. In recording of information, when, in making the access, the head reaches another track as failing to make access to the target track, the controlling unit writes information in the other track reached. | 6 |
BACKGROUND
[0001] Hydrocarbon fluids such as oil and natural gas are obtained from a subterranean geologic formation, referred to as a reservoir, by drilling a well that penetrates the hydrocarbon-bearing formation. Once a wellbore is drilled, various forms of well completion components may be installed in order to control and enhance the efficiency of producing the various fluids from the reservoir. One such component is a flow control valve used to control the amount of fluid permitted to flow upward through the completion to the surface.
SUMMARY
[0002] Embodiments of the present disclosure are directed to a flow control valve assembly including a plunger containment member and a plunger operatively coupled to the plunger containment member such that moving the plunger toward an uphole side and toward a downhole side opposite the uphole side in the plunger containment member causes the flow control valve to selectively open and close in response to administration of force to the plunger. The uphole side of the plunger and the downhole side of the plunger are exposed to a hydrostatic pressure of substantially equal magnitude. The assembly also includes a first seal between the plunger and the plunger containment member on the uphole side and a second seal between the plunger and the plunger containment member on the downhole side.
[0003] The assembly can also include a power module to provide power to move the plunger to selectively open and close the flow control valve. The first and second seals are able to withstand 1,200 psi and the power module is configured to operate with between 8-10 watts.
[0004] Further embodiments of the present disclosure are directed to a method for operating a flow control device. The method includes providing a flow control valve in a well, the flow control valve having a plunger containment member, a plunger, and a fluid port. The plunger is configured to travel forward and backward in the plunger containment member to open and close the flow control valve. The plunger has a first side and a second side opposite the first side. Both the first and second sides are exposed to pressure in the well of substantially equal magnitude, and the fluid port is opened or closed by moving the plunger within the plunger containment member. The method also includes providing a first seal for the first side of the plunger and a second seal for the second side of the plunger. The first and second seals are configured to withstand up to 1,200 psi. The method further includes operating a power module to move the plunger in the plunger containment member, wherein the power module consumes no more than 10 watts of power.
[0005] Still further embodiments of the present disclosure are directed to a flow control device for use in a downhole completion. The flow control device includes a central fluid bore configured to conduct fluid upward from the well, the central fluid bore having a fluid port in a wall of the bore, and a plurality of sand screens positioned outside the central bore and configured to filter fluid as the fluid passes through the sand screens. The device also includes an annular bore configured to receive fluid after passing through the sand screens. The annular bore is fluidly connected to the fluid port in the central fluid bore. There is also a plunger positioned in the annular bore and configured to selectively block fluid flow from the annular bore into the central bore. The plunger is selectively, continuously movable between a closed position, an intermediate position, and a fully open position, the plunger having a downhole side and an uphole side opposite the downhole side, wherein the uphole side and downhole sides are both exposed to substantially the same hydrostatic pressure in the well. The device also includes a seal assembly between the plunger and the uphole side.
BRIEF DESCRIPTION OF THE FIGURES
[0006] FIG. 1 is an illustration of an example of a completion deployed in a lateral wellbore and combined with a multi-zone control system, according to an embodiment of the disclosure;
[0007] FIG. 2 is a schematic illustration of an example of a multi-zone control system utilizing a control module combined with a plurality of flow control devices, according to an embodiment of the disclosure;
[0008] FIG. 3 is a schematic illustration of another example of a multi-zone control system utilizing a control module combined with a plurality of flow control devices, according to an embodiment of the disclosure;
[0009] FIG. 4 is a schematic illustration of an example of lateral completion arrangement for use with a multi-zone control system, according to an embodiment of the disclosure.
[0010] FIG. 5 is a cross-sectional view of a plunger-type flow control valve assembly according to embodiments of the present disclosure.
DETAILED DESCRIPTION
[0011] In the following description, numerous details are set forth to provide an understanding of the present disclosure. However, it will be understood by those skilled in the art that the embodiments of the present disclosure may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
[0012] In the following description, numerous details are set forth to provide an understanding of some embodiments of the present disclosure. However, it will be understood by those of ordinary skill in the art that the system and/or methodology may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
[0013] The present disclosure generally relates to an electrically controllable, multi-zone control system. The multi-zone control system may be used for controlling the inflow of fluids into a completion, e.g. a lateral completion, at a plurality of well zones. According to an embodiment, hydraulically actuated, flow control devices are distributed along the completion in the various well zones. Additionally, a control module is positioned between the flow control devices, e.g. in a middle region of the completion. For example, the control module may be positioned between well zones and operated downhole for controlling flow control devices uphole and downhole relative to the location of the control module.
[0014] The control module is supplied with hydraulic actuating fluid from a source, such as a downhole hydraulic fluid source or a surface source. In operation, the control module is electrically controllable to enable selective distribution of the hydraulic actuating fluid to specific flow control devices, e.g. flow control devices in a specific well zone. The control module may be actuated via electric signals to provide controlled distribution of hydraulic actuating fluid under pressure to selected flow control devices. The hydraulic actuating fluid is used to shift the selected flow control devices to a desired open or closed flow position allowing or blocking flow from the surrounding well zone.
[0015] Effectively, the control module serves as a multi-zone distribution hub. In some embodiments, the control module is supplied with hydraulic actuating fluid via a single hydraulic control line and a pump is used to place the actuating fluid under suitable pressure for actuating the flow control devices. An electric line may be routed downhole to the control module to provide electrical control signals to the control module. Based on those control signals, the control module is actuated to direct hydraulic actuating fluid through relatively short hydraulic lines to specific flow control devices. As a result, electrical signals supplied through, for example, a single electric line may be routed downhole and used to ultimately control operation of flow control devices in a plurality of well zones, e.g. 2-5 well zones. Use of the electric line enables and simplifies active surface control of fluid flow into the completion at a plurality of downhole well zones. The use of electrical control signals also enhances the ability to multi-drop such a system to various other well zones.
[0016] Referring generally to FIG. 1 , an embodiment of a well system 20 is illustrated. In this embodiment, well system 20 is deployed in a wellbore 22 having a lateral wellbore section 24 , e.g. a generally horizontal wellbore section. The well system 20 comprises a completion 26 deployed in wellbore 22 . In a variety of applications, completion 26 may be in the form of a lateral completion deployed in lateral wellbore section 24 along a plurality of well zones 28 .
[0017] In some applications, the lateral completion 26 is a lower completion initially installed downhole and then coupled with an upper completion 30 (shown in dashed lines) via a connect-disconnect system 32 . An artificial lift system, e.g. an electric submersible pumping system, may be deployed as part of or in cooperation with the upper completion 30 to produce fluids received via lateral completion 26 . During a production operation, the lateral wellbore section 24 may be isolated via a packer 34 , such as a production packer, set against a surrounding casing 35 .
[0018] Lateral completion 26 comprises an interior flow region or passage 36 which may be along the interior of a base pipe 38 . The lateral completion 26 also comprises a plurality of sand screens 40 disposed about the base pipe 38 and located in corresponding well zones 28 . Additionally, the lateral completion 26 comprises a plurality of flow control device systems 41 . Each flow control device system 41 may comprise a plurality of flow control devices 42 located in each well zone 28 , as further illustrated in FIG. 2 . In a variety of applications, the lateral completion 26 is assembled by connecting sections which may be referred to as joints 43 . For example, sand screen assembly joints 43 may be sequentially joined and deployed along lateral wellbore 24 .
[0019] Referring generally to FIGS. 1 and 2 , the flow control devices 42 are uniquely controlled via a control module 44 . The control module 44 effectively enables control of fluid flow from an exterior of lateral completion 26 to an interior of lateral completion 26 at specifically selected well zones 28 . In a variety of applications, the control module 44 may be located between sand screens 40 and between well zones 28 , e.g. at a generally central or middle location with respect to the plurality of well zones 28 . In other words, the control module 44 may be positioned such that at least some of the flow control devices 42 are uphole and at least some of the flow control devices 42 are downhole relative to the location of the control module 44 . It should be noted uphole refers to the side of the module 44 toward the surface regardless of whether the lateral wellbore 24 is horizontal or inclined. The downhole side of control module 44 is the opposite side which is farther into the wellbore relative to the control module. The well zones 28 may be separated and isolated via isolation packers 46 which are deployed in an un-set state and then set against the surrounding open hole wellbore wall, as illustrated.
[0020] To facilitate an initial gravel packing of lateral wellbore 24 after setting of the packers 46 , the completion 26 also may comprise a plurality of shunt tubes 48 which deliver the gravel packing slurry to sequential well zones 28 . The shunt tubes extending through sequential well zones 28 may be joined at a shunt tube isolation valve structure 50 having valves for controlling the flow of gravel slurry. The valves in valve structure 50 serve to further isolate adjacent well zones 28 when the valves are closed, e.g. closed after gravel packing. During a gravel packing operation, gravel packing slurry is delivered downhole by a service tool and then diverted from the inside diameter to the annulus surrounding completion 26 via a port closure sleeve 52 . The gravel slurry flows along the annulus and shunt tubes 48 to form a uniform gravel pack 54 .
[0021] In an operational example, the gravel slurry begins packing from the heel of the well and as the gravel/sand settles the dehydration fluid travels along a drainage layer between the first sand screen 40 and a solid section of the base pipe 38 . The dehydration fluid travels along this fluid return path until reaching a first sliding sleeve 56 of a plurality of sliding sleeves. In some applications, some of the returning dehydration fluid also flows through the corresponding flow control device system 41 , thus reducing or removing the use of additional sliding sleeves 56 . The dehydration fluid then flows into interior 36 and back to the surface through the base pipe 38 and corresponding tubing. Upon completion of the heel zone, the gravel slurry pumping operation is continued and this process is repeated at subsequent well zones 28 , with the aid of shunt tubes 48 , until screen out pressure is reached and the pumps are stopped.
[0022] Once the service tool is retrieved, the upper completion 30 is deployed downhole and engaged with the lower completion 26 to establish communication from the surface to the lower completion 26 . For example, electrical and/or hydraulic communication may be established through the connect-disconnect 32 which can be in the form of an electrically powered connect-disconnect system. Electrical power and electrical control signals may be provided to the control module 44 via an electric line 58 routed through the connect-disconnect 32 . The electric line 58 may be coupled with a control system 60 , e.g. a computer-based control system, located at the surface or at another suitable location.
[0023] In some applications, hydraulic actuating fluid may be provided to control module 44 via a hydraulic line 62 to enable selective actuation of the flow control devices 42 . The hydraulic line 62 may similarly be routed through the connect-disconnect 32 and coupled with a hydraulic pump and control system 64 located at the surface or at another suitable location. In other embodiments, however, the hydraulic line 62 may be routed to control module 44 from a downhole fluid reservoir as described in greater detail below.
[0024] It should be noted the electric line 58 may comprise a single or multiple conductive paths for carrying electrical power, control signals, and/or data signals, e.g. data signals from sensors or other downhole equipment. By way of example, the electric line 58 may be in the form of a single line having a plurality of conductors able to independently carry power and/or data signals between, for example, surface control 60 and control module 44 . Similarly, the hydraulic line 62 may comprise a single flow path or a plurality of flow paths for carrying hydraulic actuation fluid.
[0025] Referring again to FIG. 2 , a schematic illustration is provided of an embodiment of an overall multi-zone control system 66 in which the control module 44 is electrically controlled via electrical control line 58 and serves as a multi-zone distribution hub. In this embodiment, sequential well zones 28 are isolated via packers 46 and the control module 44 is located proximate a generally central well zone 28 . The control module 44 may comprise control electronics 68 , e.g. a controller, which receive electrical control signals via electric line 58 . The electronics 68 may comprise control and telemetry features, and it may be embodied in a printed circuit board or otherwise suitably configured in control module 44 .
[0026] Based on the control signals received via electric line 58 , the controller 68 executes flow control according to the instructions carried by the control signals. For example, the controller 68 may be used to control operation of a hydraulic manifold 70 of control module 44 . As described in greater detail below, the hydraulic manifold 70 may comprise a variety of electrically controllable valves which are actuated according to instructions carried by the electrical control signals. The control module 44 /manifold 70 are thus selectively controlled to direct flows of actuating fluid to the appropriate flow control system 41 and corresponding control devices 42 via a corresponding hydraulic line or lines 72 .
[0027] In some embodiments, each hydraulic line 72 is routed to a corresponding well zone 28 and controls the simultaneous opening or closing of the group of flow control devices 42 in that specific corresponding well zone 28 . For example, control instructions may be provided by control system 60 to controller 68 of control module 44 via appropriate electrical signals sent along electric line 58 . In response to those instructions, the control module 44 controls hydraulic manifold 70 to ensure a flow of hydraulic actuating fluid to the appropriate flow control devices 42 in a given well zone or zones 28 . Accordingly, if undesirable fluid, e.g. water or undesirable gas, begins to flow into the interior 36 of lateral completion 26 at a specific well zone 28 , the group of flow control devices 42 in that particular well zone 28 may be closed to block further inflow.
[0028] Depending on the type of surrounding formation and equipment used to construct lower completion 26 , the number and length of well zones 28 may vary. By way of example, the well zones 28 may be approximately 1000 feet in length and control module 44 may be used to control 2-5 well zones 28 . However, the lengths of well zones 28 may range from a few feet to thousands of feet, and the length may be the same or dissimilar from one well zone 28 to the next. Accordingly, the number of flow control devices 42 placed in each well zone 28 also may vary according to the parameters of a given application.
[0029] In the specific example illustrated, the overall multi-zone control system 66 employs control module 44 to control well fluid flow at five different well zones 28 . Sometimes the number of well zones 28 controlled by an individual control module 44 may be selected based on the number of control line feed throughs available at isolation packers 46 . For example, if the isolation packers 46 have three control line feed throughs, then the number of well zones 28 serviced by the control module 44 may be selected based on the ability to accommodate the single electrical line 58 and a pair of hydraulic lines 72 . If the number of feed throughs in isolation packers 46 is increased, however, the multi-drop to other well zones 28 can also be increased accordingly. Also, the electric line 58 may be routed to additional control modules 44 so as to enable further control over inflow of well fluids at additional well zones 28 .
[0030] Referring generally to FIG. 3 , another embodiment of multi-zone control system 66 is illustrated. In this example, the control module 44 is supplied with hydraulic actuating fluid from a downhole reservoir 74 which may be pressure compensated via one or more compensators 76 . For example, the downhole reservoir 74 may serve as a hydraulic fluid bank for storing hydraulic actuating fluid downhole in a closed loop while being reservoir pressure or tubing pressure compensated via compensators 76 .
[0031] The downhole reservoir 74 supplies hydraulic actuating fluid to control module 44 via hydraulic line 62 . In the embodiment illustrated, control module 44 comprises a hydraulic pump 78 powered by a motor 80 which, in turn, may be coupled to electrical power via electric line 58 . In some embodiments, the hydraulic pump 78 and the motor 80 may be combined into a single component. In the illustrated example, the hydraulic manifold 70 works in cooperation with a plurality of electrically actuated valves 82 , e.g. solenoid operated valves, to control flow of hydraulic actuating fluid along hydraulic lines 72 . An additional electrically actuated valve 84 may be used to enable circulation of hydraulic actuating fluid back to reservoir 74 when the electrically actuated valves 82 are closed to flow. This allows hydraulic pump 78 to continually operate and to simply return the pumped actuating fluid back to reservoir 74 when the electrically actuated valves 82 are in the closed position.
[0032] When the control module 44 , e.g. controller 68 , receives instructions to change the flow position of flow control devices 42 in a given well zone or zones 28 , the appropriate valves 82 are shifted electrically to the desired flow or no-flow position. In the embodiment illustrated, the electrically actuated valve 84 has been shifted to the closed or no-flow position and one of the electrically controlled valves 82 has been shifted to the open flow position to enable flow of actuating fluid to the corresponding flow control devices 42 . In the illustrated example, the valve 82 shifted to the open flow position has effectively directed actuating fluid under pressure to the flow control devices 42 in the middle well zone 28 , thus shifting those flow control devices 42 to the closed flow position. When flow control devices 42 in the middle well zone 28 are closed, well fluids are prevented from flowing from the exterior of completion 26 to interior 36 at that well zone.
[0033] Depending on the application, flow control devices 42 may have a variety of configurations. By way of example, the flow control devices 42 may comprise plunger assemblies 86 , e.g. hydraulically actuated plungers 86 . In some applications, the plungers 86 are spring biased or otherwise biased to an open flow position allowing flow of fluids from an exterior to an interior of lateral completion 26 . When hydraulic actuating fluid is allowed to flow to specific hydraulically actuated plungers 86 via manifold 70 , those plungers 86 are forced against the spring bias and into corresponding seats 88 to block further flow of fluids therethrough.
[0034] In some embodiments, individual electrically actuated valves 82 may be coupled with flow control devices 42 in more than one well zone 28 . In the embodiment illustrated in FIG. 3 , for example, one of the electrically actuated valves 82 controls corresponding flow control devices 42 in two well zones 28 on the left or heel side of control module 44 . Another one of the electrically actuated valves 82 controls the remaining flow control devices 42 in those same two well zones 28 . Depending on the parameters of a given well, formation, well zone arrangement, equipment configuration, and/or other factors, various flow control arrangements may be selected. In the illustrated example, two of the electrically actuated valves 82 are actuated to the open flow position to close the corresponding groups of flow control devices 42 and to completely block flow in each of the heel side well zones 28 .
[0035] A sensor system 90 also may be used to optimize control over fluid flow in each of the well zones 28 . By way of example, the sensor system 90 may comprise a plurality of sensors 92 positioned along completion 26 and/or at other suitable locations within well zones 28 . The sensors 92 may be in the form of pressure sensors, temperature sensors, or other sensors distributed throughout the well zones 28 . The sensor data, e.g. pressure and temperature data, may be sent along electric line 58 to at least one of the controller 68 or control system 60 for processing. The processed data provides information that can be used for controlling flow into completion 26 at each well zone 28 . For example, if the sensor data indicates the presence of water and/or gas, the flow control devices 42 for that well zone 28 may be closed to block further inflow of fluid.
[0036] Depending on the reservoir and surrounding formation, the lateral completion 26 may be constructed in various lengths and configurations. In FIG. 4 , a schematic illustration is provided in which the lateral completion 26 is structured with a plurality of screen assembly joints 43 , e.g. four screen assembly joints, on each side of a flow control device, e.g. flow control device 42 . Consequently, a given flow control device(s) is able to collect fluid flow from the drainage layer in both uphole and downhole directions. For example, a given flow control device 42 may collect fluid flow from four uphole screen joints 43 and from four downhole screen joints. In the illustrated example, twenty four screen assembly joints 43 are disposed between the illustrated pair of isolation packers 46 . Depending on the application, the number of joints 43 as well as a number of flow control devices 42 between isolation packers 46 may vary and may be selected based on, for example, zonal flow parameters. As described above, the inflow of well fluids is collected from the screens 40 and diverted along a drainage layer of the completion 26 to the flow control devices 42 , e.g. to the plunger assemblies 86 , to enable selective choking of production flow.
[0037] The overall zonal flow control system 66 may be adapted to a variety of applications and may be used to provide a low-cost, active control of multiple well zones 28 , e.g. five well zones, from a single distribution hub/module 44 . With additional feed throughs in packers 46 and in shunt tube isolation valve structures 50 , additional well zones 28 may be controlled via module 44 . The control module 44 serves as a distribution hub which can be multi-dropped to provide flow control in a plurality of well zones based on control signals through the simple electric line 58 . In some applications, the hydraulic actuating fluid may be selectively diverted by the control module 44 to actuate other components in the lower completion 26 , e.g. packers, sliding sleeves, or zonal isolation valves. The flow control devices 42 also may comprise various types of plunger assemblies which facilitate return flow through the sand screen assembly joints 43 .
[0038] Depending on parameters of a given application, the control module 44 may be constructed in a variety of configurations and may comprise various features. Examples of such features include the integral pump 78 and the motor 80 used for hydraulic power generation. The control module 44 also may incorporate or work in cooperation with a pressure compensation system, e.g. compensators 76 . In some applications, the control module may comprise or work in cooperation with an accumulator used for storing hydraulic energy. Additionally, electronics 68 may comprise various types of controllers and telemetry systems utilized for communication and for controlling the components of control module 44 and overall flow control system 66 .
[0039] Other components of the overall well system and multi-zone flow control system 66 also may be adjusted according to the parameters of a given application. The electric line 58 may comprise separate lines for power and data or a combined power/data line. The control system 60 and electric line 58 may be used for carrying a variety of signals along a wholly hardwired electrical communication line or a partially wireless communication line. Such adjustments to the well system may be made according to equipment, environmental, and/or other considerations.
[0040] FIG. 5 illustrates a plunger-type flow control valve assembly 100 according to embodiments of the present disclosure. Any of the flow control devices described herein can be this plunger type of flow control valve. The assembly 100 includes a pressure-balanced plunger 112 held within a plunger containment member 114 that is shaped and sized to house the plunger 112 within an interior region of the plunger containment member 114 such that the plunger 112 is permitted to move axially within the plunger containment member 114 as shown by arrow A. When the plunger 112 is in a closed position (as in FIG. 5 ) with the plunger 112 toward the right, the valve assembly 100 is closed. The flow control valve assembly 100 includes a fluid port 116 through which production fluid is permitted to flow into a main bore 117 when the plunger 112 is moved to the left.
[0041] The plunger 112 has a downhole side 118 and an uphole side 120 . In previous designs, the plunger 112 was exposed to pressure on the downhole side 180 which was counter balanced by a force applied to the plunger 112 to the uphole side 120 to maintain the plunger 120 in the desired position. Depending on the installation, the pressure and counter balancing forces were large. The flow control valve assembly 100 also includes a power module 124 (shown schematically) that provides power to move the plunger up and down to open and close the valve assembly 100 . The present disclosure is directed to embodiments in which the pressure is balanced between the uphole side 120 and downhole side 180 .
[0042] The assembly 100 includes a series of seals 122 which will permit the pressure to be applied to the uphole side 120 without contaminating the fluid flow through the fluid port 116 . The uphole side 120 and downhole side 180 can both be in communication with hydrostatic pressure in the wellbore mitigating and even eliminating the need to force the plunger 112 toward the closed position. The forces required to move the plunger 112 from the closed position toward any intermediate position or a fully-open position are also very low. In some embodiments the required power is 10 watts or less. The power consumption is related to the flow rates and the pressure rating. For a lower pressure and flow rate configuration, the power can be as low as 5 watts. The balanced design allows for a greater amount of pressure to be held. In some embodiments, the pressure can be as high as 5,000 psi. The seals 122 can be made of a different material and configuration than the interface between the plunger 112 and the downhole side 118 of the plunger containment member 114 , resulting in a differential force urging the plunger 112 in either direction, depending on the characteristics of the seals. The balanced design results in this resultant force being no greater than 50 pound-feet. In some embodiments the force is as much as 100 pound-feet, or as little as 20 pound-feet. Such an installation in a complex multi-zonal well installation as shown in the present disclosure was previously difficult and required power quantities greater than what was easily available.
[0043] Although a few embodiments of the disclosure have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims. | A flow control valve assembly with a plunger continuously movable between closed, intermediate, and open positions. The plunger has an uphole side and a downhole side opposite the uphole side, and both uphole and downhole sides are exposed to the same hydrostatic pressure in the well, resulting in a flow control device that can be operated with minimal power consumption and still withstanding high pressure loads. | 4 |
BACKGROUND
1. Field of the Invention
The present invention pertains generally to a system for igniting a combustible material by the relative motion of two members, and particularly to the utilization of such a system in a fumigator to burn a combustible mixture containing an active ingredient such as an insecticide or the like, to release the active ingredient.
2. Description of the Related Art
Devices for burning a combustible mixture containing an insecticide to exterminate insects, vermin or the like are well known. Such devices are commonly referred to as "thermal foggers" or "bombs". Typically, the insecticide in such a device is contained in a nonvolatile bag. The bag is placed within a heat-resistant container having a series of vents or lowers allowing the insecticide fumes to escape. The device is conventionally activated by igniting a fuse leading into the insecticide bag with a match or other source of intense heat.
Such devices have significant drawbacks from the viewpoint of safety and ease of use. For example, the device must be manipulated properly to orient the insecticide bag, the fuse, and the louvers. Also, the use of a match or other inflammable device is inconvenient and poses a safety hazard, especially since the insecticide is combustible as well as toxic.
SUMMARY OF THE INVENTION
We have conceived and contribute by the present invention a self-contained system having both an ignitor and combustible material which is activated by relative motion of two members. In the preferred form, the system comprises a fumigator, the combustible material being a slow burning mixture containing an insecticide.
In one aspect of the invention, an ignitor of the percussion type, for example, is mounted within a housing in communication with the combustible material. An actuator which may be a separate device or mounted within the housing is displaced by relative motion and subsequently springs back against the ignitor. The impact actuates the ignitor and thereby ignites the combustible material.
One of the advantages of the devices of the present invention is that, if the device fails to actuate the first time, the activation cycle can be repeated to insure activation of the device.
Although we have conceived the invention specifically for use with insecticides, it will naturally be appreciated that the invention is equally utilizable with any number of combustible materials, for example incense or slow burning mixtures primarily providing warmth, for example, to warm the extremities in the winter.
Certain aspects of our invention have been outlined rather broadly so that the detailed description which follows may be more readily and better understood. There are, of course, additional features of the invention that will be described and which will form the subject of the claims appended hereto. Those skilled in the art will appreciate that the principle upon which this disclosure is based may readily be utilized as a basis for designing other structures for carrying out the several purposes of the invention. It is important, therefore, that the claims be regarded as including such equivalent constructions as do not depart from the spirit and the scope of the invention.
DESCRIPTION OF THE DRAWINGS
Specific embodiments of the invention have been chosen for the purpose of illustration and description, and are shown in the accompanying drawings, which form a part of this specification.
FIG. 1 is a partially exploded perspective view of a first embodiment of the invention.
FIG. 2 is an elevational view of the first embodiment, while FIGS. 3 and 4 are cross-sectional views of the first embodiment during different phases of operation.
FIG. 5 is a transverse view, partially cut away, of a percussion-type ignitor.
FIG. 6 is a cross-sectional view of another percussion-type ignitor.
FIG. 7 is a cross-sectional view of another percussion-type ignitor.
FIG. 8 is a perspective view of a second embodiment of the invention in operation.
FIG. 9 is a cross-sectional view of the second embodiment.
FIG. 10 is cross-sectional view of a third embodiment of the invention.
FIG. 11 is a perspective view of a fourth embodiment of the invention.
FIGS. 12 and 13 are side and top cross-sectional views, respectively, of the fourth embodiment of the invention.
FIGS. 14 through 18 are views of a fifth embodiment of the invention, wherein FIG. 14 is a perspective view, FIG. 15 is a cross-sectional view and FIGS. 16 through 18 are diagrammatic views during different phases of operation.
FIGS. 19 through 22 are views of an actuator of the present invention, wherein FIG. 19 is a view of the actuator in place in the device to be actuated FIGS. 20 and 21 are cross-sectional views of the actuator, and FIG. 22 is an exploded view showing constructional details.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, a fumigator 10 in the form of a single container is shown. As seen in cross-section in FIG. 3, the fumigator is formed of a composite can 11 made of a heat-resistant material having a lower lid 12 which forms a space 13 at the base thereof. The space provides insulation during the operation of the fumigator to protect the user and prevent damage to the surface upon which the fumigator is placed.
Cup 14 is disposed within can 11. The cup contains a powdered insecticide mixture 15 which slowly burns without a flame and releases insecticide fumes once ignited by ignitor 18.
In a preferred form, ignitor 18 consists of percussion cap 20 and delay fuse 19. Depending on the materials chosen for the percussion cap, it may be necessary to include immediately under and in contact with the percussion cap an ignitable material which produces extreme heat. The additional material may be necessary to ignite either the fuse material or the insecticide powder itself. Since the amount of ignitable material is small, it is not shown in most of the drawings. Further it is to be understood that the term "percussion cap" as used in this application, and in the attached claims, may mean either a percussion cap alone that produces enough heat to ignite the fuse or insectiside material or a percussion cap combined with an additional ignitable material that can produce sufficient heat to ignite the fuse or insecticide material. The percussion cap is responsive to an impact force and ignites delay fuse 19. Although its inclusion is optional, use of the delay fuse is desirable since it permits the operator to withdraw from the fumigator before production of noxious fumes commences. If the delay fuse is omitted, percussion cap 20 would be placed directly in contact with mixture 15.
Ignitor 18 is mounted at the center of lid 16. Lid 16 is set at the top of can 11 and has a series of vents 17 formed in the peripheral region of the lid. The vents provide an unobstructed passage permitting insecticide fumes to escape.
Cam structure 21 is press-fit over lid 16 on the upper surface of can 11 and held stationary to prevent cam structure 21 from rotating. The cam structure has a series of ramps 22 at the periphery thereof. These cams act to lift leaf spring 26 as will be described below.
Cap 24 is mounted for rotational movement onto cam structure 21. The cap has a series of Vents 25 formed in its interior acting in conjunction with vents 17 in lid 16 to permit noxious fumes to escape. As shown in FIG. 2, cap 24 has formed therein leaf spring 26. Alternatively, leaf spring 26 may be formed from a resilient metal spring mounted at side 28. The opposite end 29 of leaf spring 26 is free to move upwardly and downwardly. When assembled onto cam structure 21, a central contactor 26a of leaf spring 26 is adjacent to but not contact with ignitor 18.
In operation, cap 24 is rotated in the direction of arrow A (counterclockwise when viewed from the top). As seen in FIG. 4, as cap 24 is rotated, the free end 29 of leaf spring 26 engages with cam 22, which causes the spring to rise. As the leaf spring reaches edge 27 of cam 22, the leaf spring is released, and through spring action snaps back against percussion cap 20. The force of contactor 26a impacting against the percussion cap ignites percussion cap 20 which in turn ignites delay fuse 19. After a predetermined interval which allows the user to leave the area, the delay fuse ignites the insectcide 15.
It should be noted that edge 27 of cam 22 prevents cap 24 from being turned in the incorrect direction. Moreover, frangible lock 24a may be provided in cap 24 to prevent premature operation of the device.
In certain applications, it may be desired to produce cup 14, insecticide 15, lid 16, and ignitor 18 as a single replaceable unit. Once insecticide 15 has been completely burned, this unit may be replaced with a new charge, and operation of the device repeated. Alternatively, cup 14 may be integrally molded with can 11.
FIGS. 5, 6 and 7 illustrate percussion-type ignitors usable to ignite the insecticide. In the embodiment shown in FIG. 5, upper cone 210 narrows to meet bulb 211. Cone 210 is formed of a rigid material, for example brass, while bulb 211 is considerably more flexible, for example very thin malleable brass. Bulb 211 is filled with an impact-sensitive material. We have found that a lead styphanate powder, being readily available, is an excellent choice for this material. Cone 211 may be filled with a material 212 which produces extreme heat yet is easily ignitable. If the material selected to fill bulb 211 does not product sufficient heat to ignite the delay fuse or the insecticide material, approximately 1.5 grains of AlA ignition compound, which will produce extreme heat, is well suited for use as material 212. AlA ignition compound is a product of pyrotechnic Specialties, Inc., Byron, Ga. This material contains 65% Zirconium, 25% red FeO 3 , and 10% SiO 2 . If either the fuse material is ignited at a lower temperature or a percussion-type ignitor is used which produces a higher temperature, then material 212 is optional.
The base of cone 210 is provided with flange 213 for mounting the igniter as desired. Cylindrical housing 214 is fixed to the flange. The housing is hollow and contains a slow burning material 215 which constitutes a delay fuse and which is ignited by the action of material 212. We have found that a mixture of nickel and zirconium is a good choice for material 215, although other equivalent materials well known in the art may be used as delay fuse materials. One prefered material comprises: 14% KClO 4 , 23% Zr/Ni blend (70/30 weight ratio), 3% Zr/Ni blend (30/70 weight ratio) and 60% BaCrO 4 . Of course, material 215 may be press-molded into a shape similar to housing 214, and may obviate the need to provide housing 214 altogether.
In operation, an impact force striking bulb 211 deforms the bulb and causes the filler material to ignite. If lead styphanate is used, the user hears a popping noise which signals the user that the material has been activated. The material in turn ignites material 212 which burns with high intensity and, in turn, ignites material 215. Material 215 burns slowly to provide a delay interval allowing the user to leave the area before material 215 ignites the insecticide.
In the embodiment shown in FIG. 6, numeral 221 refers to a rod, the lower end 221a thereof being coated with a contact sensitive material, for example mercury fulminate. End 221a is encapsulated in sheath 222 to prevent premature activation of the ignitor.
Rod 221 projects upwardly into compartment 224 which contains a slow burning material 226, for example, a mixture of nickel and zirconium.
In operation, when sheath 222 is struck, the coating on rod 221 ignites. This in turn ignites material 226. As previously described, material 226 provides a delay interval allowing the user to leave the area before material 226 ignites the insecticide.
FIG. 7 shows a still further embodiment of a percussion-type ignitor. In this embodiment, a pouch 231 of lead styphanate powder or similar impact ignitable material is placed in open enclosure 232. This enclosure has an opening 233 in the bottom to allow communication between the interior of enclosure 232 and the interior of compartment 235. If necessary opening 233 may be filled with a material 234 which can produce a temperature high enough to ignite fuse material 236 contained within compartment 235. When pouch 231 is struck, it ignites material 234 which in turn ignites fuse material 236 to provide a delay interval allowing the user to leave the area before fuse material 236 ignites the insecticide. Compartment 235 may be made from a heat conductive material to transfer the heat from fuse material 236 to insecticide mixture 15. Alternatively, compartment 235 can have an opening (not shown) in the base opposite opening 233 to allow communication between fuse material 236 and insecticide mixture 15.
FIG. 8 and 9 show a second embodiment of the invention which may utilize either of these ignitors, particularly that shown in FIG. 7. Since the embodiment in FIGS. 8 and 9 is somewhat similar to the first embodiment, elements with similar functions to that of the first embodiment have received the same reference numerals, and detailed discussion of these elements is omitted.
In FIG. 8, cap 30 is mounted directly to can 11 over lid 16. Cap 30 has a series of vents 32 formed in the periphery thereof. An integrally molded spring 31 extends laterally across the center of cap 30. Alternatively, a resilient metallic spring may be utilized and mounted at end 33 to cap 30. The free end of spring 31 has handle 34 formed therein. When assembled, a contactor 31a of spring 31 is adjacent to but not in contact with ignitor 18.
To operate the device, handle 34 is lifted in the direction of arroW B until spring 31 contacts stop 30a, which prevents defomation of spring 31. When released, spring 31 snaps back and contactor 31a is forced against percussion cap 20. The force of this impact ignites the percussion cap and in turn, delay fuse 19. After a predetermined period which allows the user to leave the area, the delay fuse ignites the insecticide.
If desired, a frangible lock (not shown) may be provided to prevent unintentional and premature operation of the device. Also, as in the device in the first embodiment, cup 14, insecticide 15, lid 16 and ignitor 18 may be provided as a single, replaceable unit permitting repeated operations of the device, or cup 14 and can 11 may be integrally molded for single-use applications.
FIG. 10 shows another embodiment of the invention, somewhat similar to the first and second embodiments. In FIG. 10, elements whose function is similar to that of the previously described embodiments have received the same reference numeral, and detailed description thereof has been omitted.
In FIG. 10, ignitor 18 is mounted at the bottom of container 14. Thus, insecticide 15 is ignited from the bottom.
Cup 14 is mounted in the center of housing 35. Leaf spring 36 is molded from one edge of housing 35 and extends through opening 38 in the housing. Alternatively, a resilient metallic spring may be mounted at end 39 to housing 35. The free end of the leaf spring has handle 37 formed therein. When assembled, contactor 36a of the spring is adjacent to but not in contact with ignitor 18.
To operate the device handle 37 is depressed in the direction of arrow C to a position indicated by the broken lines. When released, the leaf spring springs back and contactor 36a strikes ignitor 18. The impact actuates the ignitor which in turn, ignites the delay fuse 19. After a predetermined interval allowing a user to leave the area, the delay fuse ignites insecticide 15.
As before, cup 14, insecticide 15, lid 16 and ignitor 18 may be formed into a single replaceable unit, or cup 14 and housing 35 may be integrally molded for single-use applications. Additionally while a percussion ignitor has been illustrated, other forms of ignitor are equally applicable. Finally, frangible lock 39 may be provided to prevent premature and unintentional operation of the device.
FIGS. 11 through 13 show another embodiment of the invention somewhat similar to the previous embodiments. In these figures, elements with similar functions to that in the first embodiment have received the same reference numerals and the description thereof is omitted.
As shown in FIGS. 11 and 12 ignitor 18 is mounted at the bottom of inner cup 14, as in the third embodiment. Inner cup 14 is disposed within housing 40. Housing 40 has post 41 formed therein to support torsional spring 42. Bend 44 is formed in the free end of leaf spring 42 to engage with pawl 45 of handle 46. Handle 46 is mounted for rotational movement at the circumference of housing 40. The engagement of bend 44 with pawl 45 effectively provides a preload for spring 42.
To operate the device, a user rotates handle 46 in the direction of arrow D as shown in FIG. 13. This motion releases spring 42 which springs in the direction of arrow E and strikes ignitor 18. The impact actuates percussion cap 20 of ignitor 18 which in turn ignites the delay fuse 19. After a predetermined interval which allows a user to leave the area, the delay fuse ignites the insecticide 15. In this embodiment the insecticide is shown as a solid material with a central hole 47 which accepts the ignitor. In this case, the insecticide burns from the central hole toward the edge of the solid.
Although the invention has been described with specific percussion ignitors, other types of ignitor are equally applicable. Also torsional spring 42 may be integrally molded with housing 40. Finally, as in the other embodiments, inner cup 14, insecticide 15, lid 16 and ignitor 18 may be formed into a single, replaceable unit, or cup 14 and housing 40 may be integrally molded for single-use applications.
FIGS. 14 through 18 show another embodiment of the invention somewhat similar to the previous embodiments. In these figures elements performing a function similar to that in the previous embodiments have received the same reference numerals and detailed discussion thereof has been omitted.
In FIGS. 14 and 15 cup 14 and housing 50 have been integrally molded, although as before, cup 14 may be formed separately so as to be removable. Insecticide 51 is contained within pouch 54 at the bottom of cup 14. Lid 52 having a series of vents 53 covers cup 14. Optionally insecticide 51 can be contained loose within cup 14. Ignitor 18 is mounted at one side of lid 52 and extends downwardly through the pouch into contact with the insecticide. A support bracket 56 is formed diametrically opposed to ignitor 18. Support 56 supports leaf spring 55 which is positioned adjacent to but not in contact with ignitor 18.
Cover 57 is mounted for rotational movement on housing 50. The cover has a series of holes 59 cooperating with holes 53 to allow insecticide fumes to escape. On the underside of cover 57, cam arm 60 is formed at a position where it can engage the free end of leaf spring 55. It is prefered that cam arm 60 be mounted eccentrically to leaf spring 55.
Operation of the device will be illustrated in connection with FIGS. 16 through 18. As shown in FIG. 16, cover 57 is rotated in the direction of arrow F. As cam arm 60 contacts leaf spring 55, continued rotation of cover 57 draws leaf spring 55 also in the direction of arrow F, as shown in FIG. 17. FIG. 18 shows the device when the cover has rotated to a point sufficient to release the leaf spring. At this point, the leaf spring springs back in the direction of arrow G and strikes ignitor 18. This impact actuates percussion cap 20 which, in turn, ignites delay fuel 19. After a predetermined interval which allows the user to leave the area, the delay fuse ignites the insecticide.
Although not illustrated, a ratchet mechanism may be incorporated in this embodiment to prevent rotation of cover 57 in the incorrect direction. Additionally, frangible lock 60 may be provided to prevent premature and unintentional operation of the device. Also, while a percussion type ignitor has been described, other types of ignitors are equally applicable and can be used. Also ignitor means with or without a delay fuse or delay mechanism can also be used..
FIGS. 19 through 22 show another embodiment of the invention in which the actuator for the ignitor 18 has been conceived as a separate unit. Of course, this principle is equally applicable to embodiments heretofore described. In FIG. 19, elements having a similar function to that of the previous embodiments have been numbered With the same reference numerals, and detailed description thereof has been omitted.
In FIG. 20, hollow button 62 is disposed in the center of cylindrical housing 61, and plunger 63 is contained within the hollow of the button, plunger 63 is urged downwardly by the action of inner spring 64, while outer spring 65 biases button 62 upwardly. FIG. 21 depicts the concentric arrangement of the housing, the button, and the plunger.
As seen in FIG. 22, button 62 has a pair of cam openings 66 at opposite surfaces thereof. The cam openings support pin 67 which fixes plunger 63 within the button against the action of the inner spring 64. The cam openings are significantly wider than the diameter of pin 67, and each has an incline 66a toward the top of the opening. The inclines interact with pin 67 to twist the plunger in a manner to be described below.
As also seen in FIG. 22, housing 61 has a pair of tracks 68, each of which terminates in narrow portion 68a and ledge 68b. The width of the main portion is approximately the same as the width of the cam openings, and accommodates rotational motion of pin 67 within the cam openings. Additionally, the tracks accommodate lugs 62a formed on button 62 to prevent rotation of the button within the housing.
To operate, the actuator is placed adjacent the object device as shown in FIG. 19. The object device includes an exposed ignitor 18. As button 62 is depressed, lugs 62a and pin 67 descend in tracks 68 until pin 67 contacts ledge 68b which temporarily stops further downward travel of the plunger. Continued depression of the button compresses inner spring 64 to preload the plunger until pin 67 is adjacent inclines 66a. Further depression of the button causes the inclines to interact with the pin to rotate the plunger and the pin. When the pin is rotated into alignment with narrow portions 68a, the inner spring is released, driving the plunger forceably downward to strike ignitor 18 as shown by arrow H. The extent of narrow portion 68a limits the travel of the plunger. As previously described the impact of the plunger against the ignitor 18 ignites percussion cap 20 which, in turn, ignites delay fuse 19. After a predetermined interval, the delay fuse ignites insecticide 15.
Once ignition of the insecticide has been detected, the actuator is withdrawn from the object device. Outer spring 65, which was compressed during operation of the actuator, allows button 62, and consequently the plunger, to return to their starting positions when released.
If desired, the relative orientation of the structure shown in FIG. 19 may be inverted, and the actuator may be molded into a base structure for supporting the combination of cup 14, insecticide 15, lid 16 and ignitor 18. Thus, a reuseable actuator/base assembly may be repeatedly utilized with replaceable insecticide units.
While preferred embodiments of our invention, and indeed the best embodiments known to us, have been described in detail, it should be understood that the invention should not be limited to any specific structure described above. Rather, the scope of the invention should be ascertained by reference to the following claims. | An ignition system for a combustible insecticide forming a fumigation device. The ignition system utilizes relative motion to actuate an ignitor which, in turn, ignites the insecticide. In one aspect, the relative motion is used to load a spring which, when released, strikes the ignitor to actuate it. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for sensing thread movements and generating an electric signal corresponding to a thread movement for indicating at least signal loss, and, thereby cessation of thread movement in a thread brake in textile machines of different types, for example looms, embroidery machines, sewing machines, thread manufacturing machines etc.
Many textile machines are not provided with equipment for thread monitoring because of the difficulties and problems which are intimately linked to the arrangement and positioning of a signal emitter which generates an electric signal corresponding to thread movement. In order that the signal emitter be capable of generating a signal, it is necessary that the thread passes through the emitter at a certain tension and preferably also with a certain angle of deflection. However, it has proved difficult to monitor, in addition to the previously prevailing angle deflections and tensions in the thread, further angle deflections and tension influences, to permit signal generation using per se conventional signal emitters of different types.
SUMMARY OF THE INVENTION
The task forming the basis of the present invention is to realize an apparatus for generating a signal in response to thread movements without giving rise to the above-mentioned drawbacks.
This task is solved according to the present invention in the apparatus disclosed by way of introduction, in that a transducer unit of a piezoelectric type is disposed in direct contact with an element included in the brake, this element being, either by the intermediary of further elements included in the brake, or directly, in contact with the thread which is to be braked and sensed in order that those movements which occur in the thread on braking thereof shall be transmitted to the transducer unit; and that the electric signal corresponding to thread movements is impressed upon a monitoring circuit for providing an indication of whether the signal ceases during a period of time when a signal should be present, and for possibly causing arrest of the operation of the machine on signal loss. The transducer unit is mounted on a circuit board with components for generating an electric signal in response to the above-mentioned thread movements. In that case when the apparatus according to the present invention is intended for a disk brake with disks disposed on a frame-mounted shaft, between which disks the thread runs, and which are urged against one another by means of a spring on the shaft (the spring force being adjustable by means of a nut on the shaft), a flat annular transducer unit is fixed on a circuit board which is placed on the shaft with the transducer unit in contact with one of the brake disks. In that case when the apparatus according to the present invention is intended for a flat brake with a brake spindle and a brake plate between which the thread runs, a rod-shaped transducer unit is disposed on a circuit board and is in contact with the brake spindle. The transducer unit is fixedly retained on one side of the circuit board, while the components included in the circuit proper and disposed on the opposite side of the circuit board. The components included in the circuit are of the surface-mounting type and, hence, are mounted on the surface of the circuit board.
An apparatus according to the present invention will make possible the generation of a signal in response to thread movements in already existing brake devices, whereby all problems inherent in uncontrolled thread tension, and uncontrolled thread movements because of vibrations and the elasticity of the thread will be obviated. In addition, an apparatus according to the present invention makes for extremely accurate signal monitoring, which may be utilized in many different manners by, int. al., monitoring not only interruptions in the signal, but also the appearance of the signal, for example the length of the signal. An apparatus according to the present invention has further proved to be suitable for use in regulating the brake in different desirable manners. For example, the braking force may be reduced (the brake is lifted) on a certain appearance of the signal. Furthermore, the brake may be released entirely in the event of signal loss.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described in greater detail below with reference to the accompanying Drawings. In the accompanying Drawings,
FIG. 1 is a schematic perspective exploded view of a disk brake with an apparatus according to one embodiment of the present invention.
FIG. 2 is a schematic front elevational view of the apparatus of FIG. 1.
FIG. 3 is a side elevational view of the apparatus of FIG. 2.
FIG. 4 is a schematic perspective view of a flat brake with an apparatus according to a further embodiment of the present invention.
FIG. 5 is a schematic end elevational view of the apparatus of FIG. 4.
FIG. 6 is a wiring diagram of an electronics circuit for an apparatus according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an apparatus according to the present invention for mounting in a disk brake of a per se conventional type. A shaft 1 is secured on a frame portion 2 of the textile machine which is to be provided with an apparatus according to the present invention. The shaft 1 is intended for a per se known thread brake which has a brake disk 3 and a brake disk 4, between which the thread is to run. For attaining the desired braking force, the disks 3 and 4 are urged towards one another by means of a spring 5. The brake disks 3, 4 and the spring 5 are retained on the shaft 1 by means of a nut 6 which is provided with a threaded through-hole whose thread mates with a thread on the shaft 1. Between the frame portion 2 and the brake disk 3, there is disposed a signal emitter or signal generator 7 which has a through-hole 8 for the shaft 1. On its side facing the brake disk 3, the signal generator is provided with a piezoelectric element 9 which is in the form of a flat ring and is glued or otherwise secured to one side of a circuit board 10. On the opposite side of the circuit board 10, there are disposed a number of electronics components which together form, for instance, the circuit shown in FIG. 6. The electronics components are enclosed in a casing 11 which is primarily intended for protective purposes. A suitable signal lead or cable 12 extends to the circuit board 10 and the electronics components mounted thereon, the lead or cable being connected to a suitable monitoring circuit for the execution of different desired functions such as arresting the operation of the machine upon signal loss, regulating the brake in response to the appearance of the signal obtained, monitoring the length of the signal, arresting the operation of the machine in response to undesirable changes in the length of the signal or other configurational changes in the signal.
Experiments carried out with a prototype of the apparatus according to the present invention have shown that the arrangement as shown in Drawing FIG. 1 is fully sufficient provided that the per se conventional brake disk 3 is in direct contact with the flat annular piezoelectric element 9. However, there is naturally nothing to prevent the brake disk 3 from being given another configuration and being adapted to attain maximum cooperation with the flat annular piezoelectric element 9.
In the embodiment of the present invention illustrated in FIGS. 4 and 5, the apparatus is arranged at a flat brake of a per se conventional type which is intended to brake a thread 13 in that the thread, under angular deflection, is urged with a certain force against a brake plate 14 which is mounted on a pair of feet 15 and 16 secured to the machine. Naturally, the brake plate 14 may be mounted directly on the machine. It is further conceivable according to the invention that either one or both of the feet 15, 16 are adjustable for regulating the braking force, or, alternatively, that the signal generator or signal emitter 17 for urging the thread 13 against the brake plate 14, is adjustable. On the side of the signal emitter 17 which faces the thread 13, there is disposed a brake spindle 18 which may be of a per se known type. The brake spindle 18 is disposed on one side of a housing 19 which accommodates a circuit board 20 with electronics components on one side and a piezoelectric element 21 on the opposite side. The piezoelectric element 21 may consist of a rectangular rod with its one short edge side or longitudinal edge side in contact with the brake spindle 18. Suitably, the element 21 is glued or otherwise secured to the circuit board 20. The electronics components on the opposite side of the board in relation to the element 21 may form the circuit illustrated in FIG. 6. For conservation of space, the electronics components may suitably be surface-mounted and be of the requisite type for such assembly.
The circuit illustrated in FIG. 6 may be considered as a circuit for converting a signal corresponding to thread movements into a logic signal. The circuit includes an integrated circuit IC1 with a number of inputs and outputs 1-6. In the present case, the integrated circuit IC1 is designated MOG2632B/C5191. The inputs and the outputs may also be considered as connection pins 1-16. In this circuit diagram, the piezoelectric element 9 or 21 is designated X1 and is coupled-in to earth and the pin 15. A capacitor C1 is coupled-in between earth and the pin 16, while another capacitor C5 is coupled-in between the pin 16 and the pin 1 which is further coupled to the pin 2 via a capacitor C6. The capacitors C1 and C5 serve for providing frequency characteristics, while the capacitor C6 is a coupling capacitor. The pin 3 is coupled to earth, while the pin 4 is coupled to the pin 6 by the intermediary of a coupling capacitor C7. The pin 5 is coupled to the pin 8 by the intermediary of a capacitor C8. The pin 8 is further coupled to earth by the intermediary of a capacitor C10. The capacitor C8 determines the desired time period after disappearance of an output signal from the integrated circuit IC1, which entails so-called arrest-time-lag, while the capacitor C10 determines the time-lag on signal appearance. The circuit portion coupled to the pin 7 provides amplification means for the integrated circuit and consists of a capacitor C11 which is coupled-in between the pin 7 and earth, and of a parallel circuit consisting of a diode D1 and a resistor R1, the diode D1 being turned to face away from the pin towards the regulating voltage receiver connection G. Such a connection or circuit is often designated by a gain voltage, for example a d.c. voltage of between 0 and 6.5 V. The pins 9, 10, 11 and 12 are earthed and are not employed in the present case. The pin 13 provides the output of the circuit and follows the input signal on the pin 15 in such a manner that the pin 13 is zero on the presence of a thread signal on the pin 15 and is high or 1 when there is no signal on the pin 15. A capacitor C4 is coupled-in between the pin 13 and the pin 14. The pin 14 serves to receive a driving voltage for the integrated circuit IC1. The pin 13 is further coupled to a connection U by the intermediary of a resistor R2. The voltage input pin 14 is coupled to earth by the intermediary of a capacitor C2 and to a circuit TI (7812). This circuit serves for stabilizing the driving voltage impressed on the input I, which may be a voltage of 15-30 V. The circuit T1 is coupled to the input I by the intermediary of a resistor R3. The circuit T1 is further earthed while the connection between the circuit T1 and the resistor R is earthed by the intermediary of two capacitors C3 and C9. A zero or earth lead J also leads to the circuit on the circuit board 10, 20 via the cable 12. Thus, the cable 12 includes at least four leads which are coupled to the connections I, U, G and J.
Naturally, the integrated circuit IC1 may be arranged in a number of different ways. In the present case, an analog portion and a logic portion are included. The logic portion includes int. al., two comparators, and both the analog and the logic portions may be arranged in a plurality of different manners for attaining the desired output signal on the output U which is connected to a suitable monitoring circuit for executing different functions, as was mentioned in the foregoing.
In addition to signal monitoring, an apparatus according to the present invention may, on application in a sewing machine, be employed for monitoring not only the upper thread which passes the thread brake with the apparatus according to the present invention, but also the underthread. When a seam is produced in a sewing machine, the thread is pulled out in jerks for each stitch. The length of the pulled-out thread corresponds to the stitch length plus the thickness of the fabric. Hence, the signal emitter can emit a pulse for each stitch in the fabric. As a result of the apparatus according to the present invention, the pulses obtained from the emitter or emitters will be extremely distinct and clearly defined. If, for example, the underthread breaks or is run off the bobbin, the upper thread will be entrained up through the cloth. The signal obtained from the emitter, or the pulses obtained from the emitter will be changed and this change may be monitored, for instance to arrest the operation of the machine.
The present invention should not be considered as restricted to that described above and shown on the Drawings, many modifications being conceivable without departing from the spirit and scope of the appended claims. | The disclosure relates to an apparatus for generating an electric signal corresponding to thread movement in a thread brake in textile machines of different types. A transducer element (9, 21) of piezoelectric type is disposed in direct contact with an element (3, 18) included in the brake and, by the intermediary of a further element included in the brake, or directly, is in contact with that thread (13) which is to be braked and sensed, so that movements which occur in the thread (13) on braking thereof shall be transmitted to the transducer element (9, 21) and the electric signal corresponding to thread movements is impressed on a monitoring circuit for indication of whether the signal ceases during a period of time when the signal should exist. It is possible to arrest the operation of the machine upon loss of the signal. | 3 |
BACKGROUND OF THE INVENTION
Benzaldehyde is an important starting material in various chemical syntheses, including those relating to the synthesis of scents and flavors. In these applications the benzaldehyde is often required to have a high degree of purity, but unfortunately crude benzaldehyde, and especially benzaldehyde prepared by the oxidation of toluene with a gas containing molecular oxygen will contain certain impurities that are very difficult to remove. One very significant problem presented by these impurities is that it is particularly difficult to obtain a product from such crude benzaldehyde that will satisfy olfactory specifications. Furthermore, the presence of such impurities also causes a quite rapid discoloration of the benzaldehyde during storage. Such discoloration will occur even at very low concentrations of the impurities, such as a few p.p.m. by weight. It is of interest to note that benzyl hydroperoxide is not normally present in the crude benzaldehyde in any significant quantities.
One suggested solution which appears in Japanese Pat. Publication No. 24,467/74 is to purify the crude benzaldehyde by treating it with an aqueous solution of sodium hydroxide. However, this method of purification does not give satisfactory results, as shown, by the fact that benzaldehyde treated in this manner is still found to discolor quite rapidly.
One method which does give satisfactory results is that disclosed in U.S. Pat. application Ser. No. 952,609 filed Oct. 18, 1978. The process disclosed in that application employs an oxidizing agent and a distillation step to accomplish the purification.
Still another method is disclosed in a sister application to the present application filed on the same date in the United States Patent Office. In that application, the difficulty was in trying to purify an impure benzaldehyde in the presence of water. That problem was overcome by treating the impure benzaldehyde simultaneously with water and a metal less noble than hydrogen followed by a distillation step.
DESCRIPTION OF THE INVENTION
The present invention provides an additional process for purifying the crude benzaldehyde. According to the process of the present invention, pure benzaldehyde is obtained by treating impure benzaldehyde, which contains no significant quantities of benzyl hydroperoxide, with hydrogen in the presence of a suitable hydrogenation catalyst to achieve hydrogenation of the impurities without significant hydrogenation of benzaldehyde. This is followed by a distillation step.
One advantage of the process of the present invention is that the loss of benzaldehyde is relatively small, usually in the range of about 1 to 5% by weight, while still producing benzaldehyde with satisfactory olfactory characteristics even if the crude benzaldehyde was prepared by the oxidation of toluene.
Hydrogenation catalysts which are suitable for use in the process of the present invention are the known hydrogenation catalysts such as the metals of Group VIII of the periodic table of elements, e.g., palladium, nickel, platinum, irdium or rhodium. The catalyst may be placed on a typical carrier such as carbon, aluminum oxide, silicon or titanium oxide. Catalyst which are particularly suitable for use in the process of the present invention are Raney nickel and palladium on carbon.
Preferably, the catalyst employed will be used in quantities varying from about 0.5 to about 200 mgat of active substance per kg of benzaldehyde. In particular, quantities of catalyst in the range of from about 1.0 mgat to about 100 mgat of active substance per kg of benzaldehyde may be advantageously used in the present process.
Normally, the amount of hydrogen taken up in purification of the impure benzaldehyde will range from about 1 to about 100 liters of hydrogen (N.T.P.) per kg of benzaldehyde per hour. Often, the amount of hydrogen taken up will be in the range of about 3 to about 40 liters of hydrogen (N.T.P.) per kg of benzaldehyde per hour.
The contacting of hydrogen with the impure benzaldehyde can be done in a number of ways including, for example, by stirring the benzaldehyde in a hydrogen atmosphere or by bubbling hydrogen through or over the impure benzaldehyde. The duration of the hydrogenation process is usually between about 0.25 and about 4 hours and is preferably in the range of from about 0.5 to 2 hours. The use of larger quantities of catalyst and/or of larger excesses of hydrogen eventually during longer treatment periods is acceptable but offer no significant advantages.
Treatment of the impure benzaldehyde with hydrogen in the presence of a suitable hydrogenation catalyst is preferably, effected at a moderate temperature in order to suppress hydrogenation of the benzaldehyde. A suitable temperature range is between about 270 and about 400 K. Particularly suitable are temperatures between about 285 and about 340 K. The reaction pressure should be such that the liquid phase is maintained. A suitable reaction pressure is, for example, between about 100 and about 1000 Kpa. A particularly suitable reaction pressure is in the range of about 100 and about 500 kPa. The distillation subsequent to the hydrogenation treatment may be carried out at atmospheric or elevated pressure, but is preferably conducted at a reduced pressure, for instance, a pressure in the range of between about 2kPa and about 35 kPa.
U.S. Pat. No. 3,387,036 discloses that an oxidation product of toluene, consisting of a mixture of toluene, benzyl hydroperoxide, benzaldehyde, benzoic acid and some other by-products, may be processed in such a manner that the benzyl hydroperoxide is converted, for instance, by catalytic hydrogenation of the benzylhydroperoxide. However, such a "deperoxidation" is completely different from the method of the present invention.
The invention will be elucidated by means of the following non-restrictive examples and comparative experiment. The color value in degrees Hazen (°H) was determined by ASTM D 1209/62.
EXAMPLES
EXAMPLE I
A sample of benzaldehyde, prepared by oxidation of toluene in the liquid phase by means of a gas containing molecular oxygen with the use of a homogeneous cobalt catalyst, was treated with hydrogen for 2 hours at 295 K. and a pressure of 350 KPa in the presence of 0.5% by wt. Raney nickel, dring which treatment 10 liters hydrogen (N.T.P.) per kg benzaldehyde per hour was taken up. Subsequently, the mixture was distilled in a sieve-tray column with 30 trays at a top pressure of 20 kPa and with a reflux ratio of 1:3. The color value of the main fraction was 10° H. This main fraction was divided into two portions. One portion was heated for 1 hour under a nitrogen atmosphere. The color value rose to 25° H. The other portion was stored for 30 days in a dark bottle under a nitrogen atmosphere. At the end of this period, the color value had risen to 20° H.
EXAMPLE II
A sample of the same liquid crude benzaldehyde as used in Example I was treated with hydrogen for 0.5 hour at 305 K. and a pressure of 300 kPa in the presence of 0.5% by wt. 5% palladium-on-carbon catalyst, during which treatment 30 liters hydrogen (N.T.P.) per kg benzaldehyde per hour was taken up. Subsequently, the mixture was distilled under the same conditions as in Example I. The color value of the main fraction was 10° H. This main fraction was divided into two portions. One portion was heated for 1 hour under a nitrogen atmosphere. The color value rose to 35° H. The other portion was stored for 30 days in a dark bottle under a nitrogen atmosphere. At the end of this period, the color value had risen to 25° H.
Comparative Experiment
A sample of the same liquid benzaldehyde as used in Example I was distilled without previcus treatment, under the same circumstances as in Example I. The color value of the main fraction was 25° H. This main fraction was divided into two portions. One portion was heated under a nitrogen atmosphere. After 0.2 hour, the color value of this portion had already arisen to well over 100° H. The other portion was stored for 30 days in a dark bottle under a nitrogen atmosphere. At the end of this period, the color value had risen to 50° H. | A process for purification of impure benzaldehyde by which purified benzaldehyde is prepared which has improved color stability and improved olfactory characteristics. The process is comprised of the steps of treatment with hydrogen in the presence of a hydrogenation catalyst followed by distillation.
The present invention is a new and novel process for the purification of benzaldehyde and, is in particular, a unique and novel process for the purification of benzaldehyde prepared by the oxidation of toluene with a gas containing molecular oxygen. | 2 |
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to methods for producing purine derivatives that are useful as medicinal agents through N-9 regioselective and N-9 regiospecific glycosylation of 6-(azolyl)purines.
BACKGROUND OF THE INVENTION
[0002] Nucleoside derivatives which can be selectively incorporated into viral DNA or RNA to inhibit the replication of viral DNA or RNA, are highly effective agents for treating viral infectious diseases such as herpesvirus, herpes zoster, AIDS, hepatitis, cytomegalovirus and the like. Similarly, such incorporation of nucleoside derivatives into the DNA or RNA of cancer cells can result in tumor cell death and effective treatment of neoplastic diseases. Especially useful are purine derivatives, which have a substituent in the 9-position. These purine derivatives include a large number of significant known compounds having antiviral activity such as acyclovir, ganciclovir, famciclovir, and the like. Also useful for their anticancer activity are purine derivatives such as cladribine (2-CdA), fludarabine, clofarabine, and the like.
[0003] Achieving regiospecific and stereoselective glycosylation of purine derivatives at the 9-position is difficult. Glycosylation procedures in which a 2-deoxysugar moiety is coupled with an aglycon invariably provide anomeric mixtures as well as positional isomers, which can result in low yields of the desired nucleoside and often requires troublesome purification protocols. A simplified procedure for N-9 glycosylation that is regiospecific would be highly desirable.
[0004] Attempts to enhance N-9 regioselective glycosylation have been made. Gupta et al. (U.S. Patent Application Publication 2004/0039190) describes glycosylation of 6-(acylamido)purines, but notes that the disclosed procedure also produces N-7 glycosylate products. Others have noted that the introduction of larger substituents at C-6 of the purine ring can result in larger ratios of N-9 to N-7 isomer products from simple alkylation reactions (Tetrahedron 1990, 46, 6903). Alarcon et al. (Tetrahedron Lett. 2000, 41, 7211) prepared 2-amino-6-(1,2,4-triazol-4-yl)purine, and reported that alkylation of its sodium salt in DMF with methyl iodide or 1-bromopropane gave the simple N-9 alkyl isomers. Alarcon et al. attributed this selectivity to the introduction of a bulky easily hydrolysable group at C-6 of the purine ring. The use of 6-(acylamido)purines in coupling reactions with sugar derivatives has been performed. Gupta et al. apply potassium salts of 6-(acylamido)purines to prepare 9-glycosyl derivatives of purines that are contaminated with lesser amounts of the 7-glycosyl isomers. Glycosyl coupling with a purine sodium salt in a polar aprotic solvent such as DMF is known to give anomeric mixtures of nucleosides resulting from extensive isomerization of the halo sugar intermediate. Such conditions give stereo- and regioisomeric mixtures as well as extensive sugar decomposition by-products. Gupta et al. use anhydrous THF as a solvent and the strong base potassium hexamethyldisilazide (KHMDS) in toluene to generate potassium salts of 6-(acylamido)purines, followed by addition of the sugar glycosyl chloride derivative. No attempt to enhance the respective solubilities of the 6-(acylamido)purine and sugar derivative was noted.
SUMMARY OF THE INVENTION
[0005] The invention provides methods for preparing regiospecific and highly stereoselective synthesis of 9-0 anomeric purine nucleosides including 2′-deoxy, 3′-deoxy, 2′-deoxy-2′-halo-arabino and 2′,3′-dideoxy-2′-halo-threo purine nucleoside analogs, in high yields without formation of the 7-positional regioisomers.
[0006] In one embodiment, the invention provides a method that includes (a) glycosylating a 6-(azolyl)purine at the N-9 position and (b) displacing the 6-(azolyl) group from the glycosylate from step (a) with a nucleophile to yield an N-9 purine nucleoside.
[0007] In another embodiment, the invention provides a method that includes (a) introducing an (azolyl) group at the 6 position of a purine, (b) glycosylating the purine product from step (a) at the N-9 position and (c) displacing the 6-(azolyl) group from step (a) with a nucleophile to yield an N-9 purine nucleoside.
[0008] The invention also provides a method that includes (a) contacting a 6-(azolyl)-substituted purine of Formula I
[0000]
[0000] with a glycosylating agent in the presence of a base, where each W, W′ and W″ is independently selected from —N—, —CH— and CR 2 , and where R 1 , R 2 , and R 5 are independently selected from hydrogen, C 1-10 allyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, (b) alkylating the appended 6-(azolyl) ring on the 6-substituted purine nucleoside from step (a), (c) contacting the alkylated 6-substituted purine nucleoside from step (b) with ammonia to obtain a nucleoside of Formula III
[0000]
[0000] where R 6 is a glycosyl group.
[0009] In some embodiments, a method of the invention involves a 6-(imidazol-1-yl)purine of Formula XV
[0000]
[0000] where R 4 is selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl.
[0010] In some embodiments, a method of the invention involves a 6-(1,2,4-triazol-4-yl)-substituted purine of Formula XXII.
[0000]
[0011] In some embodiments, a method of preparing 2-chloro-2′-deoxyadenosine (2-CdA, cladribine) comprises (a) contacting a compound having Formula XXVIII
[0000]
[0000] where each W, W′ and W″ is independently selected from —N—, —CH— and CR 2 , where R 2 and R 5 are independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, with a base in a first polar solvent followed by contacting an activated and hydroxyl-protected 2-deoxy-α-D-erythro-pentofuranosyl compound in a second less polar solvent to form a glycosylate product, (b) contacting the glycosylate product from step (a) with ammonia in a third solvent to obtain cladribine.
[0012] In some embodiments, a method for preparing 2-chloro-2′-deoxyadenosine (2-CdA, cladribine) comprises (a) contacting a compound having Formula XXVIII
[0000]
[0000] where each W, W′ and W″ is independently selected from —N—, —CH— and CR 2 , and where R 2 and R 5 are independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, with a base in a first polar solvent followed by contacting an activated and hydroxyl-protected 2-deoxy-α-D-erythro-pentofuranosyl compound in a second less polar solvent to form a glycosylate product, (b) alkylating the appended 6-(azolyl) ring on the 6-substituted purine nucleoside from step (a), (c) contacting the alkylated glycosylate product from step (b) with ammonia in a third solvent to obtain cladribine.
[0013] In some embodiments, a method of preparing cladribine involves a compound having Formula XXIX.
[0000]
[0014] In some embodiments, a method of preparing cladribine involves a compound having Formula XXX.
[0000]
[0015] In some embodiments, a method for preparing a 6-(azolyl)-substituted purine includes (a) introducing an azolyl ring at the 6 position of a purine nucleoside and (b) cleaving the glycosidic bond of the nucleoside from step (a) to yield a 6-(azolyl)purine.
[0016] In some embodiments, a method for preparing a purine of Formula I
[0000]
[0000] where each W, W′ and W″ is independently selected from —N—, —CH— and CR 2 , and where R 1 , R 2 , and R 5 are independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl includes contacting a compound of Formula XXXI:
[0000]
[0000] where R 10 , R 11 , and R 12 are hydroxyl-protecting groups, with a deglycosylation agent.
[0017] In some embodiments of the invention, a method for preparing a purine of Formula XV
[0000]
[0000] where R 1 , R 2 , R 4 , and R 5 are independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, includes a compound of Formula XXXII
[0000]
[0000] where R 10 , R 11 , and R 12 are hydroxyl protecting groups, with a deglycosylation agent.
[0018] In some embodiments of the invention, a method for preparing a purine of Formula XXII
[0000]
[0000] where R 1 , R 2 , and R 5 are independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, includes contacting a compound of Formula XXXIII
[0000]
[0000] where R 10 , R 11 , and R 12 are hydroxyl protecting groups, with a deglycosylation agent.
[0019] In some embodiments of the invention, a compound of Formula I
[0000]
[0000] is described where each W, W′ and W″ is independently selected from —N—, —CH— and CR 2 , and where at least one of W, W′ and W″ is —N—, R 1 , R 2 , and R 5 are independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl and pharmaceutically acceptable salts of these compounds, provided that (1) when R 1 is amino and both W and W′ are N, then R 5 is not hydrogen, (2) when R 1 is hydrogen and W′ and W″ are CH, then R 5 is not hydrogen, (3) when R 1 is hydrogen and R 5 is methyl, then W′ and W″ are not CH, (4) when R 1 and R 5 are hydrogen and W′ is CCH 3 , then W″ is not CH, (5) when R 1 and R 5 are hydrogen and W′ is CH, then W″ is not N, (6) when R 1 and R 5 are hydrogen and W″ is N, then W and W′ are not CH, (7) when R 1 and R 5 are hydrogen and W″ is N, then W is not CCH 3 , and (8) when R 1 and R 5 are hydrogen and W″ is N, then W′ is not CCH 3 .
[0020] In some embodiments of the invention, a compound of Formula XV
[0000]
[0000] is described where R 1 , R 2 , R 4 , and R 5 are independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl and pharmaceutically acceptable salts of these compounds, provided that (1) when R 1 , R 2 and R 4 are hydrogen, then R 5 is not hydrogen, (2) when R 1 , R 2 and R 5 are hydrogen, then 4 is not methyl, and (3) when R 1 , R 4 and R 5 are hydrogen, then R 2 is not methyl.
[0021] In some embodiments of the invention, a compound of Formula XXII
[0000]
[0000] is described where R 1 , R 2 , and R 5 are independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl and pharmaceutically acceptable salts of these compounds, provided that when R 1 is amino, then at least one of R 2 and R 5 is not hydrogen.
[0022] In some embodiments of the invention, a compound of Formula XXXVI
[0000]
[0000] is described where each W, W′ and W″ is independently selected from —N—, —CH— and CR 2 , and where at least one of W, W′ and W″ is —N—, and where R 2 and R 5 are independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl and pharmaceutically acceptable salts of these compounds.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The term “alkyl” as used herein means aliphatic carbon substituents of the alkane, alkene, and alkyne families, straight-chain or branched-chain, with or without other substituents on the carbon atoms of the chain, and also includes cyclic-“alkyl” substituents of the noted categories.
[0024] The term “aglycon” as used herein means the non-sugar component of a glycoside molecule. Hydrolysis of a glycoside can result in the aglycon and the sugar compound.
[0025] The term “glycosyl group” as used herein means the structure obtained by removing the hydroxyl group from the hemiacetal function of a protected or unprotected monosaccharide or a lower oligosaccharide.
[0026] The term “glycoside” as used herein means the attachment of a glycosyl group to a non-acyl group, particularly N-glycosides. The bond between the glycosyl group and the non-acyl group is called a glycosidic or glycosyl bond.
[0027] The term “nucleoside” as used herein refers to a molecule composed of a heterocyclic nitrogenous base, particularly a purine, containing an N-glycosidic linkage with a sugar, particularly a pentose. Nucleosides include both L- and D-nucleoside enantiomers. For brevity, only the structures of the D enantiomers are shown in all drawings; the enantiomeric L structures are the mirror images of the D isomers shown.
[0028] The term “ribofuranosyl nucleoside” as used herein refers to a nucleoside or nucleoside analog containing a 2′-hydroxyl group in an L- or D-β-ribofuranosyl configuration.
[0029] The term “arabinofuranosyl nucleoside” as used herein refers to a nucleoside or nucleoside analog containing a 2′-hydroxyl group in an L- or D-β-arabinofuranosyl configuration.
[0030] The term “nucleophile” as used herein refers to an electron-rich reagent that is an electron pair donor (contains an unshared pair of electrons) and forms a new bond to a carbon atom. Nucleophiles can be anions or neutrally charged. Examples include, but are not limited to, carbanions, oxygen anions, halide anions, sulfur anions, nitrogen anions, nitrogen bases, alcohols, ammonia, water, and thiols.
[0031] The term “leaving group” as used herein refers to a weakly basic chemical entity that is released from carbon, and takes the pair of bonding electrons binding it with the carbon atom. Leaving groups can be chemical functional groups that can be displaced from carbon atoms by nucleophilic substitution. Examples include, but are not limited to, halides including chloride, bromide, and iodide, alkylsulfonates, substituted alkylsulfonates, arylsulfonates, substituted arylsulfonates, heterocyclicsulfonates, and trichloroacetimidate groups. Preferred leaving groups include, but are not limited to, chloride, bromide, iodide, p-nitrobenzenesulfonate (nosylate), p-(2,4-dinitroanilino)benzenesulfonate, benzenesulfonate, methylsulfonate (mesylate), p-methylbenzenesulfonate (tosylate), p-bromobenzenesulfonate (brosylate), trifluoromethylsulfonate (triflate), 2,2,2-trifluoroethanesulfonate, imidazolesulfonate, trichloroacetimidate, trifluoroacetate and other acylates, and 2,4,6-trichlorophenoxide.
[0032] The synonymous terms “hydroxyl protecting group” and “alcohol-protecting group” as used herein refer to substituents attached to the oxygen of an alcohol group commonly employed to block or protect the alcohol functionality while reacting other functional groups on the compound. Examples of such alcohol-protecting groups include the 2-tetrahydropyranyl group, 2-(bisacetoxyethoxy)methyl group, trityl group, trichloroacetyl group, carbonate-type blocking groups such as benzyloxycarbonyl, trialkylsilyl groups, examples of such being trimethylsilyl, tert-butyldimethylsilyl, tert-butyldiphenylsilyl, phenyldimethylsilyl, triiospropylsilyl and thexyldimethylsilyl, ester groups, examples of such being formyl, (C 1 -C 10 ) alkanoyl optionally mono-, di- or tri-substituted with (C 1 -C 6 ) alkyl, (C 1 -C 6 ) alkoxy, halo, aryl, aryloxy or haloaryloxy, the aroyl group including optionally mono-, di- or tri-substituted on the ring carbons with halo, (C 1 -C 6 ) alkyl, (C 1 -C 6 ) alkoxy wherein aryl is phenyl, 2-furyl, carbonates, sulfonates, and ethers such as benzyl, p-methoxybenzyl, methoxymethyl, 2-ethoxyethyl group, etc. The choice of alcohol-protecting group employed is not critical so long as the derivatized alcohol group is stable to the conditions of subsequent reaction(s) on other positions of the compound of the formula and can be removed at the desired point without disrupting the remainder of the molecule. Further examples of groups referred to by the above terms are described by J. W. Barton, “Protective Groups In Organic Chemistry”, J. G. W. McOmie, Ed., Plenum Press, New York, N.Y., 1973, and T. W. Greene and P. G. M. Wuts, “Protective Groups in Organic Synthesis”, Wiley, New York, N.Y., 1999, which are hereby incorporated by reference. The related terms “protected hydroxyl” or “protected alcohol” define a hydroxyl group substituted with a hydroxyl protecting group as discussed above.
[0033] The term “transient protection” as used herein refers to the practice of masking one or more sugar hydroxyl groups of a nucleoside with a protecting group, for example through formation of a trimethylsilyl ether, prior to the introduction of a nucleic acid base protecting group, for example an acyl group, followed by the hydrolysis of the protecting group(s) to reveal (unmask) one or more free hydroxyls.
[0034] The terms “azole” and “azolyl” as used herein refer to nitrogenous aromatic compounds with (1) a “pyrrole-type” trivalent nitrogen atom, (2) either 1, 2 or 3 “pyridine-type” aromatic trivalent nitrogen(s), (3) a five-membered ring, and (4) aromaticity. A number of azole groups satisfy these criteria including substituted and unsubstituted pyrazoles, substituted and unsubstituted imidazoles, substituted and unsubstituted triazoles (including the 1,2,3- and 1,2,4-triazoles) and substituted and unsubstituted tetrazoles.
[0035] The term “acyl group” as used herein refers to a chemical entity comprising the general formula R—C(O)— where R represents any aliphatic, alicyclic, or aromatic group and C(O) represents a carbonyl group.
[0036] The term “acylation” as used herein refers to any process whereby an acid, or an acid derivative such as an acid halide or an acid anhydride is used to convert a hydroxyl group into an ester, or an amine into an amide.
[0037] The terms “halogen” or “halo” as used herein refer to fluorine, chlorine, bromine and iodine, and the term “halide” refers to fluoride, chloride, bromide and iodide.
[0038] The term “nitrogen protecting group,” as used herein, refers to groups known in the art that are readily introduced on to and removed from a nitrogen atom. Examples of nitrogen protecting groups include acetyl (Ac), trifluoroacetyl, Boc, Cbz, benzoyl (Bz), trityl and benzyl (Bn). See also T. W. Greene and P. G. M. Wuts, “Protective Groups in Organic Synthesis”, Wiley, New York, N.Y., 1999 and related publications.
[0039] The term “torsion angle” as used herein refers to the dihedral angle between the plane containing atoms A, B, C and the plane containing B, C, D in a chain of atoms A-B-C-D. Stereochemical arrangements corresponding to torsion angles between 0° and ±90° are called syn (s), those corresponding to torsion angles between ±90° and 180° anti (a). Similarly, arrangements corresponding to torsion angles between 30° and 150° or between −30° and −150° are called clinal (c) and those between 0° and 30° or 150° and 180° are called periplanar (ap). The two types of terms can be combined so as to define four ranges of torsion angle; 0° to 30° synperiplanar (sp); 30° to 90° and −30° to −90° synclinal (sc); −90° to 150° and −90° to −150° anticlinal (ac); +150° to 180° antiperiplanar (ap).
[0040] The compounds described herein and used or made in the methods described herein can contain one or more asymmetric carbon atoms (chirality centers), so that the compounds can exist in different stereoisomeric forms. These compounds can be, for example, racemic mixtures, optically active non-racemic mixtures or diastereomers. In these situations, the single enantiomers, i.e., optically pure forms, can be obtained by asymmetric synthesis or by resolution of racemic mixtures. Resolution of racemic mixtures can be accomplished, for example, by conventional methods such as crystallization in the presence of a resolving agent, chromatography, using, for example a chiral HPLC column, or derivatizing the racemic mixture with a resolving reagent to generate diastereomers, separating the diastereomers via chromatography, and removing the resolving agent to generate the original compound in enantiomerically enriched form. Any of the above procedures can be repeated to increase the enantiomeric purity of a compound.
[0041] In one aspect, a novel method for preparing N-9 purine nucleosides is provided. In one embodiment, a method for preparing an N-9 purine nucleoside, comprises the steps of:
[0042] (a) glycosylating a 6-(azolyl)purine at the N-9 position; and,
[0043] (b) displacing the azolyl group from the glycosylate in step (a) with a nucleophile to yield an N-9 purine nucleoside.
[0044] In some embodiments, the method results in highly regioselective glycosylation, and in some embodiments, the method results in regiospecific glycosylation.
[0045] In some embodiments, the method results in a substantially pure regioisomer, and in some embodiments, the method results in a substantially pure regio- and stereoisomer.
[0046] In some embodiments, the 6-azolyl substituent is selected from the group consisting of unsubstituted imidazole and unsubstituted triazole. In some embodiments, the 6-azolyl substituent is selected from the group consisting of substituted imidazoles and substituted triazoles. In some embodiments, the 6-azolyl substituent is selected from the group consisting of unsubstituted imidazole and substituted imidazoles. In some embodiments, the 6-azolyl substituent is selected from the group consisting of unsubstituted triazole and substituted triazoles. In some embodiments, the 6-azolyl substituent is selected from the group consisting of 1,2,3- and 1,2,4-triazoles and substituted 1,2,3- and 1,2,4-triazoles.
[0047] In some embodiments, the nucleophile in step (b) is a nitrogen-containing nucleophile that is converted into an amino substituent by a subsequent transformation (e.g., azide followed by reduction, benzylamine followed by hydrogenolysis, etc.).
[0048] In one embodiment, the nucleophile in step (b) is ammonia.
[0049] In other embodiments, the nucleophile in step (b) is an oxygen- or sulfur-nucleophile.
[0050] In another aspect, a method for preparing an N-9 purine nucleoside, comprises the steps of:
[0051] (a) introducing an azolyl group at the 6 position of a purine;
[0052] (b) glycosylating the 6-(azolyl)purine product from step (a) at the N-9 position; and,
[0053] (c) displacing the 6-azolyl group with a nucleophile to yield an N-9 purine nucleoside.
[0054] In some embodiments, the method results in highly regioselective glycosylation and in some embodiments, the method results in regiospecific glycosylation.
[0055] In some embodiments, the method results in a substantially pure regioisomer, and in some embodiments, the method results in a substantially pure regio- and stereoisomer.
[0056] In some embodiments, the 6-azolyl substituent is selected from the group consisting of unsubstituted imidazole and unsubstituted triazole. In some embodiments, the 6-azolyl substituent is selected from the group consisting of substituted imidazoles and substituted triazoles. In some embodiments, the 6-azolyl substituent is selected from the group consisting of unsubstituted imidazole and substituted imidazoles. In some embodiments, the 6-azolyl substituent is selected from the group consisting of unsubstituted triazole and substituted triazoles. In some embodiments, the 6-azolyl substituent is selected from the group consisting of 1,2,3- and 1,2,4-triazoles and substituted 1,2,3- and 1,2,4-triazoles.
[0057] In some embodiments, the nucleophile in step (b) is a nitrogen-containing nucleophile that is converted into an amino substituent by a subsequent transformation (e.g., azide followed by reduction, benzylamine followed by hydrogenolysis, etc.).
[0058] In one embodiment, the nucleophile in step (c) is ammonia.
[0059] In other embodiments, the nucleophile in step (b) is an oxygen- or sulfur-nucleophile.
[0060] In some embodiments an azolyl substituent is introduced at the 6 position of the purine by contacting the purine with an azole under nucleophilic displacement conditions. Alternatively, the azole can be formed at the 6 position on the purine by cyclization of a 6-aminopurine with an azine or substituted hydrazine.
[0061] Suitable agents for introducing an azolyl group on to a 6-substituted purine with a leaving group at the 6 position include substituted and unsubstituted imidazoles and substituted and unsubstituted triazoles. Nucleophilic displacement reactions can transpire in polar unreactive solvents such as dimethylformamide or acetonitrile at about 15° to about 100° C.
[0062] Suitable agents for cyclization reactions to introduce an azolyl group on to a 6-aminopurine include, for example, 1,2-bis[(dimethylamino)methylene]hydrazine, 1,2-diformylhydrazine, and other 1,2-diacylhydrazines. Cyclization reactions can transpire in polar unreactive solvents such as dimethylformamide at between about 35° to about 200° C.
[0063] Suitable agents for adding an azolyl group at the 6 position when the purine has a carbonyl group at the 6 position (such as guanine and hypoxanthine bases) include substituted and unsubstituted imidazoles, substituted and unsubstituted triazoles. Such reactions can be performed using triphenyl phosphine (Ph 3 P), iodine (I 2 ), and an aprotic base such as diisopropylethylamine (EtN(i-Pr) 2 ) in an aprotic solvent such as toluene at elevated temperatures from about 35° to about 120°.
[0064] In some embodiments, the glycosylation step is performed by contacting a glycosylating agent in an unreactive solvent with an anionic 6-(azolyl)purine salt, in which the azolyl ring at the 6-position is substantially coplanar with or periplanar with the purine ring.
[0065] Suitable glycosylation agents for glycosylating a 6-(azolyl)purine include, but are not limited to, pentofuranoses, 2-deoxypentofuranoses, 3-deoxypentofuranoses, 2,3-dideoxypentofuranoses, substituted pentofuranoses, substituted 2-deoxypentofuranoses, substituted 3-deoxypentofuranoses and substituted 2,3-dideoxypentofuranoses, and analogs of all of the above classes of carbohydrate derivatives with a sulfur atom in place of the furanosyl ring oxygen atom, all with protected alcohol (OH) groups. Preferably, the activated sugar is selected from a group consisting of activated and O-protected sugars including, but not limited to, 2,3,5-tri-O-acetyl-β-D- or L-ribofuranosyl chloride, 2,3,5-tri-O-benzoyl-β-D- or L-ribofuranosyl bromide, 2-deoxy-3,5-di-O-p-toluoyl-α-D- or L-erythro-pentofuranosyl chloride, 3-deoxy-2,5-di-O-benzoyl-β-D- or L-erythro-pentofuranosyl chloride, 2-deoxy-2-fluoro-3,5-di-O-benzoyl-α-D- or L-arabinofuranosyl bromide, 2,3-dideoxy-2-fluoro-5-O-p-toluoyl-α-D- or L-glycero-pentofuranosyl chloride (also called 2,3-dideoxy-2-fluoro-5-O-p-toluoyl-α-D- or L-arabinofuranosyl chloride), 2-deoxy-2,2-difluoro-3,5-di-O-benzoyl-β-D- or L-erythro-pentofuranosyl triflate and 2,3,5-tri-O-benzyl-α-D- or L-arabinofuranosyl bromide, and their analogs with a sulfur atom in place of the furanosyl ring oxygen atom. In these embodiments, chloride and bromide are leaving groups. Other leaving groups may be substituted for the chloride or bromide leavings groups including, but not limited to, fluoride, iodide, triflate, mesylate, tosylate, trichloroacetimidate, acetate, benzoate, and other acylates, etc. Other hydroxyl protecting groups, which are familiar to those skilled in the art, may be substituted for the indicated acetyl, benzoyl, p-toluoyl, etc. groups.
[0066] Suitable glycosylating agents may also be represented by Formula XXXVIII
[0000]
[0000] in which Lg is a leaving group; R 7 , R 8 and R 9 are each independently selected from hydrogen, protected hydroxyl, halogen including fluoro, chloro, bromo and iodo, alkyl (C 1 -C 6 ), alkoxyl (C 1 -C 6 ), protected nitrogen; and X is oxygen, sulfur or a nitrogen atom with a bonded hydrogen atom, an alkyl (C 1 -C 6 ) or an acyl group.
[0067] Glycosylations can be carried out using glycosylating agents with transiently protected hydroxyl groups.
[0068] Glycosylations can be performed in solutions of mixed solvents with a minimum amount of a more polar (higher dielectric constant) unreactive solvent such as acetonitrile or dimethylformamide to increase the solubility of the anionic 6-(azolyl)purine salt, and a less polar (lower dielectric constant) unreactive solvent such as chloroform, dichloromethane, tetrahydrofuran, or toluene. The protected and activated sugar derivative can be soluble in the less polar solvent and the low polarity (lower dielectric constant) of that solvent strongly retards ionization of the glycosyl-leaving group bond thus minimizing (or eliminating) anomerization of the activated sugar derivative and maximizing formation of the desired nucleoside diastereoisomer.
[0069] Alternatively, glysosylations may be performed in a single solvent. Glycosylations may also be performed in three or more solvents to fine-tune the polarity (average dielectric constant) and preferential solvation characteristics of the combination. The solvents of single and multiple solvent combinations can be anhydrous.
[0070] Glycosylations can transpire with a metal salt of a 6-(azolyl)purine, initially formed in situ by treatment of the 6-(azolyl)purine with a hydride base such as sodium hydride or potassium hydride, a strong base such as sodium hexamethyldisilazide or potassium hexamethyldisilazide, or alkaline metal carbonates such as sodium carbonate and potassium carbonate. Glycosylations carried out in polar solvent systems can solubilize partially or fully the resultant metal salt of a 6-(azolyl)purine.
[0071] Optionally, strong bases with both organic cation and anion components may be used to enhance the solubility of the resulting purine salt in non-polar solvents. When strong bases with organic cation and anion components are used, glycosylations with an anionic 6-(azolyl)purine salt may be carried out in a single solvent.
[0072] Optionally, catalysts such as sodium iodide can be included. The glycosylations can be conducted at temperatures from about 0° to about 50° C. Glycosylations may proceed very slowly at temperatures below 0° C. Glycosylation may be carried out at a temperature that is about room temperature (˜25° C.).
[0073] In some embodiments, the appended 6-(azolyl) ring and the purine ring have a dihedral angle of between about 0° and about 3°. In other embodiments, the appended 6-(azolyl) ring and the purine ring have a dihedral angle of between about 0° and about 5°. In other embodiments, the appended 6-(azolyl) ring and the purine ring have a dihedral angle of between about 0° and about 10°. In still other embodiments, the appended 6-(azolyl) ring and the purine ring have a dihedral angle of between about 0° and about 15°. In other embodiments, the appended 6-(azolyl) ring and the purine ring have a dihedral angle of between about 0° and about 20°. In other embodiments, the appended 6-(azolyl) ring and the purine ring have a dihedral angle of between about 0° and about 25°. In still other embodiments, the appended 6-(azolyl) ring and the purine ring have a dihedral angle of between about 0° and about 30°. In other embodiments, the appended 6-(azolyl) ring and the purine ring have a dihedral angle of between about 0° and about 35°. In still other embodiments, the appended 6-(azolyl) ring and the purine ring have a dihedral angle of between about 0° and about 45°. In some embodiments, the appended 6-(azolyl) ring and the purine ring have a dihedral angle of between about 0° and about 90°.
[0074] When regiospecificity is unnecessary (or undesired), highly regioselective glycosylations may nevertheless be obtained when the dihedral angle between the appended 6-(azolyl) ring and the purine ring is between about 0° and about 90° or between about 0° and about 45°.
[0075] In some embodiments following glycosylation, step (c) may be performed by activation of the appended 6-(azolyl) ring using a reactive alkylating agent followed by nucleophilic displacement of the alkylated 6-(azolyl) group. In some embodiments, concomitant displacement of the 6-(azolyl) group and any O-protection groups can occur by direct ammonolysis at the 6-position.
[0076] Feasible reactive alkylating agents include allylic alkyl halides as well as benzyl halides, α-alkoxyalkyl halides, and the like. The alkylated 6-(azolyl)-substituted nucleoside undergoes ammonolysis by heating a solution of the nucleoside in a solvent containing ammonia at an elevated temperature relative to room temperature and at as much as about 100° C., until the reaction is complete, usually for a period of from about 5 to about 12 hours. In one embodiment, the solvent containing ammonia is methanol, commonly referred to as methanolic ammonia.
[0077] In some embodiments following glycosylation, displacement of the appended 6-(azolyl) ring by a hydroxide nucleophile gives the corresponding 6-oxopurine compound. In some embodiments, concomitant displacement of the 6-(azolyl) group and any O-protection groups occurs by base-promoted hydrolysis at the 6-position.
[0078] In some embodiments following glycosylation, displacement of the appended 6-(azolyl) ring by a nitrogen-, oxygen- or sulfur-based nucleophile gives the corresponding 6-(substituted-amino)-, 6-(disubstituted-amino)-, 6-(substituted-oxy)- or 6-(substituted-sulfanyl)purine compound in which the substituents on nitrogen, oxygen, or sulfur are chosen from groups including, but not limited to, hydrogen, alkyl (C 1 -C 6 ), aryl, heteroaryl and arylalkyl. In some embodiments, concomitant displacement of the 6-(azolyl) group and any O-protection groups occurs.
[0079] The N-9 regiospecific glycosylation methods provide efficient access to 9-β-D- or L-purine nucleosides, including the adenosines, guanosines, inosines and substituted derivatives thereof, and deoxynucleosides including the deoxyadenosines, deoxyguanosines, deoxyinosines and substituted derivatives thereof. Specific nucleosides and deoxynucleosides include, but are not limited to, the 2′-deoxyadenosines, 2′-deoxy-α- or β-2′-halogenated-deoxyadenosines, 3′-deoxyadenosines, 2′,3′-dideoxyadenosines, 2′-deoxy-2′-β-F-adenosines (such as 2-chloro-2′-deoxy-2′-F-araA, clofarabine), 2′,3′-dideoxy-2′-β-F-adenosines, adenine arabinosides such as adenine arabinoside (araA) and 2-F-araA (fludarabine) and the like.
[0080] In one embodiment, a method of regiospecific N-9 glycosylation of purines comprises contacting a 6-(azolyl)-substituted purine of Formula I
[0000]
[0000] with a base in a more polar solvent, and treating the resulting anionic salt with a glycosylating agent of the formula R 6 -Lg wherein each W, W′ and W″ is independently selected from —N—, —CH— and —CR 2 —, and where at least one of W, W′ and W″ is —N—, and where R 1 , R 2 , and R 5 are independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, and where R 6 is a glycosyl group, and Lg is a leaving group. The method may be followed by allylation of the appended 6-(azolyl) ring to obtain an activated 6-(azolium) salt of Formula II
[0000]
[0000] where W, W′, and W″ are independently selected from —N—, —NR 13 —, —CH— and —CR 2 —, and where one of W, W′, and W″ is —NR 13 — and R 13 is alkyl or alkylaryl, and where X is a counter anion. The activated nucleoside may be subjected to ammonolysis to obtain nucleosides of Formula III.
[0000]
[0081] In one such process, 9-β-D- or L-purine 2′-deoxynucleosides, including the deoxyadenosines, are prepared by glycosylating an anionic 6-(azolyl)purine salt derived from a purine having the Formula I
[0000]
[0000] with 2-deoxy-3,5-di-O-p-toluoyl-α-D- or L-erythro-pentofuranosyl chloride. The resulting compound of Formula IV
[0000]
[0000] can be optionally alkylated to activate the appended 6-(azolyl) ring followed by ammonolysis at C-6 and the alcohol protecting groups resulting in formation of the 2′-deoxynucleosides of Formula V.
[0000]
[0082] Where the glycosylating agent is 3-deoxy-2,5-di-O-benzoyl-β-D- or L-erythro-pentofuranosyl chloride, glycosylation results in the compound with Formula VI.
[0000]
[0083] The compound of Formula VI can be optionally alkylated to activate the appended 6-(azolyl) ring followed by ammonolysis at C-6 and the alcohol protecting groups resulting in formation of the 3′-deoxynucleosides of Formula VII.
[0000]
[0084] Where the glycosylating agent is 3,5-di-O-benzoyl-2-deoxy-2-fluoro-α-D- or L-arabinofuranosyl bromide, glycosylation results in formation of the compound with Formula VIII.
[0000]
[0000] The compound of Formula VIII can be optionally alkylated to activate the appended 6-(azolyl) ring followed by ammonolysis at C-6 and the alcohol protecting groups resulting in formation of the 2′-deoxy-2′-fluoro arabino nucleosides of Formula IX.
[0000]
[0085] Where the glycosylating agent is 2,3-dideoxy-2-fluoro-5-O-p-toluoyl-α-D- or L-threo-pentofuranosyl chloride, glycosylation results in formation of the compound with Formula X.
[0000]
[0000] The compound of Formula X can be optionally alkylated to activate the appended 6-(azolyl) ring followed by ammonolysis at C-6 and the alcohol protecting groups resulting in formation of the 2′,3′-dideoxy-2′-fluoro threo nucleosides of Formula XI.
[0000]
[0086] Where the glycosylating agent is 2,3,5-tri-O-benzyl-α-D- or L-arabinofuranosyl bromide, glycosylation results in formation of the compound with Formula XII.
[0000]
[0087] The compound of Formula XII can be optionally alkylated to activate the appended 6-(azolyl) ring followed by ammonolysis at C-6 and removal of the alcohol protecting groups resulting in formation of the nucleoside of Formula XIII.
[0000]
[0088] In some embodiments W″ is CR 2 and has Formula XIV.
[0000]
[0089] The 2-chloro-2′-deoxyadenosine (cladribine) and 2′-deoxyadenosine products from the aforementioned methods are useful cytotoxic agents and deoxynucleosides useful for the production of 2′-deoxyadenosine analogs (Cancer Res. 1982, 42, 3911). 3′-Deoxyadenosine (cordycepin) is a nucleoside antibiotic having antitumor activity (Suhadolnik, R. J. Nucleoside Antibiotics: New York, Wiley-Interscience). 2-Chloro-3′-deoxyadenosine is a direct analog of cladribine (a useful cytotoxic agent). 2′-F-2′-deoxy-araA is an analog of 2-chloro-2′-F-2′-deoxy-araA (clofarabine, a cytotoxic agent against different human cell lines; murine leukemia L 1210 and P388 leukemia in mice; J. Med. Chem. 1992, 35, 397). 2-Chloro-2′-F-2′,3′-dideoxy-araA is an analog of 2′-F-2′,3′-dideoxy-araA (an anti-HIV agent, J. Med. Chem. 1990, 33, 978). 2-Fluoro-araA (fludarabine) is the precursor for the synthesis of fludarabine phosphate, an FDA approved product for the treatment of refractory chronic lymphocytic leukemia.
[0090] In another embodiment, a method of regiospecific N-9 glycosylation of purines comprises contacting an anionic 6-(imidazol-1-yl)purine salt derived from a 6-(imidazol-1-yl)-substituted purine of Formula XV
[0000]
[0000] with a glycosylating agent of the Formula R 6 -Lg. The method may be followed by allylation of the appended 6-(imidazol-1-yl) ring to obtain an activated 6-(3-alkylimidazolium-1-yl)purine nucleoside of Formula XVI
[0000]
[0000] and ammonolysis to obtain nucleosides of Formula III
[0000]
[0000] wherein R 1 , R 2 , R 4 , R 5 are independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, R 6 is a glycosyl group and Lg is a leaving group, R 13 is alkyl or alkylaryl, and X is a counter anion.
[0091] In one such process, 9-β-D- or L-purine 2′-deoxynucleosides, including the deoxyadenosines, are prepared by glycosylating an anionic 6-(azolyl)purine salt derived from a purine having the Formula XV
[0000]
[0000] with 2-deoxy-3,5-di-O-p-toluoyl-α-D- or L-erythro-pentofuranosyl chloride. The resulting compound of Formula XVII
[0000]
[0000] can be optionally alkylated to activate the appended 6-(azolyl) ring followed by ammonolysis at C-6 and the alcohol protecting groups resulting in formation of the 2′-deoxynucleosides of Formula V.
[0000]
[0092] Where the glycosylating agent is 3-deoxy-2,5-di-O-benzoyl-α-D- or L-erythro-pentofuranosyl chloride, glycosylation results in the compound with Formula XVIII.
[0000]
[0000] The compound of Formula XVIII can be optionally alkylated to activate the appended 6-(azolyl) ring followed by ammonolysis at C-6 and the alcohol protecting groups resulting in formation of the 3′-deoxynucleosides of Formula VII.
[0000]
[0093] Where the glycosylating agent is 3,5-di-O-benzoyl-2-deoxy-2-fluoro-α-D- or L-arabinofaranosyl bromide, glycosylation results in formation of the compound with Formula XIX.
[0000]
[0000] The compound of Formula XIX can be optionally alkylated to activate the appended 6-(azolyl) ring followed by ammonolysis at C-6 and the alcohol protecting groups resulting in formation of the 2′-deoxy-2′-fluoro arabino nucleosides of Formula IX.
[0000]
[0094] Where the glycosylating agent is 2,3-dideoxy-2-fluoro-5-O-p-toluoyl-α-D- or L-threo-pentofuranosyl chloride, glycosylation results in formation of the compound with Formula XX.
[0000]
[0000] The compound of Formula XX can be optionally alkylated to activate the appended 6-(azolyl) ring followed by ammonolysis at C-6 and the alcohol protecting groups resulting in formation of the 2′,3′-dideoxy-2′-fluoro threo nucleosides of Formula XI.
[0000]
[0095] Where the glycosylating agent is 2,3,5-tri-O-benzyl-α-D- or L-arabinofuranosyl bromide, glycosylation results in formation of the compound with Formula XXI.
[0000]
[0096] The compound of Formula XXI can be optionally alkylated to activate the appended 6-(azolyl) ring followed by ammonolysis at C-6 and removal of the alcohol protecting groups resulting in formation of the nucleoside of Formula XIII.
[0000]
[0097] In some embodiments, the sodium salts of the 2-chloro-6-(imidazol-1-yl)purines can be coupled with 2-deoxy-3,5-di-O-(p-toluoyl)-α-D-erythro-pentofuranosyl chloride according to Scheme (1). In some embodiments, the glycosylation is carried out in binary solvent mixtures with the more polar (higher dielectric constant) solvent used to solubilize the purine salt and the non-polar solvent (low dielectric constant) used to dissolve the sugar derivative and minimize anomerization of the glycosyl halide. In other embodiments, the glycosylation is carried out in a single solvent. Various embodiments are given in Table 1.
[0000]
TABLE 1
Scheme 1
R 2 , R 4 , R 5
1-β:1-α
% Yield
H, H, H
1.85:1
71
CH 2 CH 2 CH 3 (propyl), H, H
1:0
83-95
CH(CH 3 ) 2 (isopropyl), H, H
98:2-1:0
100
CH 2 CH 2 CH 2 CH 3 (butyl), H, H
96:4-97:3
86
CH 2 CH 2 CH 2 CH 2 CH 3
1:0
100
(pentyl), H, H
CH 2 CHPhCH 3 (2-
1:0
99
phenylpropyl), H, H
H, Ph, Ph
1:0
100
CH 2 Ph (benzyl), H, H
1:0
85
[0098] The β anomers (1-β) from Scheme 1 can be alkylated with benzyl iodide to activate the 6-(imidazol-1-yl) groups followed by ammonolysis at C-6 and the alcohol protecting groups resulting in formation of the cladribine product according to Scheme 2.
[0000]
[0099] Benzylation of sterically hindered 6-(imidazol-1-yl)purines can result in mixtures of benzylated and nonbenzylated products such as when benzylating 2-chloro-9-[2-deoxy-3,5-di-O-p-toluoyl)-β-D-erythro-pentofuranosyl]-6-(4,5-diphenylimidazol-1-yl)purine, 2-chloro-9-[2-deoxy-3,5-di-O-(p-toluoyl)-β-D-erythro-pentofuranosyl]-6-(2-isopropylimidazol-1-yl)purine. Partial decomposition can also result with 6-(2-benzylimidazol-1-yl)-2-chloro-9-[2-deoxy-3,5-di-O-p-toluoyl)-β-D-erythro-pentofuranosyl]purine.
[0100] In another embodiment, a method of regiospecific N-9 glycosylation of purines comprises contacting an anionic 6-(1,2,4-triazol-4-yl)purine salt derived from a 6-(1,2,4-triazol-4-yl)-substituted purine of the Formula XXII
[0000]
[0000] with a glycosylating agent of the Formula R 6 -Lg. The method may be followed by ammonolysis to obtain nucleosides of Formula III
[0000]
[0000] wherein R 1 , R 2 , and R 5 are independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, R 6 is a glycosyl group and Lg, is a leaving group.
[0101] In one such process, 9-β-D- or L-purine 2′-deoxynucleosides, including the deoxyadenosines, are prepared by glycosylating an anionic 6-(1,2,4-triazol-4-yl)purine salt derived from 6-(1,2,4-triazol-4-yl)purine having the Formula XXII
[0000]
[0000] with 2-deoxy-3,5-di-O-p-toluoyl-α-D- or L-erythro-pentofuranosyl chloride. The resulting compound of Formula XXIII
[0000]
[0000] can be subjected to ammonolysis at C-6 and the alcohol protecting groups resulting in formation of the 2′-deoxynucleosides of Formula V.
[0000]
[0102] Where the glycosylating agent is 3-deoxy-2,5-di-O-benzoyl-β-D- or L-erythro-pentofuranosyl chloride, glycosylation results in the compound with Formula XXIV.
[0000]
[0000] The compound of Formula XXIV can be optionally alkylated to activate the appended 6-(azolyl) ring followed by ammonolysis at C-6 and the alcohol protecting groups resulting in formation of the 3′-deoxynucleosides of Formula VII.
[0000]
[0103] Where the glycosylating agent is 3,5-di-O-benzoyl-2-deoxy-2-fluoro-α-D- or L-arabinofuranosyl bromide, glycosylation results in formation of the compound with Formula XXV.
[0000]
[0104] The compound of Formula XXV can be optionally alkylated to activate the appended 6-(azolyl) ring followed by ammonolysis at C-6 and the alcohol protecting groups resulting in formation of the 2′-deoxy-2′-fluoro arabino nucleosides of Formula IX.
[0000]
[0105] Where the glycosylating agent is 2,3-dideoxy-2-fluoro-5-O-p-toluoyl-α-D- or L-threo-pentofuranosyl chloride, glycosylation results in formation of the compound with Formula XXVI.
[0000]
[0000] The compound of Formula XXVI can be subjected to ammonolysis at C-6 and the alcohol protecting groups resulting in formation of the 2′,3′-dideoxy-2′-fluoro threo nucleosides of Formula XI.
[0000]
[0106] Where the glycosylating agent is 2,3,5-tri-O-benzyl-α-D- or L-arabinofuranosyl bromide, glycosylation results in formation of the compound with Formula XXVII.
[0000]
[0000] The compound of Formula XXVII can be subjected to ammonolysis at C-6 and removal of the alcohol protecting groups resulting in formation of the nucleoside of Formula XIII.
[0000]
[0107] In the embodiments with 6-(imidazol-1-yl)- and 6-(1,2,4-triazol-4-yl)-substituted purines, either of R 2 and R 5 may be substituted with C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl to enhance solubility of the 6-(azolyl)-substituted purines.
[0108] In one embodiment, a method for the preparation of cladribine (2-CdA) comprises:
[0109] (a) contacting a compound having Formula XXVIII:
[0000]
[0000] where each W, W′ and W″ is independently selected from —N—, —CH— and CR 2 , each of R 2 and R 5 is independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, with a base in a first polar solvent followed by contacting an activated and hydroxyl-protected 2-deoxy-α-D-erythro-pentofuranosyl compound in a second less polar solvent to form a nucleoside product,
[0110] (b) alkylating the appended 6-(azolyl) ring of the nucleoside product from step (a) for activation for nucleophilic displacement at C-6 of the purine ring,
[0111] (c) contacting the alkylated 6-(azolium) salt from step (b) with ammonia in a third solvent to obtain 2-CdA.
[0112] In another embodiment, a method for the preparation of cladribine (2-CdA) comprises:
[0113] (a) contacting a compound having Formula XXVIII:
[0000]
[0000] where each W, W′ and W″ is independently —N—, —CH— or CR 2 , each of R 2 and R 5 is independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, with a base in a first polar solvent followed by contacting an activated and hydroxyl-protected 2-deoxy-α-D-erythro-pentofuranosyl compound in a second less polar solvent to form a nucleoside product,
[0114] (b) contacting the nucleoside product from step (a) with ammonia in a solvent to obtain 2-CdA.
[0115] In one example, a method for the preparation of 2-CdA (cladribine) comprises:
[0116] (a) contacting a 6-(imidazol-1-yl)purine compound having Formula XXIX:
[0000]
[0000] where each of R 2 , R 4 and R 5 is independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, with a base in a first polar solvent followed by contacting an activated and hydroxyl-protected 2-deoxy-α-D-erythro-pentofuranosyl compound in a second less polar solvent to form a nucleoside product,
[0117] (b) alkylating the appended 6-(imidazol-1-yl) ring of the nucleoside product from step (a) for activation of nucleophilic displacement at C-6 of the purine ring,
[0118] (c) contacting the alkylated 6-(imidazolium) salt from step (b) with ammonia in a third solvent to obtain 2-CdA.
[0119] In another example, a method for the preparation of 2-CdA (cladribine) comprises:
[0120] (a) contacting a 6-(imidazol-1-yl)purine compound having Formula XXIX:
[0000]
[0000] where each of R 2 , R 4 and R 5 is independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, with a base in a first polar solvent followed by contacting an activated and hydroxyl-protected 2-deoxy-α-D-erythro-pentofuranosyl compound in a second less polar solvent to form a nucleoside product,
[0121] (b) contacting the 6-(imidazol-1-yl)purine nucleoside product from step (a) with ammonia in a third solvent to obtain 2-CdA.
[0122] In yet another example, a method for the preparation of 2-CdA (cladribine) comprises:
[0123] (a) contacting a 6-(1,2,4,-triazol-4-yl)purine compound having Formula XXX:
[0000]
[0000] where each of R 2 and R 5 is independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, with a base in a first polar solvent followed by contacting an activated and hydroxyl-protected 2-deoxy-α-D-erythro-pentofuranosyl compound in a second less polar solvent to form a nucleoside product,
[0124] (b) alkylating the appended 6-(1,2,4-triazol-4-yl) ring of the nucleoside product from step (a) for activation of nucleophilic displacement at C-6 of the purine ring,
[0125] (c) contacting the alkylated 6-(triazolium) salt from step (b) with ammonia in a third solvent to obtain 2-CdA.
[0126] In still another example, a method for the preparation of 2-CdA (cladribine) comprises:
[0127] (a) contacting a 6-(1,2,4,-triazol-1-yl)purine compound having Formula XXX:
[0000]
[0000] where each of R 2 and R 5 is independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, with a base in a first polar solvent followed by reaction with an activated and hydroxyl-protected 2-deoxy-α-D-erythro-pentofuranosyl compound in a second less polar solvent to form a nucleoside product,
[0128] (b) contacting the 6-(1,2,4-triazol-4-yl)purine nucleoside product from step (a) with ammonia in a third solvent to obtain 2-CdA.
[0129] In some of the embodiments, the first polar solvent is a single solvent or a binary solvent mixture with an average dielectric constant of between about 5 and about 40. In other embodiments, the first polar solvent has an average dielectric constant of about 20. In some embodiments, the first polar solvent is acetonitrile. In other embodiments, the first polar solvent is a mixture of acetonitrile and dichloromethane. In other embodiments, the first polar solvent is a mixture of three solvents such as acetonitrile, acetone, tetrahydrofuran, toluene, and the like.
[0130] In another aspect of the present invention, a novel method for the preparation of 6-(azolyl)purines is provided. In one embodiment, the invention provides a method for the synthesis of 6-(azolyl)-substituted purines from naturally occurring nucleoside sources, comprising the steps of:
[0131] (a) introducing an azolyl substituent at C-6 of a purine nucleoside; and,
[0132] (b) cleaving the glycosidic bond of the 6-(azolyl)-nucleoside from step (a) to yield a 6-(azolyl)-substituted purine.
[0133] In some embodiments, the 6-(azolyl) group is introduced when the glycosyl portion has transiently protected hydroxyl groups.
[0134] In some embodiments with a 6-(azolyl) substituent, the azolyl ring is introduced at C-6 of the purine by contacting a purine derivative with an azole under nucleophilic displacement conditions. The leaving group can already be in place at C-6 or can be generated in situ in the reaction medium. Alternatively, the azole can be formed by cyclization of a 6-aminopurine with an azine or a 1,2-diacyl-substituted hydrazine.
[0135] Suitable agents for introduction of an azole at C-6 of a purine with a leaving group already at the 6 position include, but are not restricted to, substituted and unsubstituted imidazoles, and substituted and unsubstituted triazoles. Nucleophilic displacement reactions preferably transpire in polar unreactive solvents such as dimethylformamide or acetonitrile at about 15° to about 100° C.
[0136] Suitable agents for cyclization reactions to elaborate an azolyl ring at C-6 of a 6-amino purine include 1,2-bis[(dimethylamino)methylene]hydrazine, 1,2-diformylhydrazine, 1,2-diacylhydrazines and the like. Such cyclization reactions preferably transpire in polar unreactive solvents such as dimethylformamide at about 35° to about 200° C.
[0137] Suitable agents for replacing the oxo group with an azolyl ring when the purine has a carbonyl group at the 6 position (such as guanine and hypothanine) include, but are not limited to, substituted and unsubstituted imidazoles, substituted and unsubstituted triazoles and the like. Such reactions can be carried out using triphenylphosphine (Ph 3 P), iodine (I 2 ) and an aprotic base such as diisopropylethylamine (EtN(i-Pr) 2 , in an aprotic solvent such as toluene at elevated temperatures from about 35° to about 120°.
[0138] Suitable agents for cleaving the glycoside bond (deglycosylating agents) of the nucleosides include organic acids, mixtures of organic acids, acid chlorides, and mixtures of organic acids and organic chlorides. In some embodiments, acetic acid, acetyl chloride, or mixtures of acetic acid and acetyl chloride may be used for cleaving the glycoside bonds. Such reagents may be referred to categorically as “a deglycosylating agent.”
[0139] In one example, a method for preparing 6-(azolyl)-substituted purines comprises deglycosylating a nucleoside of Formula XXXI
[0000]
[0000] wherein each W, W′ and W″ is independently —N—, —CH— or CR 2 and at least one of W, W′ and W″ is —N—, R 1 , R 2 and R 5 are independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, each of R 10 , R 11 and R 12 are hydroxyl protecting groups, with a deglycosylating agent. In some examples, the hydroxyl protecting groups may be acyl, acetal, ketal, allylic or vinylic “alkyl”, substituted silyl (such as tert-butyldimethylsilyl) and others well known to persons skilled in the art.
[0140] In one embodiment, a method of preparing 6-(imidazol-1-yl)-substituted purines comprises deglycosylating a nucleoside of Formula XXXII
[0000]
[0000] wherein R 1 , R 2 , R 4 and R 5 are independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, and each of R 10 , R 11 and R 12 are hydroxyl protecting groups, with a deglycosylating agent. In some examples, the hydroxyl protecting groups may be acyl, acetal, ketal, allylic or vinylic “alkyl”, substituted silyl (such as tert-butyldimethylsilyl) and others well known to persons skilled in the art.
[0141] The 6-(imidazol-1-yl)purines can be prepared from inosine according to procedures shown in Scheme 3. The substituted-imidazoles can be prepared either by alkylation or cyclization
[0000]
[0142] The 2-chloro-6-(imadzol-1-yl)purines can be prepared from guanosine according to procedures shown in Scheme 4. The substituted-imidazoles can be prepared either by alkylation or cyclization.
[0000]
[0143] Examples of 2-chloro-6-(substituted-imidazol-1-yl)purines prepared according to Scheme 4 in Table 2. The overall yield for steps a-c is 74%.
[0000]
TABLE 2
% Yield (combined
R 2 , R 4 , R 5
steps d and e)
CH(CH 3 ) 2 (isopropyl), H, H
54
CH 2 CH 2 CH 3 (propyl), H, H
82
CH 2 CH 2 CH 2 CH 3 (butyl), H, H
57
CH 2 CH 2 CH 2 CH 2 CH 3 (pentyl), H, H
48
CH 2 CHPhCH 3 (2-phenylpropyl), H, H
62
H, Ph, Ph
61
CH 2 Ph(benzyl), H, H
62
[0144] In another embodiment, a method of preparing 6-(1,2,4-triazol-4-yl)-substituted purines comprises deglycosylating a nucleoside of Formula XXXIII
[0000]
[0000] wherein each R group is defined as above, and contacted with a deglycosylating agent.
[0145] In another aspect of the present invention, a novel method for the preparation of 6 substituted purines is provided. In one embodiment, the invention provides a method for the synthesis of 6-substituted purines from purine sources, comprising introduction of an azolyl ring at the 6 position of a purine. The 6-substituted purine may have the Formula I
[0000]
[0000] where W, W′, W″ and the R groups have the definitions previously described.
[0146] In some embodiments with a 6-(azolyl)purine, the azole ring is introduced at C-6 of the purine by contacting the purine with an azole under nucleophilic displacement conditions using conditions analogous to those previously described. Alternatively, the azole can be formed by cyclization of a 6-aminopurine with an azine or substituted hydrazine using conditions analogous to those previously described.
[0147] In some embodiments, 6-(imidazol-1-yl)purines can be prepared from hypoxanthine according to procedures shown in Scheme 5. The 2-substituted imidazoles can be prepared either by alkylation or cyclization.
[0000]
[0148] In another example, 2-chloro-6-(2-alkylimidazol-1-yl)purines can be prepared by contacting 2,6-dichloropurine with 2-substituted imidazoles in DMF at 65° C.
[0149] In yet another example, 2-amino-6-(imidazol-1-yl)purine and 2-acetamido-6-(imidazol-1-yl)purine can be prepared according to procedures described in Scheme 6 below.
[0000]
[0150] The maximum dihedral angle tolerated between the planes of the purine ring and the appended azole ring at C-6 while still resulting in regiospecific glycosylation depends upon the nature of the electrophile (glycosylating agent). The more bulky and more reactive the electrophile, the further from coplanarity the 6-(azolyl) ring and the purine ring can be and still result in formation of regiospecific products. The less bulky and less reactive the electrophile, the closer to coplanarity these rings must be to result in regiospecific products. For example, glycosylation of the sodium salt of 2-chloro-6-(4,5,-diphenylimidazol-1-yl)purine with the bulky and reactive 2-deoxy-3,5-di-O-(p-toluoyl)-α-D-erythro-pentofuranosyl chloride gives the N-9 glycosylated product exclusively in quantitative yield, whereas treatment of the sodium salt of 2-chloro-6-(4,5,-diphenylimidazol-1-yl)purine with the smaller and less reactive ethyl iodide in DMF gives both the N-9 and N-7 alkylated products in a ratio of about 5:1 (N-9:N-7) in quantitative yield.
[0151] In yet another aspect of the invention, novel 6-(azolyl)purine compounds are provided. The 6-(azolyl) groups are useful for directing regiospecific and regioselective N-9 glycosylation reactions to provide therapeutic agents.
[0152] In one example, a compound of Formula I is provided
[0000]
[0000] where each W, W′ and W″ is independently selected from —N—, —CH— and CR 2 , and where at least one of W, W′ and W″ is —N—, and where R 1 , R 2 , and R 5 are independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, and pharmaceutically acceptable salts of these compounds, provided that:
[0153] (1) when R 1 is amino and both W and W′ are N, then R 5 is not hydrogen;
[0154] (2) when R 1 is hydrogen and W′ and W″ are CH, then R 5 is not hydrogen;
[0155] (3) when R 1 is hydrogen and R 5 is methyl, then W′ and W″ are not CH;
[0156] (4) when R 1 and R 5 are hydrogen and W′ is CCH 3 , then W″ is not CH;
[0157] (5) when R 1 and R 5 are hydrogen and W′ is CH, then W″ is not N;
[0158] (6) when R 1 and R 5 are hydrogen and W″ is N, then W and W′ are not CH;
[0159] (7) when R 1 and R 5 are hydrogen and W″ is N, then W is not CCH 3 ;
[0160] (8) when R 1 and R 5 are hydrogen and W″ is N, then W′ is not CCH 3 .
[0161] In another example, a compound of Formula XV is provided
[0000]
[0000] where R 1 , R 2 , R 4 and R 5 are independently selected from hydrogen, C 1-10 allyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, and pharmaceutically acceptable salts of these compounds, provided that:
[0162] (1) when R 1 , R 2 and R 4 are hydrogen, then R 5 is not hydrogen;
[0163] (2) when R 1 , R 2 and R 5 are hydrogen, then R 4 is not methyl;
[0164] (3) when R 1 , R 4 and R 5 are hydrogen, then R 2 is not methyl.
[0165] In still another example, a compound of Formula XXII is provided
[0000]
[0000] where R 1 , R 2 , and R 5 are independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, and pharmaceutically acceptable salts of these compounds; provided that when R 1 is amino, then at least one of R 2 and R 5 is not hydrogen.
[0166] In yet another example, a compound of Formula XXXIV is provided
[0000]
[0000] where R 1 , R 2 , and R 5 are independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, and pharmaceutically acceptable salts of these compounds; provided that when R 1 is hydrogen, then at least one of R 2 and R 5 is not hydrogen.
[0167] In another example, a compound of Formula XXXV is provided
[0000]
[0000] where R 1 , R 2 , R 4 and R 5 are independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, and pharmaceutically acceptable salts of these compounds; provided that:
[0168] (1) when R 1 is hydrogen, then at least one of R 2 , R 4 and R 5 is not hydrogen;
[0169] (2) when R 1 , R 2 and R 5 are hydrogen, then R 4 is not methyl;
[0170] (3) when R 1 , R 4 and R 5 are hydrogen, then R 2 is not methyl.
[0171] In another example, a compound of Formula XXXVI is provided
[0000]
[0000] where each W, W′ and W″ is independently selected from —N—, —CH— or CR 2 and at least one of W, W′ and W″ is —N—, R 2 and R 5 are independently selected from hydrogen, C 1-10 alkyl, C 1-10 alkoxy, C 1-10 alkylthio, halogen, amino, C 1-10 alkylamino, di-C 1-10 alkylamino, C 1-10 acylamino, aryl, and heteroaryl, and pharmaceutically acceptable salts of these compounds.
EXAMPLES
General Method 1
6-(azolyl)purine glycosylation
[0172] A mixture of the 6-(azolyl)purine (1 mmol) and sodium hydride (0.06 g, 60% w/w suspension, 1.5 mmol) in a dried polar solvent (A) was stirred at ambient temperature under N 2 for 2 h. A solution of 2-deoxy-3,5-di-O-(p-toluoyl)-α-D-erythro-pentofuranosyl chloride (1.8 mmol) in a less polar dried solvent (B) was added with a syringe. The mixture was stirred for 22 h, and volatiles were evaporated in vacuo.
General Method 2
6-(azolyl)purine glycosylation
[0173] A mixture of a 6-(2-alkylimidazol-1-yl)-2-chloropurine (1 mmol) and sodium hydride (60% w/w suspension, 1.5 mmol) in dried CH 3 CN (10 mL) was stirred at ambient temperature under N 2 for 8 h. The solution was chilled to 0° C., and a solution of 2-deoxy-3,5-di-O-p-toluoyl)-α-D-erythro-pentofuranosyl chloride (1.8 mmol) in cold, dried CH 2 Cl 2 (10 mL, 0° C.) was added with a syringe. The reaction mixture was then stirred for 22 h, and allowed to gradually warm to ambient temperature. Volatiles were evaporated in vacuo and the residue was chromatographed (25 g silica gel, MeOH/CH 2 Cl 2 , 1:30).
General Method 3
Alkylation of the 6-(azolyl) ring and Ammonolysis
[0174] The 6-(2-allylimidazol-1-yl)-2-chloro-9-[2-deoxy-3,5-di-O-(p-toluoyl)-β-D-erythro-pentofuranosyl]purine (1 mmol) was added to 0.3 M BnI/CH 3 CN (40 mL, 12 mmol), which was prepared in situ from NaI (15 g, 94 mmol) and BnCl (3.5 mL, 3.85 g, 30.4 mmol) in CH 3 CN (100 mL). The mixture was stirred at 60° C. for 1.5 h. Removal of volatiles and chromatography (MeOH/CH 2 Cl 2 , 1:90→1:30) gave the benzylimidazolium iodide salt as yellow foam, which was transferred into a pressure flask and cooled at −4° C. Cold NH 3 /MeOH (26%, 50 mL) was added, and the sealed mixture was stirred at 60° C. for 11 h. Volatiles were evaporated, and the residue was chromatographed [Dowex 1×2 (OH − ) resin, H 2 O/MeOH, 1:0-3:2] to give 2-chloro-2′-deoxyadenosine.
Preparation of 2-propylimidazole
[0175] To a suspension of NH 4 HCO 3 (16.45 g, 208.1 mmol) in H 2 O (10 mL) was added butyraldehyde (9.2 mL, 7.52 g, 104 mmol) and glyoxal/H 2 O (40% w/w, 11.9 mL, 15.09 g, 104.0 mmol). The mixture was stirred at ambient temperature overnight, and volatiles were evaporated. The residue was extracted with THF. The extracts were combined, and volatiles were evaporated to give the crude material (11 g, 96%), which was chromatographed (CH 2 Cl 2 →MeOH/CH 2 Cl 2 , 1:60→1:30) to give 2-propylimidazole (7.45 g, 65%): 1 H NMR (500 MHz, CDCl 3 ) δ 11.50 (s, 1H), 6.96 (s, 2H), 2.72 (t, J=7.4 Hz, 2H), 1.77 (sext, J=7.4 Hz, 2H), 0.98 (t, J=7.4 Hz, 3H); 13 C NMR (125 MHz, CDCl 3 ) δ 149.1, 121.4, 30.7, 22.3, 14.0.
Preparation of 6-(2-propylimidazol-1-yl)purine
[0176] A suspension of 2′,3′,5′-tri-O-acetylinosine (1.58 g, 4.0 mmol), 2-propylimidazole (1.60 g, 14.4 mmol), Ph 3 P (2.58 g, 9.6 mmol), I 2 (2.14 g, 8.32 mmol), and EtN(i-Pr) 2 (3.6 mL, 2.67 g, 20.2 mmol) in dried toluene (40 mL) was stirred at 95° C. for 4 h. Volatiles were evaporated in vacuo, and the residue was extracted with boiling EtOAc. The combined extracts were evaporated to dryness, and the residue was chromatographed (CH 2 Cl 2 /MeOH, 1:40) to give a solid contaminated with Ph 3 PO. This material was dissolved in AcOH (160 mL), and AcCl (2.2 mL, 2.43 g, 31 mmol) was added. The solution was stirred at 65° C. overnight, and volatiles were evaporated in vacuo. The residue was dissolved in CH 2 Cl 2 and extracted with 0.1 N NaOH/H 2 O. The aqueous layer was washed (CH 2 Cl 2 ), and precipitation with CO 2 followed by filtration and thorough washing (H 2 O) gave a solid (0.66 g, 72%). This material was dissolved in MeOH and decolorized with charcoal. Recrystallization (MeOH) gave 6-(2-propylimidazol-1-yl)purine as a colorless solid: mp 242.5-243.5° C.; UV (MeOH) max 278 nm (∈ 13 700), min 235 nm (∈ 5000); 1 H NMR (300 MHz, DMSO-d 6 ) δ 13.90 (br s, 1H), 8.86 (s, 1H), 8.69 (s, 1H), 8.36 (s, 1H), 7.07 (d, J=1.5 Hz, 1H), 3.18 (t, J=7.3 Hz, 2H), 1.72 (sext, J=7.3 Hz, 2H), 0.93 (t, J=7.3 Hz, 3H); 13 C NMR (75 MHz, CDCl 3 ) δ 155.5, 152.0, 149.8, 146.9, 145.8, 128.5, 123.6, 121.4, 32.2, 21.5, 14.5; HRMS m/z 228.1109 (M + [C 11 H 12 N 6 ]=228.1123). Anal. Calcd for C 11 H 12 N 6 : C, 57.88; H, 5.30; N, 36.82. Found: C, 58.09; H, 5.19; N, 37.00.
Preparation of 2-chloro-6-(2-propylimidazol-1-yl purine
[0177] Method 1:
[0178] 2,6-Dichloropurine (0.38 g, 2 mmol) and 2-propylimidazole (1.32 g, 12 mmol) were dissolved in freshly distilled DMF (10 mL), and the mixture was stirred at 65° C. for 20 h. Volatiles were evaporated in vacuo, and the residue was dissolved in 0.1 N NaOH/H 2 O//CH 2 Cl 2 (100 mL/50 mL). The organic phase was extracted with 0.1 N NaOH/H 2 O (3×50 mL). The combined aqueous phase was washed with CH 2 Cl 2 (2×50 mL) and neutralized with CO 2 . The precipitated solid was filtered and washed (H 2 O) to give 2-chloro-6-(2-propylimidazol-1-yl)purine (0.38 g, 72%): mp 224.5-225° C.; UV (MeOH) max 215, 288 nm (∈ 25 800, 16 700), min 332, 241 nm (∈ 2500, 4500); 1 H NMR (500 MHz, DMSO-d 6 ) δ 14.04 (br s, 1H), 8.69 (s, 1H), 8.43 (s, 1H), 7.06 (s, 1H,), 3.12 (t, J=7.5 Hz, 2H), 1.72 (sext, J=7.3 Hz, 2H), 0.95 (t, J=7.3 Hz, 3H); 13 C NMR (125 MHz, DMSO-d 6 ) δ 157.3, 151.7, 150.2, 147.2, 146.6, 128.9, 122.5, 121.1, 32.4, 21.5, 14.5; HRMS m/z 262.0723 (M + [C 11 H 11 ClN 6 ]=262.0734). Anal. Calcd for C 11 H 11 ClN 6 : C, 50.29; H, 4.22; N, 31.99. Found: C, 50.02; H, 4.28; N, 31.64.
[0179] Method 2:
Preparation of 9-(2,3,5-tri-O-acetyl-β-D-ribofuranosyl)-2-chloro-6-(2-propylimidazol-1-yl)purine
[0180] Method A:
[0181] A mixture of 2′,3′,5′-tri-O-acetyl-2-N-tritylguanosine (5.92 g, 9.1 mmol), I 2 (11.55 g, 45.5 mmol), Ph 3 P (11.93 g, 45.5 mmol) and 2-propylimidazole (5.01 g, 45.5 mmol) was stirred in toluene (180 mL) at 95° C. for 15 min. DIPEA (15.9 mL, 11.80 g, 91.3 mmol) was added, and the mixture was stirred at 95° C. overnight. After removal of volatiles in vacuo, the residue was extracted with boiling EtOAc. The combined EtOAc extracts were evaporated to dryness, and the residue was dried under vacuum. The material obtained was stirred in TFA/H 2 O (9:1, 250 mL) at 0° C. for 4 h. Volatiles were evaporated in vacuo, and the residue was chromatographed (CH 2 Cl 2 →MeOH/CH 2 Cl 2 , 1:12). This solid material was treated with charcoal in MeOH. Volatiles were evaporated in vacuo, and the residue was dissolved in CH 2 Cl 2 and washed (NaHCO 3 /H 2 O, brine) and dried (Na 2 SO 4 ) to give 9-(2,3,5-tri-O-acetyl-β-D-ribofuranosyl)-2-amino-6-(2-propylimidazol-1-yl)purine as a colored solid (3.20 g, 81%, contaminated with Ph 3 PO).
[0182] To a stirred solution of 9-(2,3,5-tri-O-acetyl-β-D-ribofuranosyl)-2-amino-6-(2-propylimidazol-1-yl)purine (2.37 g, 4.72 mmol) in CH 2 Cl 2 (120 mL) was added TMSCl (5.3 mL, 4.54 g, 42.5 mmol) dropwise under N 2 , and then BTEANO 2 (7.1 g, 29.8 mmol) in CH 2 Cl 2 (40 mL). Evolution of gas was observed, and when this subsided, additional TMSCl (5.3 mL) was added. The mixture was then stirred at ambient temperature for 3 h. The solution was diluted with CH 2 Cl 2 and washed (NaHCO 3 /H 2 O, 2×200 mL+100 mL), and the aqueous layer was extracted with CH 2 Cl 2 . The combined organic phase was dried (Na 2 SO 4 ), and volatiles were evaporated in vacuo. The residue was chromatographed (MeOH/CH 2 Cl 2 , 1:99-1:90) to give crude product (1.40 g, 57%, contaminated with Ph 3 PO), which was recrystallized (i-PrOH) to give 9-(2,3,5-tri-O-acetyl-β-D-ribofuranosyl)-2-chloro-6-(2-propylimidazol-1-yl)purine: mp 126-127.5° C.; UV (MeOH) max 217, 287 nm (∈ 25 300, 15 000), min 238, 261 nm (∈ 4200, 6200); 1 H NMR (500 MHz, CDCl 3 ) δ 8.57 (d, J=1.8 Hz, 1H), 8.25 (s, 1H), 7.11 (d, J=1.5 Hz, 1H), 6.27 (d, J=5.5 Hz, 1H), 5.83 (t, J=5.5 Hz, 1H), 5.60-5.62 (m, 1H), 4.49-4.51 (m, 1H), 4.43-4.44 (m, 2H), 3.29 (t, J=7.7 Hz, 2H), 2.19 (s, 3H), 2.17 (s, 3H), 2.11 (s, 3H), 1.86 (sext, J=7.6 Hz, 2H), 1.07 (t, J=7.7 Hz, 3H); 13 C NMR (125 MHz, CDCl 3 ) δ 170.5, 169.9, 169.7, 154.6, 153.8, 151.6, 148.4, 142.5, 129.3, 123.0, 120.5, 86.6, 81.0, 73.5, 70.8, 63.2, 33.2, 21.6, 21.1, 20.8, 20.7, 14.2; HRMS m/z 520.1476 (M + [C 22 H 25 ClN 6 O 7 ]=520.1473). Anal. Calcd For C 22 H 25 ClN 6 O 7 : C, 50.73; H, 4.84; N, 16.13. Found: C, 50.58; H, 4.87; N, 16.15.
[0183] Method B:
[0184] A mixture of 9-(2,3,5-tri-O-acetyl-β-D-ribofuranosyl)-2,6-dichloropurine (1.12 g, 2.5 mmol) and 2-propylimidazole (2.20 g, 20 mmol) was dissolved in CH 3 CN (30 mL) and stirred at 65° C. under N 2 for 2 h (reaction complete, TLC). After removal of volatiles, the residue was dissolved in CH 2 Cl 2 (200 mL) and washed (H 2 O, 3×50 mL). The aqueous phase was extracted with CH 2 Cl 2 , and the combined organic phase was dried (Na 2 SO 4 ) and evaporated to dryness. The residue was chromatographed (MeOH/CH 2 Cl 2 , 1:95) to give 9-(2,3,5-tri-O-acetyl-β-D-ribofuranosyl)-2-chloro-6-(2-propylimidazol-1-yl)purine (977 mg, 93%).
[0185] An extended reaction time (20 h) caused minor formation of bis-substituted product: LRMS m/z 594 (M + [C 28 H 34 N 8 O 7 ]=594).
[0186] 9-(2,3,5-Tri-O-acetyl-β-D-ribofuranosyl)-2-chloro-6-(2-propylimidazol-1-yl)purine (4.99 g, 9.6 mmol) was dissolved in HOAc (400 mL). To the solution was added AcCl (4.0 mL, 4.42 g, 56.3 mmol), and the mixture was stirred at 65° C. for 1.5 h in a sealed flask (reaction almost complete, TLC). Volatiles were evaporated in vacuo, and the residue was washed (CH 2 Cl 2 ), and dissolved in 0.1 N NaOH/H 2 O. Precipitation with CO 2 gave 2-chloro-6-(2-propylimidazol-1-yl)purine (2.20 g, 88%). Recrystallization (MeOH) gave the pure material (1.93 g, 77%).
Preparation of 2-chloro-6-(2-isopropylimidazol-1-yl)purine
[0187] 9-(2,3,5-Tri-O-acetyl-β-D-ribofuranosyl)-2-chloro-6-(2-isopropylimidazol-1-yl)purine (2.96 g, 5.7 mmol, contaminated with 2-isopropylimidazole) was dissolved in HOAc (190 mL). To the solution was added AcCl (1.9 mL, 2.10 g, 26.7 mmol), and the mixture was stirred at 65° C. for 20 h in a sealed flask (reaction was complete, TLC). Volatiles were evaporated in vacuo, and the residue was washed (CH 2 Cl 2 ) and dissolved in 0.1 N NaOH/H 2 O (200 mL). Precipitation with CO 2 gave 2-chloro-6-(2-isopropylimidazol-1-yl)purine (0.675 g, 54%). This solid was washed (boiling MeOH/iPrOH) to give the title compound (0.60 g, 48%): mp 268-268.5° C.; UV (MeOH) max 213, 254, 288 nm (∈ 26 100, 4600, 13 100), min 239, 257 nm (∈ 3700, 4600); 1 H NMR (500 MHz, DMSO-d 6 ) δ 14.06 (s, 1H), 8.71 (s, 1H), 8.36 (s, 1H), 7.07 (d, J=1.6 Hz, 1H), 3.93 (br s, 1H), 1.29 (d, J=6.8 Hz, 6H); 13 C NMR (125 MHz, DMSO-d 6 ) δ 156.4, 154.3, 151.0, 146.5, 145.8, 127.9, 122.0, 120.4, 27.7, 21.6; HRMS m/z 285.0626 (MNa + [C 11 H 11 ClN 6 Na]=285.0631). Anal. Calcd for C 11 H 11 ClN 6 : C, 50.29; H, 4.22; N, 31.99. Found: C, 50.12; H, 4.27; N, 32.16.
Preparation of 6-(2-butylimidazol-1-yl)-2-chloropurine
[0188] A solution of 9-(2,3,5-tri-O-acetyl-β-D-ribofuranosyl)-2,6-dichloropurine (2.41 g, 5.4 mmol) and 2-butylimidazole (6.68 g, 54 mmol) in CH 3 CN (60 mL) was stirred at 65° C. under N 2 for 32 h (reaction complete, TLC). Volatiles were evaporated in vacuo, and the residue was chromatographed (MeOH/CH 2 Cl 2 , 1:90) to give crude 9-(2,3,5-tri-O-acetyl-β-D-ribofuranosyl)-6-(2-butylimidazol-1-yl)-2-chloropurine (3.33 g, contaminated with 2-butylimidazole): 1 H NMR (500 MHz, CDCl 3 ) δ 8.56 (s, 1H), 8.24 (s, 1H), 7.10 (s, 1H), 6.26 (d, J=5.8 Hz, 1H), 5.83 (t, J=5.6 Hz, 1H), 5.61 (t, J=5.6 Hz, 1H), 4.43-4.51 (m, 3H), 3.31 (t, J=7.9 Hz, 2H), 2.18 (s, 3H), 2.16 (s, 3H), 2.11 (s, 3H), 1.81 (quint, J=7.7 Hz, 2H), 1.50 (sext, J=7.7 Hz, 2H), 0.98 (t, J=7.3 Hz, 3H); HRMS m/z 535.1702 (MH + [C 23 H 28 ClN 6 O 7 ]=535.1708).
[0189] Crude 9-(2,3,5-tri-O-acetyl-β-D-ribofuranosyl)-6-(2-butylimidazol-1-yl)-2-chloropurine (2.16 g, 4 mmol) was dissolved in acetic acid (167 mL). To the solution was added AcCl (1.67 mL, 1.84 g, 23.5 mmol), and the mixture was stirred at 65° C. for 23 h in a sealed flask (reaction complete, TLC). Volatiles were evaporated in vacuo, and the residue was washed (CH 2 Cl 2 ) and dissolved in 0.1 N NaOH/H 2 O (130 mL). Precipitation with CO 2 gave a solid (0.76 g, 57%) that was recrystallized (MeOH) to give 6-(2-butylimidazol-1-yl)-2-chloropurine (0.58 g, 44%): mp 247-247.5° C.; UV (MeOH) max 214, 254, 288 nm (∈ 25 600, 4700, 13 900), min 239, 257 nm (∈ 3800, 4600); 1 H NMR (500 MHz, DMSO-d 6 ) δ 14.05 (s, 1H), 8.71 (s, 1H), 8.44 (s, 1H), 7.07 (d, J=1.5 Hz, 1H), 3.17 (t, J=7.7 Hz, 2H), 1.70 (quint, J=7.6 Hz, 2H), 1.39 (sext, J=7.6 Hz, 2H), 0.91 (t, J=7.4 Hz, 3H); 13 C NMR (125 MHz, DMSO-d 6 ) δ 156.3, 151.0, 149.5, 146.4, 145.7, 128.1, 121.7, 120.3, 29.5, 29.3, 21.9, 13.6; HRMS m/z 277.0973 (MNa + [C 12 H 14 ClN 6 Na]=277.0968). Anal. Calcd for C 12 H 14 ClN 6 : C, 52.08; H, 4.74; N, 30.37. Found: C, 51.96; H, 4.85; N, 30.52.
Preparation of 2-chloro-6-(2-hexylimidazol-1-yl)purine
[0190] A sample of 2,6-dichloropurine (0.19 g, 1 mmol) and 2-hexylimidazole (0.97 g, 6.36 mmol) were dissolved in freshly distilled DMF (20 mL), and the mixture was stirred at 65° C. for ˜20 h (reaction incomplete, TLC). Volatiles were evaporated in vacuo, and the residue was dissolved in HOAc (5 mL), and volatiles were evaporated. The residue was chromatographed (MeOH/CH 2 Cl 2 , 1:30) to give a solid contaminated with both starting materials. This solid was washed thoroughly with CH 2 Cl 2 , then saturated NaHCO 3 /H 2 O to give 2-chloro-6-(2-hexylimidazol-1-yl)purine (0.17 g, 56%): mp 192-193° C.; UV(MeOH) max 214, 288 nm (∈ 25 900, 41 200), min 240 nm (∈ 4500); 1 H NMR (500 MHz, DMSO-d 6 ) δ 14.03 (br, 1H), 8.70 (s, 1H), 8.42 (s, 1H), 7.06 (s, 1H), 3.16 (t, J=7.7 Hz, 2H), 1.69 (quint, J=7.3 Hz, 2H), 1.39-1.33 (m, 2H), 1.22-1.30 (m, 4H), 0.84 (t, J=7.0 Hz, 3H); 13 C NMR (500 MHz, DMSO-d 6 ) δ 157.3, 151.7, 150.3, 147.2, 146.7, 128.9, 122.6, 121.1, 31.7, 31.4, 30.4, 29.2, 28.2. 22.7; HRMS m/z 304.1185 (M [C 14 H 17 ClN 6 ]=304.1203).
Preparation of 2-chloro-6-[2-(2-phenylpropyl)imidazol-1-yl]purine
[0191] A mixture of 9-(2,3,5-tri-O-acetyl-β-D-ribofuranosyl)-2,6-dichloropurine (0.98 g, 2.19 mmol) and 2-(2-phenylpropyl)imidazole (4.07 g, 21.9 mmol) in CH 3 CN (20 mL) was stirred at 65° C. for 17 h (reaction complete, TLC). Volatiles were evaporated in vacuo, and the residue was chromatographed (MeOH/CH 2 Cl 2 , 1:90) to give a mixture of diastereomers (quantitative, contaminated with 2-(2-phenylpropyl)imidazole). The mixture was dissolved in HOAc (91 mL), and to the solution was added AcCl (0.92 mL, 1.00 g, 12.8 mmol). The mixture was stirred at 65° C. for 25.5 h in a sealed flask (reaction complete, TLC). Volatiles were evaporated in vacuo, and the residue was dissolved in 0.1 N NaOH/H 2 O (300 mL) and CHCl 3 (150 mL). The mixture was stirred for 2 h, and then neutralized with CO 2 . The organic phase was separated, and the aqueous phase was extracted with CH 2 Cl 2 . The combined organic phase was dried (Na 2 SO 4 ) and concentrated to dryness. The residue was washed (H 2 O), suspended in EtOH, and filtered to give 2-chloro-6-[2-(2-phenylpropyl)imidazol-1-yl]purine (0.46 g, 62%) of material. The mother liquor was evaporated to dryness, and the residue was chromatographed (MeOH/CH 2 Cl 2 , 1:30→1:12) to give a solid, which was washed (H 2 O) to give the second crop (0.18 g, 86% total). The combined solids were dissolved in 0.1 N NaOH/H 2 O (300 mL). Precipitation with CO 2 gave 2-chloro-6-[2-(2-phenylpropyl)imidazol-1-yl]purine as an enantiomeric mixture (0.59 g, 80%): mp 258.5-259° C.; UV (MeOH) max 254, 289 nm (∈ 12 000, 4100), min 240, 256 nm (F 3600, 4100); 1 H NMR (500 MHz, DMSO-d 6 ) δ 14.00 (s, 1H), 8.68 (s, 1H), 8.35 (s, 1H), 7.13-7.14 (m, 4H), 7.07 (d, J=1.9 Hz, 1H), 7.00-7.04 (m, 1H), 3.58 (dd, J=14.4, 6.7 Hz, 1H), 3.43 (dd, J=14.2, 7.7 Hz, 1H), 3.30 (sext, J=7.0 Hz, 1H), 1.23 (1.22) (s, 3H); 13 C NMR (125 MHz, DMSO-d 6 ) δ 156.4, 150.9, 147.9, 146.4, 145.8, 145.7, 128.2, 127.9, 126.6, 125.7, 121.7, 120.5, 38.3, 37.7, 21.0; HRMS m/z 361.0935 (MNa + [C 17 H 15 ClN 6 Na]=361.0944). Anal. Calcd for C 17 H 15 ClN 6 : C, 60.27; H, 4.46; N, 24.81. Found: C, 60.12; H, 4.60; N, 24.66.
Preparation of 2-chloro-6-(4,5-diphenylimidazol-1-yl)purine
[0192] A solution of 9-(2,3,5-tri-O-acetyl-β-D-ribofuranosyl)-2,6-dichloropurine (0.45 g, 1.0 mmol) and 4,5-diphenylimidazole (2.21 g, 10 mmol) in DMF (15 mL) was stirred at 65° C. under N 2 for 67 h (reaction almost complete, TLC). Volatiles were evaporated in vacuo, and the residue was chromatographed (MeOH/CH 2 Cl 2 , 1:90) to give 9-(2,3,5-tri-O-acetyl-β-D-ribofuranosyl)-2-chloro-6-(4,5-diphenylimidazol-1-yl)purine (0.53 g, 83%) and a mixture of 4,5-diphenylimidazole (19 mg) and the title compound (52 mg, 91% total). Recrystallization (iPrOH) gave 9-(2,3,5-tri-O-acetyl-β-D-ribofuranosyl)-2-chloro-6-(4,5-diphenylimidazol-1-yl)purine: mp 146-146.5° C.; UV (MeOH) max 279 nm (∈ 18 300), min 267 nm (∈ 16 800); 1 H NMR (500 MHz, CDCl 3 ) δ 9.03 (s, 1H), 8.22 (s, 1H), 7.55-7.57 (m, 2H), 7.35-7.40 (m, 4H), 7.21-7.27 (m, 4H), 6.21 (d, J=5.5 Hz, 1H), 5.80 (“t”, J=5.6 Hz, 1H), 5.58 (“t”, J=5.1 Hz, 1H), 4.41-4.48 (m, 3H), 2.16 (s, 31), 2.15 (s, 3H), 2,09 (s, 3H); 13 C NMR (125 MHz, CDCl 3 ) δ 170.2, 169.5, 169.4, 154.3, 153.5, 147.4, 142.9, 140.5, 139.2, 133.5, 131.1, 131.0, 128.33, 128.28, 128.17, 127.5, 127.2, 124.1, 86.4, 80.7, 73.2, 70.5, 62.9, 20.8, 20.5, 20.4; HRMS m/z 631.1694 (MNa + [C 31 H 28 ClN 6 O 7 Na]=631.1708). Anal. Calcd for C 31 H 28 ClN 6 O 7 : C, 59.00; H, 4.31; N, 13.32. Found: C, 58.89; H, 4.45; N, 13.24.
[0193] 9-(2,3,5-Tri-O-acetyl-β-D-ribofuranosyl)-2-chloro-6-(4,5-diphenylimidazol-1-yl) purine (1.41 g, 1.7 mmol) was dissolved in HOAc (69 mL). To the solution was added AcCl (0.68 mL, 0.75 g, 9.6 mmol), and the mixture was stirred at 65° C. for 60 h in a sealed flask (reaction complete, TLC). Volatiles were evaporated in vacuo, and the residue was washed (CH 2 Cl 2 ) and dissolved in 0.1 N NaOH/H 2 O. Precipitation with CO 2 gave material (0.41 g, 67%) that was recrystallized (MeOH) to give 2-chloro-6-(4,5-diphenylimidazol-1-yl)purine: mp 277.5-278° C.; UV (MeOH) max 277 nm (∈ 16 100), min 264 nm (∈ 14 800); 1 H NMR (500 MHz, DMSO-d 6 ) δ 14.04 (s, 1H), 8.84 (s, 1H), 8.73 (s, 1H), 7.20-7.49 (m, 10H); 13 C NMR (125 MHz, DMSO-d 6 ) δ 157.2, 151.6, 147.4, 146.2, 139.7, 139.5, 134.3, 131.3, 131.1, 129.02, 128.98, 128.92, 128.08, 127.8, 127.6, 124.0; HRMS m/z 395.0792 (MNa + [C 20 H 13 ClN 6 Na]=395.0788). Anal. Calcd for C 20 H 13 ClN 6 : C, 64.43; H, 3.51; N, 22.54. Found: C, 64.29; H, 3.78; N, 22.53.
Preparation of 2-amino-6-(imidazol-1-yl)purine
[0194] Freshly activated guanine (0.45 g, 3 mmol) and (NH 4 ) 2 SO 4 (60 mg) were stirred in HMDS (50 mL) under reflux for 24 h to give a clear solution. Volatiles were evaporated in vacuo, and the residue was dissolved in dried CH 3 CN (50 mL). Trityl chloride (3.5 g, 12.6 mmol) was added, and the solution was stirred under reflux for 48 h. Volatiles were evaporated in vacuo, and the residue was dissolved in CH 2 Cl 2 (10 mL). NH 3 /H 2 O (28-30%, 30 mL) was added, and precipitation was observed immediately. The mixture was stirred at ambient temperature overnight. Volatiles were evaporated in vacuo, and the residue was washed (H 2 O, CH 2 Cl 2 ) to give 2-N,9-bistritylguanine as a solid (1.37 g, 72%), which was further purified by dissolving in MeOH/CH 2 Cl 2 (1:15) and filtering: 1 H NMR (500 MHz, DMSO-d 6 ) δ 10.75 (s, 1H), 7.35 (s, 1H), 7.08-7.19 (m, 19H), 6.87 (d, J=7.4 Hz, 6H), 6.81 (d, J=7.3 Hz, 6H); 13 C NMR (125 MHz, DMSO-d 6 ) δ 157.3, 151.8, 151.0, 145.3, 142.4, 139.6, 129.6, 128.8, 128.5, 128.3, 127.6, 126.9, 120.3, 75.4, 71.1; HRMS m/z 635.2675 (M + [C 43 H 33 N 5 O]=635.2685).
[0195] A mixture of 2-N,9-bistritylguanine (1.90 g, 3 mmol), I 2 (3.88 g, 15 mmol), Ph 3 P (3.99 g, 15 mmol) and imidazole (1.10 g, 15 mmol) was stirred in toluene (150 mL) at 95° C. for 15 min, and DIPEA (2.9 mL, 2.15 g, 16.6 mmol) was added. The mixture was stirred at 95° C. overnight. After removal of volatiles, the residue was boiled with EtOAc (3×) and filtered hot. The combined EtOAc extracts were evaporated to dryness. The residue was dissolved in TFA/H 2 O (9:1, 60 mL), and the solution was stirred at 0° C. for 4 h. Volatiles were evaporated in vacuo, and the residue was dissolved in 0.1 N NaOH/H 2 O//CH 2 Cl 2 (100 mL/100 mL). The organic layer was extracted with 0.1 N NaOH/H 2 O (50 mL×2), and the aqueous phase was combined, washed [CH 2 Cl 2 (2×50 mL)], and neutralized with CO 2 . Volatiles were evaporated in vacuo, and the residue was washed (H 2 O, CH 2 Cl 2 ) to give 2-amino-6-(imidazol-1-yl)purine (0.40 g, 69%): UV (MeOH) max 222, 320 nm (∈ 29 800, 8700), min 207, 280 nm (∈ 16 100, 1500); 1 H NMR (500 MHz, DMSO-d 6 ) δ 12.89 (s, 1H), 8.94 (s, 1H), 8.25 (s, 1H), 8.16 (s, 1H), 7.18 (s, 1H), 6.67 (s, 2H); 13 C NMR (125 MHz, DMSO-d 6 ) δ 160.7, 157.5, 145.4, 141.9, 137.2, 130.5, 117.7, 115.4; HRMS m/z 201.0753 (M + [C 8 H 7 N 7 ]=201.0763).
Preparation of 9-(2,3,5-tri-O-benzoyl-β-D-ribofuranosyl)-6-(imidazol-1-yl)purine
[0196] 6-(Imidazol-1-yl)purine (52 mg, 0.28 mmol) was suspended in a solution of 1-O-acetyl-2,3,5-tri-O-benzoyl-β-D-ribofuranose (160 mg, 0.32 mmol) in dried CH 3 CN (10 mL). Stannic chloride (0.10 mL, 0.22 g, 0.85 mmol) was added, and the mixture very rapidly became a clear solution. The solution was stirred at ambient temperature for 4 h. NaHCO 3 (0.8 g) and H 2 O (0.1 mL) were added sequentially, and the suspension was stirred for 1 h. The clear solution layer was separated, and the residue was extracted with CH 3 CN. The extracts and the solution layer were combined, and volatiles were evaporated in vacuo. The residue was chromatographed (CH 2 Cl 2 /MeOH, 1:90→1:15) to give 9-(2,3,5-tri-O-benzoyl-β-D-ribofuranosyl)-6-(imidazol-1-yl)purine (179 mg, quantitative): 1 H NMR (500 MHz, CDCl 3 ) δ 4.72 (dd, J=4.3, 12.2 Hz, 1H), 4.88 (br s, 1H), 4.95 (dd, J=3.0, 12.3 Hz, 1H), 6.29 (“t”, J=5.2 Hz, 1H), 6.47-6.50 (m, 2H), 7.24 (s, 1H), 7.35-7.60 (m, 9H), 7.93 (d, J=7.6 Hz, 2H), 8.03 (d, J=7.6 Hz, 2H), 8.07 (d, J=7.6 Hz, 2H), 8.28 (s, 1H), 8.35 (s, 1H), 8.65 (s, 1H), 9.13 (s, 1H); 13 C NMR (125 MHz, CDCCl 3 ) δ 165.0, 164.3, 164.1, 152.1, 151.5, 144.9, 142.2, 136.6, 132.9, 132.8, 132.4, 129.7, 128.8, 128.7, 128.2, 127.5, 127.2, 122.0, 116.3, 86.4, 79.9, 72.9, 70.3, 62.3; HRMS m/z 653.1749 (MNa + [C 34 H 26 N 6 O 7 Na]=653.1761).
Preparation of 9-[2-deoxy-3,5-di-O-(p-toluoyl)-β-D-erythro-pentofuranosyl]-6-(2-propylimidazol-1-yl)purine
[0197] The sodium salt of 6-(2-propylimidazol-1-yl)purine (55 mg, 0.24 mmol) in dried CH 3 CN (5 mL) was treated with 2-deoxy-3,5-di-O-(p-toluoyl)-α-D-erythro-pentofuranosyl chloride (0.15 g, 0.39 mmol) in toluene (5 mL) by general method 1. The residue was chromatographed (25 g silica gel, MeOH/CH 2 Cl 2 , 1:12) to give the two diastereomers [quantitative, containing traces of α-anomer (α/β ˜1:34)]. Recrystallization (EtOAc) gave 9-[2-deoxy-3,5-di-O-(p-toluoyl)-β-D-erythro-pentofuranosyl]-6-(2-propylimidazol-1-yl)purine (68.7 mg, 53%): mp 197-197.5° C.; UV(MeOH) max 242, 276 nm (∈ 31200, 12 500), min 223, 263 nm (∈ 16 400, 9700); 1 H NMR (500 MHz, CDCl 3 ) δ 8.80 (s, 1H), 8.41 (s, 1H), 8.28 (s, 1H), 8.00 (d, J=8.3 Hz, 2H), 7.89 (d, J=8.3 Hz, 2H), 7.31 (d, J=8.3 Hz, 2H), 7.21 (d, J=8.3 Hz, 2H), 7.12 (s, 1H) 6.65 (dd, J=6.2, 8.1 Hz, 1H), 5.85-5.87 (m, 1H), 4.68-4.83 (m, 3H), 3.30 (t, J=7.3 Hz, 2H), 3.17-3.23 (m, 1H), 2.91-2.95 (m, 1H), 2.47 (s, 3H), 2.39 (s, 3H), 1.85 (sext, J=7.5 Hz, 2H), 1.03 (t, J=7.3 Hz, 3H); NOE difference: irradiation at H1′ gave enhancement of the H4′ (small), H8 and H2′,2″ signals; 13 C NMR (125 MHz, CDCl 3 ) δ 166.4, 166.2, 153.1, 152.1, 151.0, 148.1, 144.9, 144.6, 142.4, 130.1, 129.8, 129.6, 129.5, 128.8, 126.8, 126.5, 124.6, 120.8, 85.5, 83.6, 75.2, 64.1, 38.3, 32.8, 22.0, 21.9, 21.5, 14.3; HRMS m/z 603.2347 (MNa+[C 32 H 32 N 6 O 5 Na]=603.2332); Anal. Calcd for C 32 H 32 N 6 O 5 : C, 66.20; H, 5.56; N, 14.47. Found: C, 66.59; H, 5.67; N, 14.62.
[0198] The reaction was repeated with 6-(2-propylimidazol-1-yl)purine in DMF (342 mg, 1.5 mmol) by general method 1. Volatiles were evaporated in vacuo, and the residue was chromatographed (EtOAc/hexanes˜1:1→7:3) to give α-(114 mg) and β-nucleoside (54 mg, contaminated with α-nucleoside, 1:7.3), and a mixture (321 mg, 1:1.3; 56% total, cc/1, 1.14:1).
[0199] The α-nucleoside: 1 H NMR (500 MHz, CDCl 3 ) δ 8.79 (s, 1H), 8.47 (s, 1H), 8.44 (s, 1H), 7.97 (d, J=8.2 Hz, 2H), 7.55 (d, J=8.2 Hz, 2H), 7.29 (d, J=8.0 Hz, 2H), 7.14 (s, 1H), 7.12 (d, J=8.0 Hz, 2H), 6.71 (dd, J=1.5, 7.0 Hz, 1H), 5.71-5.73 (m, 1H), 4.94-4.97 (m, 1H), 4.61-4.68 (m, 2H), 3.30 (t, J=7.3 Hz, 2H), 3.07-3.21 (m, 2H), 2.44 (s, 3H), 2.35 (s, 3H), 1.84 (sext, J=7.5 Hz, 2H), 1.01 (t, J=7.3 Hz, 3H).
Preparation of 2-chloro-9-[2-deoxy-3,5-di-O-(p-toluoyl)-β-D-erythro-pentofuranosyl]-6-(4,5-diphenylimidazol-1-yl)purine
[0200] The sodium salt of 2-chloro-6-(4,5-diphenylimidazol-1-yl)purine (94 mg, 0.25 mmol) in dried CH 3 CN (10 mL) was treated with 2-deoxy-3,5-di-O-(p-toluoyl)-α-D-erythro-pentofuranosyl chloride (0.334 g, 0.86 mmol) in CH 2 Cl 2 (10 mL) by general method 2. Sampling of the reaction mixture showed no α-nucleoside by 1 H NMR (500 MHz). Volatiles were evaporated in vacuo, and the residue was chromatographed (25 g silica gel, EtOAc/hexanes, 3:7→1:1) to give the β-anomer (quantitative). Recrystallization (EtOAc/hexanes) gave 2-chloro-9-[2-deoxy-3,5-di-O-(p-toluoyl)-β-D-erythro-pentofuranosyl]-6-(4,5-diphenylimidazol-1-yl)purine: UV (MeOH) max 240, 275 nm (∈ 53 400, 19 300), min 223, 270 nm (∈ 42 000, 19 100); 1 H NMR (500 MHz, CDCl 3 ) δ 8.97 (s, 1H), 8.25 (s, 1H), 7.97 (d, J=7.9 Hz, 2H), 7.86 (d, J=7.9 Hz, 2H), 7.55 (d, J=8.2 Hz, 2H), 7.19-7.40 (m, 13H), 6.56 (t, J=7.0 Hz, 1H), 5.77-5.78 (m, 1H), 4.76-4.79 (m, 1H), 4.65-4.69 (m, 2H), 2.92-2.96 (m, 2H), 2.45 (s, 3H), 2.40 (s, 3H); 13 C NMR (125 MHz, CDCl 3 ) δ 166.06, 165.94, 154.03, 153.17, 147.13, 144.71, 144.45, 142.81, 140.38, 139.24, 133.50, 131.02, 129.85, 129.55, 129.37, 129.34, 128.25, 128.17, 127.47, 127.17, 126.41, 126.18, 124.00, 85.11, 83.52, 74.85, 63.84, 38.57, 21.78, 21.71; HRMS m/z 747.2100 (MNa + [C 41 H 33 ClN 6 O 5 Na]=747.2099).
Preparation of 6-(2-butylimidazol-1-yl)-2-chloro-9-[2-deoxy-3,5-di-O-(p-toluoyl)-β-D-erythro-pentofuranosyl]purine
[0201] The sodium salt of 6-(2-butylimidazol-1-yl)-2-chloropurine (0.139 g, 0.5 mmol) in dried CH 3 CN (10 mL) was treated with 2-deoxy-3,5-di-O-(p-toluoyl)-α-D-erythro-pentofuranosyl chloride (0.334 g, 0.86 mmol) in CH 2 Cl 2 (10 mL) by general method 2. Sampling of the reaction mixture showed traces of α-nucleoside by 1 H NMR (500 MHz) (1:24). Volatiles were evaporated in vacuo, and the residue was chromatographed (25 g silica gel, EtOAc/hexanes, 3:7 EtOAc) to give the β-anomer (274 mg, 86%) with traces of the α-anomer. Recrystallization (EtOAc/hexanes) gave 6-(2-butylimidazol-1-yl)-2-chloro-9-[2-deoxy-3,5-di-O-(p-toluoyl)-β-D-erythro-pentofuranosyl]purine: UV (MeOH) max 223, 241, 287 nm (∈ 29 900, 33 400, 13 200), min 230, 265 nm (∈ 28 100, 7500); 1 H NMR (500 MHz, CDCl 3 ) δ 8.51 (s, 1H), 8.26 (s, 1H), 7.98 (d, J=8.0 Hz, 2H), 7.84 (d, J=8.0 Hz, 2H), 7.30 (d, J=8.0 Hz, 2H), 7.19 (d, J=8.0 Hz, 2H), 7.09 (s, 1H), 6.60 (t, J=6.9 Hz, 1H), 5.80 (br s, 1H), 4.78-4.81 (m, 1H), 4.66-4.70 (m, 2H), 3.31 (t, J=7.8 Hz, 2H), 2.97-3.00 (m, 2H), 2.46 (s, 3H), 2.37 (s, 3H), 1.80 (quint, J=7.4 Hz, 2H), 1.50 (sext, J=7.4 Hz, 2H), 0.97 (t, J=7.5 Hz, 3H); 13 C NMR (125 MHz, CDCl 3 ) δ 166.05, 165.98, 154.13, 153.17, 151.43, 147.92, 144.71, 144.39, 142.18, 129.87, 129.53, 129.35, 129.31, 128.91, 126.38, 126.20, 122.70, 120.33, 85.20, 83.57, 74.94, 63.87, 38.61, 30.70, 30.07, 22.64, 21.79, 21.66, 13.91; HRMS 771/z 629.2270 (MH + [C 33 H 34 ClN 6 O 5 =629.2279]).
[0202] α-Anomer: 1 H NMR (500 MHz, CDCl 3 ) δ 8.59 (s, 1H), 8.41 (s, 1H), 7.97 (d, J=8.3 Hz, 2H), 7.57 (d, J=8.3 Hz, 2H), 7.30 (d, J=8.0 Hz, 2H), 7.13-7.14 (m, 3H), 6.67 (dd, J=1.8, 6.4 Hz, 1H), 5.72-5.73 (m, 1H), 4.96-4.97 (m, 2H), 4.62-4.70 (m, 2H), 3.31 (t, J=7.8 Hz, 2H), 3.06-3.15 (m, 2H), 2.46 (s, 3H), 2.14 (s, 3H), 1.80 (quint, J=7.4 Hz, 2H), 1.50 (sext, J=7.4 Hz, 2H), 0.97 (t, J=7.3 Hz, 3H).
Preparation of 2-chloro-9-[2-deoxy-3,5-di-O-(p-toluoyl)-β-D-erythro-pentofuranosyl]-6-(2-isopropylimidazol-1-yl)purine
[0203] The sodium salt of 2-chloro-6-(2-isopropylimidazol-1-yl)purine (0.132 g, 0.5 mmol) in dried CH 3 CN (10 mL) was treated with 2-deoxy-3,5-di-O-(p-toluoyl)-α-D-erythro-pentofuranosyl chloride (0.334 g, 0.86 mmol) in CH 2 Cl 2 (10 mL) by general method 2 for 1 h (reaction complete, TLC). Sampling of the reaction mixture at the end of the reaction time showed no α-nucleoside by 1 H NMR (500 MHz). The residue was chromatographed (25 g silica gel, EtOAc/hexanes˜1:1) to give 2-chloro-9-[2-deoxy-3,5-di-O-(p-toluoyl)-β-D-erythro-pentofuranosyl]-6-(2-isopropylimidazol-1-yl)purine (quantitative). Recrystallization (EtOAc) gave the compound (0.22 g, 70%): UV (MeOH) max 223, 241, 285 nm (∈ 32 100, 35 400, 14 800), min 230, 265 nm (∈ 30 300, 9200); 1 H NMR (500 MHz, CDCl 3 ) δ 8.42 (d, J=1.0 Hz, 1H), 8.26 (s, 1H), 7.99 (d, J=7.8 Hz, 2H), 7.85 (d, J=8.3 Hz, 2H), 7.30 (d, J=7.8 Hz, 2H), 7.20 (d, J=8.8 Hz, 2H), 7.11 (d, J=1.0 Hz, 1H), 6.60 (t, J=6.8 Hz, 1H), 5.81 (br s, 1H), 4.78-4.83 (m, 1H), 4.67-4.71 (m, 2H), 4.08 (sept, J=6.8 Hz, 1H), 2.97-3.01 (m, 2H), 2.46 (s, 3H), 2.37 (s, 3H), 1.43 (d, J=6.8 Hz, 3H), 1.41 (d, J=6.8 Hz, 3H); 13 C NMR (125 MHz, CDCl 3 ) δ 166.05, 165.99, 156.18, 154.20, 153.21, 148.15, 144.72, 144.40, 142.25, 129.88, 129.55, 129.36, 129.33, 128.82, 126.44, 126.26, 123.00, 120.38, 85.23, 83.59, 74.93, 63.87, 38.63, 28.81, 21.78, 21.61; HRMS 77/z 637.1931 (MNa + [C 32 H 31 ClN 6 O 5 Na=637.1942]).
[0204] This reaction was repeated on a larger scale with the sodium salt of 2-chloro-6-(2-isopropylimidazol-1-yl)purine (902 mg, 3.43 mmol) in dried CH 3 CN (70 mL) treated with 2-deoxy-3,5-di-O-(p-toluoyl)-α-D-erythro-pentofuranosyl chloride (2.62 g, 6.73 mmol) in CH 2 Cl 2 (70 mL) by general method 2 for 5 h. Sampling of the reaction mixture showed traces of α-nucleoside by 1 H NMR (500 MHz) (<1:20). Column chromatography (EtOAc/hexanes, 1:1→7:3) gave the β-anomer (quantitative, with traces of α-nucleoside). Recrystallization (EtOAc) gave the β-anomer 2-chloro-9-[2-deoxy-3,5-di-O-(p-toluoyl)-β-D-erythro-pentofuranosyl]-6-(2-isopropylimidazol-1-yl)purine (1.76 g, 84%).
Preparation of 2-chloro-9-[2-deoxy-3,5-di-O-(p-toluoyl)-β-D-erythro-pentofuranosyl]-6-(2-propylimidazol-1-yl)purine
[0205] The sodium salt of 2-chloro-6-(2-propylimidazol-1-yl)purine (0.13 g, 0.5 mmol) in dried CH 3 CN (10 mL) was treated with 2-deoxy-3,5-di-O-(p-toluoyl)-α-D-erythro-pentofuranosyl chloride (0.30 g, 0.8 mmol) in CH 2 Cl 2 (10 mL) by general method 2. No α-nucleoside was detected by 1 H NMR. Column chromatography was performed twice (25 g silica gel, MeOH/CH 2 Cl 2 , 1:30, and EtOAc/hexanes, 1:1) to give 2-chloro-9-[2-deoxy-3,5-di-O-(p-toluoyl)-β-D-erythro-pentofuranosyl]-6-(2-propylimidazol-1-yl)purine (0.26 g, 83%), which was recrystallized (EtOAc) to give analytically pure material (0.17 g, 55%): mp 192-193° C.; UV (MeOH) max 220, 239, 287 nm (∈ 40 700, 38 300, 16 700), min 231, 265 nm (∈ 35 900, 10 300); 1 H NMR (500 MHz, CDCl 3 ) δ 8.52 (s, 1H), 8.27 (s, 1H), 8.00 (d, J=7.8 Hz, 211), 7.86 (d, J=7.8 Hz, 2H), 7.32 (d, J=7.8 Hz, 2H), 7.28 (d, J=7.8 Hz, 2H), 7.20 (s, 1H), 6.61 (t, J=7.1 Hz, 1H), 5.82-5.83 (m, 1H), 4.84-4.68 (m, 3H), 3.29 (t, J=7.8 Hz, 2H), 2.98-3.01 (m, 2H), 2.47 (s, 3H), 2.38 (s, 3H), 1.86 (sext, J=7.5 Hz, 2H), 1.07 (t, J=7.3 Hz, 3H); NOE difference: H1′ was irradiated, and enhancement of H4′ (small), H8 and H2′,2″ signals was observed; 13 C NMR (125 MHz, CDCl 3 ) δ 166.29, 166.23, 154.38, 153.42, 151.47, 148.18, 144.97, 144.65, 142.40, 130.12, 129.78, 129.61, 129.56, 129.20, 126.63, 126.44, 122.95, 120.57, 85.46, 83.82, 75.19, 64.12, 38.88, 33.12, 22.03, 21.91, 21.60, 14.25; HRMS m/z 637.1940 (MNa + [C 32 H 31 ClN 6 O 5 Na=637.1942]). Anal. Calcd for C 32 H 31 ClN 6 O 5 : C, 62.49; H, 5.08; N, 13.66. Found: C, 62.44; H, 5.18; N, 13.72.
[0206] This reaction was repeated on a larger scale with the sodium salt of 2-chloro-6-(2-propylimidazol-1-yl)purine (1.54 g, 5.87 mmol) in dried CH 3 CN (100 mL) treated with 2-deoxy-3,5-di-O-(p-toluoyl)-α-D-erythro-pentofuranosyl chloride (3.74 g, 9.62 mmol) in CH 2 Cl 2 (100 mL) by general method 2 for 5 h (reaction complete, TLC). Sampling at different reaction times showed no α-nucleoside by 1 H NMR (500 MHz). Volatiles were evaporated, and the residue was dissolved in CH 2 Cl 2 . The solution was washed (H 2 O) and dried (Na 2 SO 4 ), and volatiles were evaporated in vacuo. The residue was chromatographed (EtOAc/hexanes, 1:1→7:3) to give 2-chloro-9-[2-deoxy-3,5-di-O-(p-toluoyl)-β-D-erythro-pentofuranosyl]-6-(2-propylimidazol-1-yl)purine (3.42 g, 95%). Recrystallization from EtOAc gave the β-anomer (2.75 g, 76%).
Preparation of 3-benzyl-1-{2-chloro-9-[2-deoxy-3,5-di-O-(p-toluoyl)-β-D-erythro-pentofuranosyl]purin-6-yl}-2-propylimidazolium iodide
[0207] 2-Chloro-9-[2-deoxy-3,5-di-O-(p-toluoyl)-β-D-erythro-pentofuranosyl]-6-(2-propylimidazol-1-yl)purine (0.615 g, 1 mmol) was treated with a solution of BnI in CH 3 CN (0.3 M, 40 mL, 12 mmol) by method 3 to give 3-benzyl-1-{2-chloro-9-[2-deoxy-3,5-di-O-(p-toluoyl)-β-D-erythro-pentofuranosyl]purin-6-yl}-2-propylimidazolium iodide (0.83 g, crude): 1 H NMR (500 MHz, CDCl 3 ) δ 8.94 (s, 1H), 8.49 (s, 1H), 8.00 (d, J=8.5 Hz, 2H), 7.88 (d, J=8.0 Hz, 2H), 7.81 (s, 1H), 7.46-7.50 (m, 5H), 7.32 (d, J=8.0 Hz, 2H), 7.25 (d, J=8.0 Hz, 2H), 6.67 (t, J=7.3 Hz, 1H), 5.75-5.85 (m, 3H), 4.71-4.82 (m, 3H), 3.67-3.74 (m, 2H), 2.99-3.02 (m, 2H), 2.47 (s, 3H), 2.42 (s, 3H), 1.75-1.81 (m, 2H), 1.17 (t, J=7.5 Hz, 3H); HRMS m/z 705.2606 (M + [C 39 H 38 ClN 6 O 5 =705.2592]).
Preparation of 6-amino-2-chloro-9-(2-deoxy-β-D-erythro-pentofuranosyl)purine (2-chloro-2′-deoxyadenosine) (cladribine)
[0208] Treatment of 3-benzyl-1-{2-chloro-9-[2-deoxy-3,5-di-O-(p-toluoyl)-β-D-erythro-pentofuranosyl]purin-6-yl}-2-propylimidazolium iodide (0.83 g, crude) with NH 3 /MeOH (26%, 50 mL) at 60° C. followed by ion exchange chromatography (Dowex 1×2 [OH − ], H 2 O/MeOH) by method 3 gave cladribine (0.31 g, quantitative). Recrystallization from EtOH gave a white solid (0.153 g, 54%), and the residue from the mother liquor was recrystallized from H 2 O to give a second crop (0.015 g, 59% total): mp>300° C.; UV (MeOH) max 212, 265 nm (∈ 24 000, 14 600), min 229 nm (∈ 2000); 1 H NMR (500 MHz, DMSO-d 6 ) δ 8.36 (s, 1H), 7.83 (br, 2H), 6.26 (t, J=6.7 Hz, 1H), 5.32 (d, J=4.3 Hz, 1H), 4.97 (t, J=5.5 Hz, 1H), 4.38 (s, 1H), 3.85 (s, 1H), 3.57-3.61 (m, 1H), 3.48-3.53 (m, 1H), 2.62-2.67 (m, 1H), 2.25-2.29 (m, 1H); 13 C NMR (125 MHz, DMSO-d 6 ) δ 157.5, 153.6, 150.8, 140.5, 118.8, 88.6, 84.2, 71.4, 62.3, 38.0; HRMS m/z 285.0615 (M + [C 10 H 12 ClN 5 O 3 ]=285.0629). Anal. Calcd for C 10 H 12 ClN 5 O 3 : C, 42.04; H, 4.23; N, 24.51. Found: C, 41.87; H, 4.50; N, 24.39.
Preparation of 6-amino-2-chloro-9-(2-deoxy-1-D-erythro-pentofuranosyl)purine (2-chloro-2′-deoxyadenosine) (cladribine)
[0209] A solution of 2-chloro-9-[2-deoxy-3,5-di-O-(p-toluoyl)-β-D-erythro-pentofuranosyl]-6-(2-pentylimidazol-1-yl)purine (0.35 g, 0.55 mmol) in methanolic ammonia (14%) was stirred at 80° C. for 13 h. Volatiles were evaporated, and the oily residue was extracted with CH 2 Cl 2 (10 mL) to remove lipophilic by-products. The semi-solid residue was dissolved in acetone (with additions of small amounts of MeOH—if necessary), volatiles were evaporated, and the semi-solid was allowed to crystallize (˜1 h). This material was extracted with CH 2 Cl 2 (10 mL) and dried. The resulting 2-chloro-2′-deoxyadenosine (white powder; 113 mg, 70%) was pure by 1 H NMR analysis. Additional amounts of cladribine (˜24 mg, 15%; containing traces of the α-anomer) were recovered from the concentrated extracts by chromatography (EtOAc→EtOAc/MeOH, 10:1) followed by a similar extraction sequence. | A process for providing regiospecific and highly stereoselective synthesis of 9-β anomeric purine nucleoside analogs is described. The introduction of the sugar moiety on to 6-(azolyl)-substituted purine bases is performed so that highly stereoselective formation of the β anomers of only the 9 position regioisomers of the purine nucleoside analogs (either D or L enantiomers) is obtained. This regiospecific and stereoselective introduction of the sugar moiety allows the synthesis of nucleoside analogs, and in particular 2′-deoxy, 3′-deoxy, 2′-deoxy-2′-halo-arabino and 2′,3′-dideoxy-2′-halo-threo purine nucleoside analogs, in high yields without formation of the 7-positional regioisomers. Processes for providing novel 6-(azolyl)purines for the regiospecific and highly stereoselective synthesis of 9-β anomeric purine nucleoside analogs are described. The compounds are drugs or intermediates to drugs. | 2 |
FIELD OF THE INVENTION
The invention relates to image sensors of small dimensions.
The application more especially aimed at here is image capture inside the human body, which requires such sensors. There is in particular a need for dental radiological sensors which are introduced into the mouth of a patient to allow radiological observation of his jaw and his dentition. The ergonomics of use and the comfort of the patient are very important elements to be taken into account in the production of these sensors.
BACKGROUND OF THE INVENTION
The image sensor is an electronic sensor with matrix structure, consisting of an array of rows and columns with a photosensitive dot at the crossover of each row and each column. Electronic circuits are provided on the sides of the matrix to ensure the operation thereof and in particular lateral registers for controlling the row conductors and a register at the bottom of the columns for ensuring the reading of the signals detected by the individual circuits. In the case of a radiological sensor, the array is covered with a scintillator to convert X-rays into light and the luminous image resulting therefrom is detected by the array of photosensitive dots.
The matrix structure of the image sensor is in general made on a semiconductor chip of square or rectangular shape as is done for almost all integrated circuits. However, to improve the ergonomics, a proposal has already been made to make the sensor on a chip with beveled corners. After encapsulation of the chip in a protective package which hugs the shape of the chip and rounds off the corners, the sensor has a shape which is more comfortable for the patient than if the chip were rectangular.
FIG. 1 represents a chip two corners of which are beveled; these are the corners situated “at the top” in the figure, in principle at the front of the sensor in the direction of introduction of the sensor into the mouth of the patient. The signals detected by the matrix are dumped vertically from the matrix to a horizontal reading register situated at the bottom of the matrix, hence here on the rear side in the direction of introduction of the sensor, just where there are no beveled corners. The charges are then dumped horizontally by the horizontal register to an output of this register. This solution is effective in respective of comfort while introducing the sensor into the mouth; it is less so in respect of comfort while removing the sensor from the mouth.
This is why one also seeks to make a sensor having a chip with four beveled corners, that is more ergonomic both in respect of introduction into the mouth and in respect of removal. However, the room required to place a reading register at the bottom of the matrix is then no longer available.
A solution to this problem has been proposed in patent U.S. Pat. No. 5,510,623. It consists in placing a reading register vertically in the middle of the matrix, as is represented in FIG. 2 , rather than horizontally at the bottom of the matrix.
In that case, the charges are dumped horizontally from the two half-matrices, left and right, to the central vertical register, then they are discharged by the vertical register to a central output situated at the bottom of the sensor. The ergonomics of the sensor is optimized by virtue of the four beveled corners, but the image is perturbed in the central zone of the sensor on account of the presence of the vertical register, even if the vertical register is itself photosensitive.
SUMMARY OF THE INVENTION
The invention proposes a solution for deriving maximum benefit from the ergonomic advantages of a chip with four beveled corners without perturbing picture capture at the center of the matrix.
For this purpose, the invention proposes an image sensor comprising a matrix of rows and columns of photosensitive dots, made on a chip of general square or rectangular shape with beveled corners, characterized in that it comprises a reading register placed at the bottom of the matrix, this register being bent so as to run alongside the beveled corners of the chip and therefore comprising a horizontal part and two oblique parts, and the sensor furthermore comprising means for directing photosensitive charges of columns terminating opposite the beveled corners to register stages situated in the oblique parts alongside the beveled corners.
The means for directing the charges to the oblique part of the register include in particular insulation zones between columns of the matrix, these zones being bent so as to aid the transfer of charges to the oblique part of the register. Moreover, certain of the row electrodes which serve for the transfer of charges in the vertical direction, and which extend linearly in the shape of a horizontal strip along the matrix, are preferably bent at their end so that at the crossover of a row end and a column end in immediate proximity to the oblique part of the register, the end of the last electrode comprises a part extending parallel to the oblique part of the register. The electrodes which immediately precede this last electrode have shapes intermediate between a horizontal strip and the bent strip constituting the end of the last electrode so as to facilitate the transfer of charges to the oblique part of the register.
The reading register may have an output situated on the right or on the left. However, it preferably has a central output, that is to say it is divided into two half-registers operating in opposite senses so as to bring the charges from the left half of the matrix to the right and the charges from the right half to the left. The register may in this case have either two central outputs side by side, one for each half-register, or a single central output, the charges of the two half-registers being dumped alternately to one and the same reading circuit which multiplexes the signals arising from the two half-registers.
The presence of a register along a beveled corner in a matrix structure modifies the order of succession of the signals extracted from the matrix, and requires that this order be restored during the utilization of the signals for the reconstruction of a global image. Means of reconstruction of the order of the image dots, as a function of the exact configuration of the beveled corners and of the register which follows their contour, must therefore be envisaged, either on the sensor itself (on the chip) or off the sensor.
BRIEF DESCRIPTION OF DRAWINGS
Other characteristics and advantages of the invention will become apparent on reading the detailed description which follows and which is offered with reference to the appended drawings in which:
FIG. 1 , already mentioned, represents a dental image sensor whose chip comprises two beveled corners; FIG. 2 , likewise already mentioned, represents a sensor whose chip comprises four beveled corners; FIG. 3 represents the principle of a sensor according to the invention, with a lateral output of the “horizontal” reading register; FIG. 4 represents a sensor with two central outputs; FIG. 5 represents a sensor with a multiplexed single central output; FIG. 6 represents the basic shape of the electrodes allowing dumping of the charges into the output register at the level of the beveled corners; FIG. 7 represents an embodiment detail in the case where the columns of the matrix operate as a charge transfer register with four electrodes per register stage; FIG. 8 represents the metallic conductors intended for conveying the control signals to the various row electrodes of the matrix of FIG. 7 .
DESCRIPTION OF PREFERRED EMBODIMENTS
The invention will be described in regard to an intraoral dental radiological sensor although it is applicable to other cases where similar problems of bulkiness, comfort and ergonomics would arise.
FIG. 3 represents an electronic chip 10 according to the invention, intended to be encapsulated in a package substantially hugging the shape of the chip; the electronic chip comprises four main sides, top, bottom, right, left, which are pairwise perpendicular, and it exhibits four beveled corners which interrupt the main sides before they cross one another. The chip will be mounted on a base (not represented), of the same rectangular shape with four beveled corners, and it will be linked to this base by bonding wires internal to the package and soldered on one side to the base and on the other to the bonding pads 12 provided on the chip. The chip and base assembly is enclosed in a leaktight package (not represented) which hugs the rectangular shape with beveled corners of the chip and of the base and which preferably has rounded corners for comfort and ergonomics. Bonding wires for connection to the outside, linked to the base, exit this package, on one side only which is preferably but not necessarily the bottom side of the figure, so that a single bundle of wires, not represented, situated at the bottom of the sensor, leaves the sensor so as to be linked to an outside apparatus; these wires serve for the electrical supply to the sensor and for gathering the electrical signals representing the image detected by the sensor; for an intraoral sensor, this bundle of wires exits the mouth of the patient during radiological picture capture of the inside of the mouth; the top side of the figure is the upstream side in the direction of introduction of the sensor into the mouth of a patient.
The sensor is a matrix sensor consisting of an array of rows and columns of photosensitive dots, each photosensitive dot gathering electric charges in proportion to the exposure of this dot to light. The active zone proper, comprising these photosensitive dots, is a zone 14 , of rectangular shape with beveled corners like the shape of the chip, represented here by its perimeter shown dashed. Around this zone are housed the electronic circuits necessary for the operation of the matrix, and in particular the registers for controlling rows. The active zone therefore comprises a bottom side, a top side, a right side and a left side, which are the four sides that may be referred to as rectangular, and it also comprises a bottom left beveled corner, a bottom right beveled corner, a top left beveled corner, and a top right beveled corner.
The angles of the beveled corners depend on the ratio between the spacing of the rows and the spacing of the columns of the matrix. Preferably, the spacing is the same row-wise and column-wise (for example 20 micrometers) and the beveled corners are then 45°, this being the easiest to produce.
The electric charges gathered by the photosensitive dots are transferred vertically column-wise to the bottom of the matrix where they are dumped into a reading register (that will be referred to as a “horizontal” register by analogy with the customary reading registers which are disposed horizontally at the bottom of the matrix); dumping is effected according to a conventional method consisting
in transferring the charges vertically from one row to the next, simultaneously for all the rows of the matrix, the last row being transferred into the horizontal register, in reading the row contained in the reading register, in performing a new vertical transfer step, and so on and so forth.
According to the invention, the so-called “horizontal” reading register 20 , which transfers to an output the charges that it has received after a step of vertical shifting of the matrix, runs alongside the two beveled corners of the bottom of the matrix. The register therefore comprises a horizontal part 22 along the bottom side of the active zone, and two oblique parts 24 and 26 , respectively along the bottom left side and along the bottom right side of the active zone. This of course raises technical problems that will be detailed hereinbelow. The charges of the various columns are dumped not only into the horizontal part 22 of the register, along the bottom side of the chip, but also directly from the columns of the matrix to the oblique parts 24 and 26 of the register.
In a first embodiment, represented in FIG. 3 , the reading register comprises a single output situated at the distal end (furthest from the horizontal part 22 ) of the oblique part 24 (or 26 ) of the register.
In a second embodiment, represented in FIG. 4 , there are two half-registers 20 ′ and 20 ″, one on the left, the other on the right; each half-register comprises a half of the horizontal part and a respective oblique part, left for the half-register 20 ′, right for the half-register 20 ″. The half-registers may have outputs at the ends of the oblique parts, in a configuration much like that of FIG. 3 but with two symmetric outputs. However, they may also have outputs side by side, at the adjacent ends of the halves of horizontal parts of the registers, hence at the center of the bottom side of the matrix, as is represented in FIG. 4 .
In a third embodiment, represented in FIG. 5 , the two half-registers 20 ′ and 20 ″ have a single output at the center of the bottom side of the matrix, and this output provides alternately, in a multiplexed manner, the charges originating from the left side and from the right side of the matrix of photosensitive dots. The signals must thereafter be demultiplexed to reconstruct an image line.
The first embodiment allows a simple layout of the register and simplifies the design of the control of the register. However, it does not make it possible to optimize the use of the chip zone available between the left (or right) edge of the active zone and the left (or right) edge of the chip.
The second embodiment makes it possible to bring the edge of the active zone closer to the left or right edge of the chip, hence to increase the area of the image capture zone for one and the same chip area, but it compels a complication in the layout of the output of the registers. Moreover, the existence of two outputs entails a risk of imbalance between the left half and the right half of the image. Also the consumption of the outputs is bigger.
The third embodiment also makes it possible to bring the edge of the active zone closer to the edge of the chip. The layout of the output is simpler than in the second solution. This third solution makes it possible to optimize the dimensions of the chip, to circumvent certain dispersions in gain between different outputs, and to minimize consumption by virtue of the use of a single reading amplifier.
FIG. 6 represents a schematic layout of electrodes making it possible to efficiently dump the charges into a bent register from columns which do not arrive perpendicularly to the register in the oblique parts of the latter.
The reading register 20 is represented in its part situated at the corner between the horizontal part 22 and the oblique part 26 of the register.
The matrix of the active zone has horizontal rows L m , L m+1 , for the rows of rank m and m+1 respectively etc., and to simplify the explanations it has been assumed, in the case of FIG. 6 , that each row comprises two electrodes only: an electrode Ea of type a, an electrode Eb of type b (electrodes Ea m , Eb m for the row of rank m, Ea m+1 , Eb m+1 for a following row). The electrodes are all intimately adjacent to one another in order to effect the charge transfers. It is also assumed for simplicity that the last electrode Eb M of the last row of the matrix, that is to say the row of rank M, closest to the reading register, is immediately adjacent to the reading register.
The matrix also has vertical columns C n , C n+1 , etc., mutually insulated (typically by P-type diffusions when the charge transfer and storage surface zones are of N type) so as to avoid a lateral transfer of charges, these columns behaving, by virtue of the row electrodes, as vertical shift registers, that is to say that during a phase of reading of the image stored in the matrix in the form of electric charges, the charges of the pixels of a column are shifted vertically row by row in this column and the charges of the last row are dumped at the end of the column.
Whereas over the whole of a conventional matrix the row electrodes are horizontal straight strip-like conductors over the entire length of the matrix, with a single electrode of type b (Eb m ) adjacent to a horizontal register over its entire length and a single electrode of type a (Ea m ) adjacent over its entire length to the electrode Eb m , it is seen that here it is necessary to adopt a special design of electrodes of type a and of type b or a special design of the reading register in order that a succession of two electrodes of type a then b is adjacent to the register even in the oblique part of the register.
The reading register could rise staircase fashion along the oblique edge of the matrix zone; this staircase configuration would have the advantage of permitting the electrodes of type a and of type b to remain theoretically straight over their entire length, including at their end adjacent to the oblique part 26 of the reading register. However, a staircase configuration of the reading register is less effective in respect of charge transfer.
In FIG. 6 , the register has by choice been given a straight rather than staircase configuration in its oblique part 26 . A particular configuration is then given to the ends of row electrodes which terminate at the register. Moreover, the vertical transfer of charges to the register is aided by turning the columns toward the register. This is done by bending perpendicularly to the register the insulation zones which separate the columns from one another (these insulation zones are symbolized by the dotted lines in FIG. 6 ).
It is assumed, in FIG. 6 , that the column C n of rank n terminates at the register at the location where the row L m+1 of rank m+1 terminates at the register. That is to say, it is row L m+1 which constitutes the last row into which the charges of column C n will be transferred before these charges are dumped into the register; and these charges will then be transferred into a stage ET n of the register, dedicated to column C n . More precisely, it is electrode Eb m+1 which constitutes the last electrode in column C n ; the electrode Ea m+1 constitutes the last but one electrode.
We shall be concerned only with the columns of the right half-matrix, it being understood that the left half-matrix is generally symmetric with the right half-matrix.
The electrode Eb m+1 of row L m+1 is straight and parallel to the horizontal part 22 of the reading register, except at its end; that is to say this electrode is straight and horizontal when it crosses the successive columns up to rank n−1, but it ceases to be straight, in the configuration of FIG. 6 , when it crosses the column of rank n.
At this location, the end of the electrode Eb m+1 of row L m+1 is bent in such a way that a part of the electrode now extends parallel to the stage ET n of the oblique register 26 . The bend is firstly a downward bends, perpendicular to the oblique part of the register, then an upward bend parallel to the register.
In the same way, the shape of the electrode Ea m+1 is that of a straight strip while it crosses the columns of the matrix up to the column of rank n−1; however, at the location where it crosses the column of rank n, it adopts another shape, such that it remains intimately adjacent both to the straight electrode which immediately precedes it (here: Eb m ) on one side and to the bent electrode Eb m+1 on the other side.
In the direction of the shifting of charges in the oblique zones of the reading register, the spacing of the stages of the register is increased all the more when the inclination of the beveled corner is large. For a 45° beveled corner, the spacing is increased in the ratio square root of 2. The horizontal register is itself composed of a succession of mutually adjacent electrodes (for example two or four electrodes per stage of the register); these electrodes are not represented in FIG. 6 ; they are wider in the oblique part 26 of the register, just where the spacing of the registers is widest, than in the horizontal part 22 .
The register stage constituting the transition where the register passes from a horizontal configuration to an oblique configuration, here the stage referenced ET n−2 may be larger than the other stages (lengthwise in the direction of flow of the charges in the register) as is represented in FIG. 6 . However, it may be preferable to cut it into several elements, for example into two half-stages, the transfer of charges in the register not being as good if the register electrodes are too wide (width in the direction of flow of the charges). However, if stage ET n−2 is cut into two, it will be understood that only one of the two half-stages has to receive charges from the column (here column C n−2 ) which emerges opposite stage ET n−2 . An insulation barrier (p+ diffusion for example) is therefore placed in front of the other half-stage so as to separate it from the adjacent columns (C n−2 as much as C n−1 ). This half-stage receiving no charges from the columns, this must be taken into account when utilizing the signal output by the horizontal register: a “hole” will be present in the series of pixel values that emanates from the register, this hole corresponding to a virtual site between the columns C n−2 and C n−1 . If the register's horizontal stages comprise two electrodes, the two half-stages constituting stage ET n−2 also comprise two electrodes each.
In FIG. 6 , for ease of explanation, ends of electrodes of type b that are mutually independent have been represented. However, in a column-wise charge transfer register, all the electrodes of type a are controlled simultaneously and all the electrodes b are controlled simultaneously. The arrangement of FIG. 6 makes it possible to link the electrodes of type b to one another, forming a single continuous electrode along the oblique part of the register since they are practically adjacent to one another just where they run alongside this oblique part. Such is not the case for the electrodes of type a which remain physically separated from one another but which have to be linked together electrically by other means that will be detailed later.
With a register thus configured with a horizontal part and an oblique part, a problem of utilization of the signals gathered by the reading register arises. Specifically, although conventionally on each occasion the reading register dumps to an output the signals corresponding to an image line, here there is a mixing of information between different rows.
If S m,n denotes the signal gathered in the photosensitive dot at the crossover of a row of rank m and of a column of rank n, a conventional reading register would provide the following signals in order in succession, assuming that only the right half of the matrix (columns 1 to N) is of concern and that the output of the register occurs towards the right:
S M,1 , S M,2 , . . . S M,N then S M−1,1 , S M−1,2 , . . . S M−1,N then S M−2,1 , S M−2,2 , . . . S M−2,N etc.
However, in the invention, the order of the signals is shuffled, the information transmitted being in succession:
firstly the information S M,1 , S M,2 , . . . of row L M in the order of the columns for all the columns which are opposite the horizontal part of the register, then S M,n−2 , S M−1,n−1 , S M−2,n , etc. if it is assumed that the oblique part of the register commences onward of column n−1, then the information S M−1,1 , S M−1,2 , . . . of row L M−1 in the order of the columns for all the columns which are opposite the horizontal part of the register, then S M−1,n−2 , S M−2,n−1 , S M−3,n , etc. and so on and so forth.
Means (in principle a buffer memory) for reorganizing the order of the signals so as to allow the reconstruction of the image are therefore provided in the sensor or preferably outside the sensor.
FIG. 7 represents a practical exemplary embodiment in the most general case where each row of the matrix comprises four adjacent electrodes controlled by signals allowing the progressive shifting of charges from one row to the next. In this example, the reading register also comprises four electrodes per register stage. Only a portion of oblique part 26 of the reading register is represented, with the intersection of two rows L m , and L m+1 and of two columns C n and C n+1 .
Each row comprises four electrodes, Ea m , Ea′ m , Ea″ m , and Eb m for row L m . The columns are delimited by insulation zones ZI n , ZI n+1 , which channel the charges vertically inside a column and which are bent at their end perpendicularly to the register so as to channel the charges obliquely towards a respective stage ET n , ET n+1 of the reading register. The column end into which the transferred charges pass is therefore bent perpendicularly to the oblique register.
Just where a column and a row finish opposite a stage of the oblique part of the reading register, the four electrodes are deformed and cease to consist of a simple straight strip of constant width:
the electrode Eb m , which is a straight strip provided that it has not arrived in front of the last column of rank n+1 is bent obliquely downwards (above the insulation zone ZI n ) then obliquely upwards above column C n+1 , the upward bend constituting an electrode portion which runs alongside the oblique register; all the electrodes Eb m are preferably attached to one another in the form of a single oblique conductor Eb which runs alongside the oblique register and which groups together all the obliquely upward bent parts of the electrodes Eb m ; the electrodes Ea m , Ea′ m , Ea″ m have intermediate shapes making it possible to pass progressively from the horizontal straight strip shape of constant width possessed by electrode Eb m−1 in the column C n+1 to the oblique strip shape of electrode Eb m is this same column.
In this embodiment matters have been contrived such that the electrodes of row L m cease to have a straight strip shape only when they arrive in the last column C n+1 but it would be conceivable for the deformation of the electrodes to commence slightly before, for example when they are still in the last but one column C n , so as to facilitate, inside this column, the progressiveness of deformation of the electrodes from a horizontal strip shape to an oblique strip shape.
The reading register has in this example four electrodes per stage E 1 n , E 2 n , E 3 n , E 4 n for stage ET n . The charges originating from the column of rank n are dumped under electrode E 2 n when the latter is at an appropriate potential; all the electrodes E 2 n , E 2 n+1 , etc. are joined together by a conductor EC 2 extending along the reading register parallel to the conductor Eb.
In a conventional matrix, the control signals for the row electrodes would be conveyed via the ends of these electrodes on one side of the matrix. However, in the matrix according to the invention there is a difficulty since the ends of the electrodes are not easily accessible from the side of the matrix, just where these electrodes terminate in front of the oblique part of the register; this being so neither on the right nor on the left.
This is why provision is made for access metallizations of these electrodes to pass along the oblique register, above the electrodes, and to come into point contact with the electrodes that have to be powered. In the register with four electrodes per row of FIG. 7 , provision is preferably made for four metallization lines Ma, Ma′, Ma″, Mb which run along the oblique register so as to come into contact respectively with the electrodes Ea, the electrodes Ea′, the electrodes Ea″, and the electrodes Eb. These lines are represented in FIG. 8 .
These metallizations (preferably aluminum) must occupy as little room as possible since they mask the photosensitive zones situated along the reading register. Matters may be contrived such that in total they mask only one or two rows of photosensitive dots.
FIG. 8 , superimposable on FIG. 7 , shows the metallization lines that may be provided, and the zones where they contact the row electrodes so as to apply the desired control signals to them. The electrodes mentioned with reference to FIG. 7 are represented dotted in FIG. 8 . The metal conductors which convey the control signals to them are represented as solid lines. The contact zones between a metal conductor and an electrode situated underneath (and insulated by an insulating layer interrupted at the location of the contacts) are represented by a square barred with a cross. The layout of the conductors is such that there is compliance at one and the same time with a sufficient width of the conductors (to ensure sufficient conductivity), a sufficient width at the location of the contacts (to avoid contact faults) and a sufficient gap between conductors (to avoid short-circuit faults).
There is point contact between the metallization Ma and the electrodes Ea m , Ea m+1 , etc., at points A m , A m+1 , etc.
There is point contact between the metallization Ma and the electrodes Ea′ m , Ea′ m+1 , etc., at points A′ m , A′ m+1 , etc.
There is point contact between the metallization Ma″ and the electrodes of even rank Ea″ m , Ea″ m+2 etc. but not between the metallization Ma″ and the electrodes of odd rank Ea″ m+1 , if there is insufficient room (but more room could possibly be created by distancing the conductors Ma, Ma′, Ma″, Mb from one another or by using a different configuration). If the contact is not made with the electrodes of odd rank, provision must of course be made for contact with these electrodes at some other location, and this other location is quite simply the other side of the matrix (left side); specifically, the conductors Ma, Ma′, Ma″, Mb extending along the whole of the reading register both in its horizontal part and in its two oblique parts.
Finally, from place to place the metallization Mb contacts, at points B m , the common electrode Eb which is linked, it will be recalled, to the electrodes Eb m , Eb m+1 , etc. Provision need not be made for contact having the same periodicity as the spacing of the rows. In the example represented, contact is made one row out of two.
The matrix sensor thus made is covered with a scintillating layer before encapsulation if one wishes to make a radiological sensor, and in particular to make an intraoral dental radiological sensor. | The invention relates to small dimension image recorders, such as an image recorder, comprising a matrix of rows and columns of photosensitive points, arranged on a chip of a generally square or rectangular form with believed corners, characterised in comprising a reading register arranged at the base of the matrix. The register is bent to follow the bevelled corners of the chip and thus comprises a horizontal piece and two oblique pieces. The sensor further comprises means (ZI n ) to direct the photosensitive charges form the columns terminating opposite the beveled corners towards the stage of the reister situated in the oblique part along the beveled corners. The above is of application to intraoral dental radiological sensors. | 7 |
BOTANICAL CLASSIFICATION
[0001]
Zoysia matrella
VARIETY DENOMINATION
[0002] ‘A-1’
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to a new and distinct asexually reproduced perennial zoysiagrass cultivar named ‘A-1’.
[0005] 2. Description of Prior Art
[0006] Zoysiagrasses are a widely used group of warm-season turfgrasses in the southern United States. The group includes three species and their interspecific hybrids: Zoysia japonica Steud., Z. matrella (L.) Merr., and (rarely) Zoysia pacifica (Goudswaard) Hotta & Kuroki (formerly assigned to Z. tenuifolia Thiele). All are rhizomatous and stoloniferous, mat-forming perennials adapted to a wide range of edaphic conditions.
[0007] Compared with other warm-season turfgrasses such as Bermudagrasses and St. Augustinegrass, zoysiagrasses are very resistant to wear damage, but slow to spread laterally by stolons and rhizomes and are therefore slower to recover from wear damage. Z. japonica produces coarse to medium-textured leaves and is adapted from subtropical to cool temperate conditions, while Z. matrella produces medium to fine-textured leaves and is adapted to warmer climates from tropical through to warm temperate.
[0008] Prior art Z. matrella and Z. matrella×Z. japonica zoysiagrasses include ‘Diamond’ (U.S. Plant Pat. No. 10,636), ‘Cavalier’ (U.S. Plant Pat. No. 10,778), ‘Zorro’ (U.S. Plant Pat. No. 14,130), and ‘Royal’ (U.S. Plant Pat. No. 14,395).
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention relates to a new and distinct perennial Zoysia matrella zoysiagrass cultivar identified as ‘A-1’.
[0010] ‘A-1’ differs from other known Z. matrella and Z. matrella×Z. japonica cultivars with respect to a number of morphological characteristics, shows greater winter hardiness, and has a distinctive DNA profile. ‘A-1’ produces shorter, narrower leaves (i.e., finer-textured foliage), shorter, erect tillers, and larger inflorescences on longer, thinner peduncles than ‘Cavalier’ and ‘Zorro’. Compared with ‘Royal’, ‘A-1’ has narrower leaves, but produces larger inflorescences on longer, thinner peduncles. ‘A-1’ produces longer stolon internodes, longer vertical tillers with more elongated leaves (i.e., greater length:width ratio), and larger inflorescences on longer, thicker peduncles than ‘Diamond’. ‘A-1’ also has good shade and salinity tolerance, is tolerant of zoysia rust and resistant to Rhizoctonia blight, and shows moderate to good resistance to tropical sod webworm and armyworm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a photograph showing stolon comparisons of five Zoysia matrella and Z. matrella×Z. japonica cultivars: ‘A-1’, ‘Cavalier’, ‘Zorro’, ‘Royal’, and ‘Diamond’.
[0012] FIGS. 2A-2C are photographs of compound stolon nodes from ‘A-1’ showing a compressed node subtended by 3 stolon leaves ( FIG. 2A ), the progressive development of branching at nodes along a stolon ( FIG. 2B ), and complex branching from older compound nodes ( FIG. 2C ). Vestigal leaf blades are present on the stolon leaves.
[0013] FIG. 3 shows the dendrogram for ‘Royal’, ‘Zorro’, ‘Cavalier’, ‘A-1’, and ‘Diamond’ constructed from 71 markers generated from two ISSR primers using Jaccard's coefficient.
[0014] FIG. 4 presents the electropherogram for ‘A-1’ versus four other zoysiagrass genotypes using primer 6FAM (AG) 9 C. The electropherograms (from the top panel to the bottom panel) are from ‘Royal’, ‘Zorro’, ‘Cavalier’, ‘A-1’, and ‘Diamond’.
DETAILED DESCRIPTION OF THE INVENTION
[0015] ‘A-1’ was selected from a breeding population of forty seedling Zoysia matrella plants from various parts of Southeast Asia (Japan, Philippines, China, Korea, Vietnam and Thailand). The original plants were vegetatively propagated and evaluated first in pots. Vegetative propagation was performed by taking stolons from the original plant and dividing them into stolon tip and single-node cuttings. These cuttings were placed into soilless peat-vermiculite potting mix in nursery cell trays to produce roots and grow through the potting medium before transplanting into larger pots.
[0016] A shortlist of selected genotypes was expanded to field plantings at Sheldon, QLD (Australia). The plants were vegetatively propagated in nursery cell trays prior to planting in the field. Once in the field, the plants were evaluated against existing Z. matrella and Z. matrella×Z. japonica hybrid cultivars under mowing heights from 10 to 25 mm and under shade levels ranging from 0 to 80%. ‘A-1’ from Okinawa (Japan) showed higher tiller density and a more prostrate growth habit than the parent ecotypes, and was selected from the wider breeding population on the basis of its superior turf colour, quality under mowing for 6 years, and its shade tolerance as shown by its ability to maintain density of the mown sward under greatly reduced light levels (70-80% shade). Additional observations regarding climatic adaptation were made in Cairns, QLD (Australia) and Melbourne, VIC (Australia) using vegetative propagules as described above. ‘A-1’ has remained true-to-type with no discernible off-types through more than four cycles of vegetative multiplication.
DETAILED BOTANICAL DESCRIPTION
[0017] ‘A-1’ is a perennial diploid (2n=40 chromosomes) zoysiagrass with a creeping growth habit. It spreads laterally by stolons and rhizomes, which produce short, erect tillers.
[0018] The stolons of ‘A-1’ consist of short, thin internodes separated by compound nodes, each of which is subtended by 3 leaves ( FIG. 2 ). Structurally, each compound node consists of two compressed internodes and one normal internode and so can produce axillary stolon shoots (i.e., branches) from any or all of the three component nodes, starting from the component node furthest from the stolon tip and subtended by the outermost stolon leaf ( FIG. 2 ).
[0019] Internodes on ‘A-1’ are longer than on ‘Diamond’, but comparable in length to those of ‘Cavalier’, ‘Zorro’ and ‘Royal’. ‘A-1’ produces fewer early stolon shoots per node than ‘Diamond’, ‘Cavalier’ and ‘Zorro’. Stolon color is reddish-purple (RHS N79A) when exposed to sunlight. Stolon leaf blades are greatly reduced (vestigal) compared with tiller leaves. Stolon leaf blades on ‘A-1’ are longer and wider (i.e., better developed) than those of ‘Cavalier’ ‘Zorro’, ‘Royal’ and ‘Diamond’.
[0020] Tiller length (i.e., vertical extension) on ‘A-1’ is shorter than ‘Cavalier’ and ‘Zorro’, but longer than ‘Diamond’. Leaf blades are rolled in the bud and later emerge to become flat and stiff and linear-triangular in shape. ‘A-1’ produces shorter, narrower leaf blades than ‘Cavalier’ and ‘Zorro’. Hairs are absent on both the abaxial and adaxial surfaces of the leaf blade and on the leaf sheath. Leaf blade color is dark green (RHS 137A—2001 edition). The ligule is a row of short silky hairs c. 2 mm long.
[0021] ‘A-1’ flowers from about April to October in the southern hemisphere, and October to April in the northern hemisphere. The inflorescence is a short, spike-like raceme. ‘A-1’ produces longer peduncles and racemes and has more spikelets per inflorescence than ‘Cavalier’, ‘Zorro’, ‘Royal’, and ‘Diamond’. Peduncles on ‘A-1’ are thinner than those on ‘Cavalier’, ‘Zorro’, and ‘Royal’, but thicker than ‘Diamond’ peduncles.
[0022] ‘A-1’ was compared against other Zoysia matrella and Z. matrella×Z. japonica cultivars ‘Diamond’, ‘Cavalier’, ‘Royal’, and ‘Zorro’ in a spaced-plant field trial at Cleveland, QLD (Australia) (Latitude 27°32′S., 153°15′E., elevation c. 50 masl). Morphological grouping characteristics used to select the most similar comparator varieties of common knowledge were stolon internode length, leaf blade length and width, leaf length and width on flowering tillers, peduncle length and width, and inflorescence length (Table 1).
[0023] Rooted vegetative plugs 5 cm in diameter were taken from nursery stock and planted on a basaltic red ferrosol soil on Mar. 3, 2003 on a 1 m×1 m grid. Thirty spaced plants from each of the five cultivars were arranged in three randomized blocks with ten plants per plot. Weed control was achieved by a pre-emergence application of oxadiazon (repeated on Jul. 23, 2003) and with post-emergence fluroxypyr for broadleaf weeds on Mar. 23, 2003. Good nutrition was maintained by regular applications of slow release complete NPK fertilizer at one- to two-month intervals. The spaced plants were allowed to grow and develop without any mowing. Leaf and stolon colors were determined on Jul. 16, 2003. Diameter of spread was taken from four measurements per plant made on Aug. 22, 2003. Shoot and inflorescence characteristics were measured on two mature tillers between Sep. 17 and 19, 2003. Stolon stem and leaf characteristics were measured on two stolons per plant between Oct. 6 and 10, 2003. Digital images of stolon characteristics ( FIG. 1 ) were taken Dec. 10, 2003.
[0000]
TABLE 1
Morphological/Agronomic Data from Comparative Growing Trial
LSD
‘Cava-
‘Dia-
(P =
Attribute
‘A-1’
lier’
‘Zorro’
‘Royal’
mond’
0.05)
Mean plant diameter
55.9
82.6
74.0
62.2
37.5
12.9
after 173 days (cm)
Number of axillary
2.30
3.18
3.05
2.83
4.13
0.51
shoots at 4th stolon
node (spaced plants)
Length of 4th
23.0
24.6
26.1
22.2
11.1
3.9
internode from
stolon tip (mm)
Diameter of 4th
1.37
1.39
1.36
1.44
1.36
0.11
internode from
stolon tip (mm)
Length of outermost
9.6
8.9
9.3
10.3
7.3
1.3
leaf sheath on 4th
visible node from
stolon tip (mm)
Length of innermost
20.1
18.1
17.4
19.1
13.5
2.7
leaf sheath on 4th
visible node from
stolon tip (mm)
Length of leaf blade
4.29
3.08
3.03
2.60
1.53
0.51
on 4th visible node
from stolon tip (mm)
Width of leaf blade
0.85
0.73
0.71
0.63
0.50
0.11
on 4th visible node
from stolon tip (mm)
Length:width ratio
5.07
4.26
4.27
4.17
3.07
0.64
of leaf blade on
fourth visible node
from stolon tip
Length of flag leaf
22.7
19.7
20.4
19.6
14.0
2.3
sheath on flowering
tillers (mm)
Length of flag leaf
3.90
3.61
3.80
3.21
3.35
0.66
blade on flowering
tillers (mm)
Width of flag leaf
0.71
0.82
0.67
0.68
0.66
0.16
blade on flowering
tillers (mm)
Length:width ratio
5.49
4.45
5.75
4.78
5.18
0.99
of flag leaf blade on
flowering tillers
Length of sheath on
10.22
14.10
16.07
12.55
7.96
1.30
fourth leaf on
flowering tillers
(mm)
Length of blade on
18.0
29.2
32.6
21.1
15.6
3.9
fourth leaf on
flowering tillers
(mm)
Width of blade on
1.61
1.93
2.01
1.66
1.53
0.27
fourth leaf on
flowering tillers
(mm)
Length:width ratio
11.12
15.04
16.16
12.83
10.33
1.03
of fourth leaf blade
on flowering tillers
Length of peduncle
41.5
34.9
35.1
32.3
19.7
5.8
(mm)
Diameter of
0.56
0.73
0.70
0.65
0.43
0.05
peduncle (mm)
Mean spike length
17.9
15.1
14.7
14.9
10.7
0.9
(mm)
Number of
23.5
18.0
17.3
16.3
9.0
1.8
spikelets per
inflorescence
Color of stolon
N79A
N79A
N79A
N79A
N79A
—
stem exposed to
sunlight
Color of leaf blade
137A
137A
137C
137A
137A
—
(RHS Colour
Chart, 2001
edition)
STRESS RESISTANCE
[0024] ‘A-1’ shows excellent salt tolerance. In a greenhouse experiment, six salinity levels covering the range from 60 to 25,600 ppm Total Dissolved Salts (TDS) applied as NaCl were imposed hydroponically through the irrigation water. After being held at the designated treatment levels for thirteen weeks, the level of leaf firing induced in ‘A-1’ was comparable to that in ‘Diamond’, ‘Cavalier’, ‘Zorro’, and ‘Royal’ (Table 2). The relative dry matter yield of clippings over the ten- to fourteen-week period in ‘A-1’ was lower than ‘Diamond’ and ‘Royal’ at the highest salinity level (25,600 ppm TDS), but was superior to the other four cultivars at 5,120 ppm TDS and generally comparable to them at intermediate salinity levels (Table 3).
[0000]
TABLE 2
Effect of salinity level on percent leaf firing of Zoysia matrella
cultivars) after thirteen weeks of treatment. LSD (P = 0.05) = 10.3.
TDS (ppm)
Cultivar
60
5,120
10,240
15,360
20,480
25,600
‘A-1’
5.0
23.3
31.7
64.2
61.7
90.7
‘Diamond’
2.8
11.7
24.2
46.7
61.7
87.5
‘Cavalier’
4.5
30.8
40.0
69.2
72.5
94.7
‘Zorro’
6.7
22.5
45.8
72.5
71.7
91.7
‘Royal’
8.3
50.0
50.0
73.3
73.3
90.7
[0000]
TABLE 3
Effect of salinity level on dried clipping yield of Zoysia
matrella cultivars relative to the control treatment (=1.000)
after fourteen weeks of treatment. LSD (P = 0.05) = 0.149.
TDS (ppm)
Cultivar
60
5,120
10,240
15,360
20,480
25,600
‘A-1’
1.000
1.073
0.773
0.448
0.270
0.081
‘Diamond’
1.000
0.680
0.604
0.427
0.449
0.307
‘Cavalier’
1.000
0.656
0.450
0.321
0.252
0.000
‘Zorro’
1.000
0.822
0.671
0.321
0.141
0.096
‘Royal’
1.000
0.716
0.833
0.462
0.326
0.238
[0025] ‘A-1’ is tolerant of zoysia rust ( Puccinia zoysiae ) and is resistant to Rhizoctonia blight. It is also resistant to sod webworm ( Herpetogramma licarsisalis ) and armyworm ( Pseudaletia spp., Spodoptera spp.), except where excessive nitrogen fertilizer use causes softer leaves.
[0026] ‘A-1’ has shown superior winter hardiness to ‘Diamond’, ‘Cavalier’, ‘Zorro’ and ‘Royal’ in Melbourne, VIC (Australia). In trial plots at South Oakleigh (37°55′S., 145°06′E.), ‘A-1’ grew in faster from cells with rooted stolon cuttings and has maintained good ground cover and turf quality, while the other four cultivars showed poor winter survival and declined rapidly to very low levels of cover and quality.
DNA PROFILING
[0027] DNA was extracted from ground leaf material using a modified CTAB (cetyl tri-methyl ammonium bromide) procedure. Inter-Simple-Sequence-Repeat (ISSR) markers were generated by the polymerase chain reaction (PCR) using a GeneWorks thermal cycler and two fluorescently labelled primers, 6FAM (AG) 9 C and NED (GA) 9 T. Amplification products were separated by capillary electrophoresis using an ABI 3130 genotyper and visualised using GENEMAPPER® software. The dominant markers generated with both primers were then used to produce a dendrogram ( FIG. 3 ) using pattern analysis. Distinctive marker loci were identified by both primers. FIG. 4 , as an example, illustrates the distinctive marker loci identified using primer 6FAM (AG) 9 C. | An asexually reproduced cultivar of perennial zoysiagrass that possesses a unique combination of characteristics including high turf quality and density under mowing, good shade tolerance, salinity tolerance, resistance to zoysia rust and Rhizoctonia blight, moderate to good resistance to tropical sod webworm and armyworm, and a distinctive DNA profile. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent application Ser. No. 13/241,039, filed Sep. 22, 2011, which is a continuation of U.S. patent application Ser. No. 12/126,476, filed May 23, 2008, the entire disclosure of which is incorporated by reference herein.
FIELD OF THE INVENTION
[0002] Embodiments of the present invention are generally related to back flow preventors that interconnect to a water source. More particularly, devices that attach to a sill cock, or any other fluid source, to prevent back flow of fluids, that may contain contaminants into the fluid supply are provided.
BACKGROUND OF THE INVENTION
[0003] Almost all buildings include some type of exterior fluid delivery system. The most common outdoor fluid delivery system is comprised of a faucet with a handle for actuating a valve that initiates or ceases fluid flow from a fluid source through a sill cock of the faucet. In order to direct the exiting fluid, it is also well known to employ a hose that is threadingly interconnected to the sill cock. Fluid in the hose may, under certain conditions, enter the faucet and ultimately the fluid source. For example, if the fluid pressure in the hose is greater than the fluid supply pressure “back flow” will occur. Such back flow may be harmless. One skilled in the art will appreciate, however, that the fluid in the hose could be harmful and result in spoilage of the water supply or contamination of fluid dispensing apparatus often interconnected to the hose.
[0004] One source of contamination includes pesticides and/or fertilizers that are often associated with a delivery system that is interconnected to the open end of the hose. Fluid from the supply is used to dilute those harmful chemicals in the delivery system prior to being distributed. Most municipalities require that a one-way check valve be included in a fluid supply line that delivers water from a public water source to a dwelling so that contaminated water cannot enter the public water supply from the dwelling. Often, there is no requirement that dictates that similar precautions are taken with respect to an exterior fluid delivery system that is associated with a dwelling. It is entirely conceivable that contaminants entering a dwelling from an outside fluid source will affect individuals associated within the dwelling but not the public at large. Further, if the above-mentioned check valve is absent or malfunctioning contaminants could also enter the public water supply via the dwelling.
[0005] Another issue related to back flow is the harmful effects of freezing when supply pressure is reduced and/or flow is stopped wherein liquid accumulates within the faucet and/or related plumbing. When the ambient temperature drops, the trapped liquid may freeze potentially causing severe damage to the faucet interconnected check valve and/or associated plumbing. To address this freezing, draining features have been incorporated into prior art check valves, such as the A. W. Cash Valve Company Model VB-111, which includes a stem that must manually be actuated to allow drainage when a hose is not connected. This type of manually draining valve relies on an operator to drain the valve, and is thus not reliable. Self-draining check valves, however, are also known in the art and are disclosed in U.S. Pat. No. 4,712,575 to Lair (“Lair I”), which is incorporated by reference herein. Lair I discloses a self-draining, single valve back flow preventor. When a hose is detached, a spool succumbs to spring pressure and moves axially outwardly from the outlet end of the check valve. A valve, housed within the spool, is thus allowed to move axially from its sealing washer to permit drainage. When the hose is connected, the spool and the valve housed therein, are forced axially toward a sealing washer to create a seal that prevents back flow. Vent holes in the check valve prevent accumulation of back pressure within the valve. Sufficient water pressure during supply flow with the hose attached overcomes a spring used to seat the valve and deflects a vent sealing washer, thereby sealing the vent holes. One drawback of the Lair valve is that foreign material may lodge between the valve and the sealing washer, creating a passage through which back flow may occur.
[0006] One way to address the major drawback of Lair I is to provide a second check valve. U.S. Pat. No. 3,905,382 to Waterston (“Waterston”), which is incorporated herein, discloses a check valve with two normally closed spring biased valves, one inside an outlet, and the other located near an inlet. The central portion of the Waterston check valve has an externally-threaded vent outlet. When flow occurs, the supply pressure forces the inlet valve axially from its seat toward the outlet and seals the vent. As flow progresses to the outlet valve, the flow pressure compresses an outlet spring and fluid is free to flow from the check valve. When flow ceases and back flow pressure is sufficient to overcome the valve in the outlet, liquid accumulates in the sealed tube and is discharged through a vent.
[0007] The Waterston valve does not provide a draining feature that relieves accumulated liquid upstream from the check valve. In the event of freezing the accumulation of liquid upstream from the check valve can result in severe damage to the check valve and plumbing upstream of the check valve. In addition, contamination may collect in the internal portion of the check valve such that when a back flow condition occurs, the contamination trapped in the check valve may enter the fluid supply.
[0008] Another system that employs more than one check valve to prevent back flow of a liquid into a distribution system by eliminating pressure differentials that may occur between the faucet and interconnected hose, is the V-444 Valve (“V-444”) manufactured by A. W. Cash Valve Company. The V-444 is succinctly described in U.S. Pat. No. 5,228,470 to Lair et al. (“Lair II”). The V-444 employs three separate valves enclosed in a housing that allows drainage of the sill cock after the hose is removed and also prevents backflow into the structure. The V-444 includes an outer housing with an internally situated movable spool. The spool includes an o-ring positioned on an angled upper surface thereof that cooperates with an angled inner surface of the housing to define a first valve that selectively opens and closes an outer passage that allows trapped fluid in the sill cock to drain from a plurality of vent holes. The V-444 also includes an inlet check valve and an outlet valve that controls fluid through the valve and that prevents backflow.
[0009] In a first mode of use, wherein no hose is connected and supply pressure is absent, the V-444 is self-draining A spring forces the spool downwardly to open a fluid path that drains fluid from the sill cock through the plurality of vent holes. Fluid trapped within the inlet and outlet check valves also drains from the outlet of the valve.
[0010] In a second mode of use, wherein the V-444 is exposed to supply pressure without a hose interconnected, the spring will force the spool downwardly, thereby creating a path for water to flow through the vents of the check valve. The supply pressure will also deflect the inlet check valve and the outlet check valve so that fluid will be able to exit the valve system.
[0011] In a third mode of operation, a hose is interconnected to the outlet portion of the V-444, but no supply pressure is provided. Any back pressure generated by fluid in the hose will force the outlet check valve to seat upon a surface provided by the spool. In this configuration, a hose forces the spool upward, thereby closing the first valve so that any fluid within the inlet check valve on the outlet valve can only travel out of the vents and not into the fluid supply.
[0012] In a fourth mode of operation, supply pressure is added to the V-444 with a blocked interconnected hose. Here, fluid from the fluid supply causes a seal to deflect, thereby blocking the vents. In addition, the outlet check valve is seated as described above, thereby preventing fluid from entering into the center of the V-444.
[0013] The V-444 includes a fifth mode of operation that is similar to the fourth mode wherein the hose is open to free flow. Again, since the hose is interconnected, the first valve is closed. Fluid pressure causes the inlet valve to transition downwardly to seat on the stem, thereby allowing fluid to flow through the center of the inlet check valve. The fluid pressure also pushes the outlet valve downwardly from its seat on the stem, which allows fluid to freely flow into the hose.
[0014] Among the major drawbacks of the V-444 are its size, weight, dimensions and inclusion of components that add to its complexity and expense, thereby rendering it unsuitable for use in various situations. More specifically, the V-444 check valve is approximately 2.2 inches in length and 1.9 inches in diameter and weighs about 200 grams. This size is attributed to the use of complex valving mechanisms and the provision of a first valve that includes a movable spool.
[0015] Other back flow preventors have been employed such as those similar to the backflow preventor shown and described in U.S. Pat. No. 7,013,910 to Tripp (“Tripp”), which is incorporated by reference herein. Tripp discloses an in-line backflow preventor that is used in fluid carbonation systems is interconnected between a fluid source and a mixing tank. The pressure in the mixing tank of these systems is often greater than the source pressure. Tripp is designed for either continuous down-steam pressure increases or intermittent down-stream pressure variations. Accordingly, Tripp does not have the capability of releasing pressure upstream of the valve outlet. Further, Tripp, due to its normally closed configuration, does not automatically drain or contain other similar features that are required for freeze prevention.
SUMMARY OF THE INVENTION
[0016] It is one aspect of the present invention to provide a double check valve for interconnection to a sill cock associated with an outside water source that prevents back flow into the water supply. Back flow can occur as a result of a siphon condition wherein a vacuum exists within the check valve, the sill cock or the water source that is apt to suction water in a hose, or in the interconnected check valve into the water supply. A back flow condition may also occur when the fluid pressure within the hose is greater than that of the water supply. For example, if the hose was taken to a roof of a building, the resulting head pressure may be greater than the supply pressure. In addition, a temporary loss or interruption in supply pressure may create a pressure differential that would create a back flow situation. The embodiments of the present invention also provide freeze protection wherein water inside the sill cock is allowed to freely drain from the double check valve after supply pressure is removed.
[0017] Embodiments of the present invention employ a valve body that includes an inlet check valve and an outlet check valve positioned within a valve body and a valve cap. The inlet check valve includes an inlet check seal and is biased from the outlet check valve via a spring (or other similar resiliently deflectable member). The inlet check seal cooperates with a main seal that is positioned between the valve body and the valve cap of the double check valve. The outlet check valve is comprised of an outlet check body with an outlet check seal that selectively engages a seat provided in the valve body. The outlet check body and the inlet check body are preferably selectively interconnected to each other, which will be described in further detail below. A hose plunger, which is adapted to selectively engage a hose, is preferably slidingly interconnected to the double check valve and is biased by a compressive member, such as a spring (or other similar resiliently deflectable member), that is associated with the seat of the valve body. The hose plunger includes a centralized hub that engages an outlet check spring (or other similar resiliently deflectable member) that is associated with the outlet check body. This combination of components is sufficient to prevent back flow and to provide self-draining (e.g. promote freeze resistance) without the need of a third check valve to control fluid flow through the vents. Detailed descriptions of the functionality of certain embodiments of the present invention will be provided below.
[0018] It is thus another aspect of the present invention to provide a check valve that omits or is devoid of components employed in prior art systems, thus rendering embodiments of the present invention easier and less expensive to manufacture, lighter, less complex, less prone to malfunction, and easier to repair. More specifically, embodiments of the present invention omit additional valves but continue to provide the same functionality of check valves of the prior art, such as the V-444 described above. That is, a system is provided that more effectively employs less than three valves and preferably two valves, thereby allowing size, weight and failure reduction. For example, it is contemplated that the double check valve of embodiments of the present invention are about ⅓ the size (preferably an about 70% reduction) of the V-444 check valve, which reduces bulk, weight and facilitates installation. Preferably, the check valve of one embodiment of the present invention is approximately 1.2 inches in length (an about 44% reduction) and approximately 1.4 inches in diameter an about 26% reduction) and weighs about 130 grams (an about 35% reduction). In one embodiment, this reduction in size and weight is attributed to the omission of a spool and a stem that controls flow out of the vents of the V-444 check valve. To achieve this, embodiments of the present invention allow for drainage from a point other than through vents in a valve body, for example, drainage from the outlet of the double check valve as opposed to primarily through vents provided in a valve body, as is done by the V-444 check valve. In addition, the present invention employs a fixed inlet valve and a fixed outlet valve as opposed to the complicated valving scheme employed by the V-444, wherein a movable spool alters the configuration of the internal volume of the valve depending on flow condition.
[0019] It is still yet another aspect of the present invention to provide a check valve that meets the American Society of Safety Engineers (AS SE) regulations. More specifically the check valve of embodiments of the present invention meets the requirements of ASSE 1052.
[0020] It is another aspect of the present invention to provide a valving system that is dual use. More specifically, embodiments of the present invention possess the capabilities of an in-line valve as disclosed in Tripp and the ability to provide automatic self draining when a hose is disconnected from the valve. The double check valve, preferably, employs normally opened inlet and outlet check valves, which allows for complete and automatic drainage. When a hose is interconnected to the dual check valve, the inlet and outlet check valves close, and will open when the faucet is turned on, for example. Normally opened (present invention) and normally closed (in-line) valves are different and are regulated separate ASSE standards. Normally opened check valves are regulated by ASSE 1052 and in-line valves are regulated by ASSE 1022. ASSE 1022 concerns backflow prevention devices that protect potable water supplies that serve beverage dispensing equipment. ASSE 1022 requires that two independently acting check valves be used that are biased to a normally closed position. Conversely, ASSE 1052 concerns basic performance requirements and test procedures for backflow preventors that are designed to interconnect to a hose. ASSE 1052 valving systems are designed to protect against backflow due to back siphonage and low-head backpressure, under the high hazard conditions present at a hose threaded outlet. ASSE 1052 also requires that the inlet and outlet check valves be biased closed. Embodiments of the present invention comply with ASSE 1052 when a hose is interconnected thereto and provide needed automatic drainage when the hose is disconnected, a technological advancement over the prior art and an improvement over prior art devices similar to Tripp.
[0021] Accordingly, it is one aspect of the present invention to provide a back flow prevention device for interconnection to a sill cock that includes a valve body with threads that are adapted to receive a hose, the valve body also having an inlet volume and an outlet volume separated by an internally-disposed wall, a lower surface of the wall defining a valve seat, the valve body further including a vent that provides a flow path between the outside of the valve body and the inlet volume; a seal positioned with the valve body in a volume located adjacent to the inlet volume, the seal adapted to selectively block the vent; a valve cap interconnected to the valve body that is positioned within the volume that maintains the seal against the valve body, the valve cap having threads for interconnection to a sill cock of a faucet; an inlet check valve comprising: an inlet check spring positioned within the inlet volume, wherein the spring contacts an upper surface of the wall, an inlet check body positioned within the inlet check spring, an inlet check seal interconnected to the inlet check body that is adapted to selectively engage the seal, thereby opening and closing an aperture of the seal to control fluid flow from the valve cap into the inlet volume; a drain spring positioned within the outlet volume that contacts the seat and a plunger that is adapted to engage a hose; an outlet check valve comprising: an outlet check body positioned within the drain spring, an outlet check seal interconnected to the outlet check body that is adapted to selectively engage the seat to either open a flow path between the inlet volume and outlet volume, or isolate the outlet volume from the inlet volume, thereby preventing fluid from flowing from an interconnected hose into the sill cock; and an outlet check spring positioned about the outlet check body that contacts a portion of the outlet check body and a hub of the plunger.
[0022] More generally, it is an aspect of the present invention to provide a back flow prevention device, that includes a valve body with a fixed inlet volume and a fixed outlet volume, the valve body also having a vent for allowing fluid from inside the valve body to escape; a valve cap; a seal positioned between the valve cap and the valve body; an inlet check valve positioned within the inlet volume; and an outlet check valve positioned within the outlet volume.
[0023] In addition, it is an aspect of the present invention to provide a back flow prevention device including a body with a fixed inlet volume and a fixed outlet volume, the body also having an aperture; a cap; a primary means for sealing positioned between the cap and the body; an inlet means for selectively preventing flow of fluid positioned within the inlet volume; and an outlet means for selectively preventing flow of fluid positioned within the outlet volume.
[0024] Further, one of skill in the art will appreciate upon review of this disclosure that it is another aspect of the present invention to provide a water delivery system including a faucet associated with a water supply; a valve associated with the faucet that is adapted to selectively control the flow of fluid from the water supply through the faucet; and a double check valve associated with the faucet that prevents fluid from entering the water supply and that allows fluid within the faucet to drain therefrom when the valve is in the off position, the double check valve comprising: a valve body with a fixed inlet volume and a fixed outlet volume, the valve body also having a vent for allowing fluid from inside the valve body to escape, a valve cap, a seal positioned between the valve cap and the valve body, an inlet check valve positioned within the inlet volume, and an outlet check valve positioned with the outlet volume.
[0025] It is also an aspect of the present invention to provide a back flow prevention device that employs a housing having a passageway configured for the transport of a fluid therethrough, the housing having an inlet and an outlet, the passageway encompassing a valve system consisting essentially of: a first check valve disposed in the passageway that allows fluid to flow through the passageway in the direction from the inlet to the outlet; and a second check valve disposed in the passageway that allows fluid to flow through the passageway in the direction from the inlet to the outlet; a diaphragm disposed in the passageway adapted to engage at least one of the first check valve and the second check valve; a vent in fluid communication with the passageway and located between the first and second check valves, the vent selectively isolated from the passageway by the diaphragm, the vent adapted to permit fluid located between the first and second check valves to exit the housing through the vent, whereby the back flow prevention device permits substantially all fluid to drain completely from the device.
[0026] It is still yet an aspect of the present invention to provide a back flow prevention device that includes a housing having first and second ends and including a means for connecting to a fluid inlet line at the first end and for connecting a fluid outlet line to the second end; a central cavity within the housing; wherein the housing includes a valve system consisting essentially of first and second drain valves and is devoid of a third drain valve, the first drain valve located within the housing between the central cavity and the fluid inlet line to permit drainage of fluid from the fluid inlet line to the fluid outlet line end of the housing when the fluid outlet line is not connected thereto, and the second valve located within the housing between the central cavity and the fluid inlet line to control flow between the fluid inlet line and the central cavity, whereby the back flow prevention device permits substantially all fluid to drain completely from the device.
[0027] The Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the present invention. The present invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description of the Invention and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary of the Invention. Additional aspects of the present invention will become more readily apparent from the Detail Description, particularly when taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of these inventions.
[0029] FIG. 1 is a perspective view of a double check valve of one embodiment of the present invention;
[0030] FIG. 1A is a partial cross-sectional view of the double check valve of one embodiment of the present invention associated with a faucet;
[0031] FIG. 2 is an exploded perspective view of the double check valve shown in FIG. 1 ;
[0032] FIG. 3 is a cross-sectional view of FIG. 2 ;
[0033] FIG. 4 is a cross-sectional view of FIG. 1 showing an open flow configuration wherein the double check valve is interconnected on one end to a sill cock and opened on the other end;
[0034] FIG. 5 is a cross-sectional view of FIG. 1 showing a no flow configuration wherein the double check valve is interconnected to a sill cock and a hose;
[0035] FIG. 6 is a cross-sectional view of FIG. 1 showing a closed flow configuration wherein the double check valve is interconnected to a sill cock and a hose;
[0036] FIG. 7 is a cross-sectional view of FIG. 1 showing a double check valve in a siphon condition;
[0037] FIG. 8 is a cross-sectional view of FIG. 1 showing the double check valve exposed to back siphonage;
[0038] FIG. 9 is a cross-sectional view of FIG. 1 showing the double check valve subsequent to hose removal;
[0039] FIG. 10 is a cross-sectional view of FIG. 1 showing the double check valve during testing;
[0040] FIG. 11 is a valve cap of an alternate embodiment of the present invention; and
[0041] FIG. 12 is a valve cap of an alternate embodiment of the present invention.
[0042] To assist in the understanding of the present invention the following list of components and associated numbering found in the drawings is provided herein:
[0000]
#
Components
2
Double check valve
4
Hose
6
Inlet check valve
10
Outlet check valve
14
Valve body
18
Valve cap
22
Vent
26
Outlet
30
Inlet
34
Main seal
38
Inlet check seal
42
Threads
46
Knurls
50
Hose plunger
51
Faucet
52
Valve
54
O-ring
58
Wrench flats
62
Annular jut
66
Inlet check body
70
Hooked surface
74
Inlet check spring
78
Seat
80
Passage
82
Drain spring
86
Outlet check body
90
Hollow portion
94
Slot
98
Stop
102
Outlet check seal
104
Outlet check spring
108
Cylindrical portion
112
Protrusion
116
Hub
118
Upper surface
120
Lip
124
Stop
128
Thumb screw hole
132
Hose washer
134
Fluid
136
Ring
140
Groove
142
Inner surface
144
Bottom inner surface
150
Inlet check seal groove
154
Outlet check seal groove
[0043] It should be understood that the drawings are not necessarily to scale, although particular perspective dimensions may be relied upon to define the present invention. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.
DETAILED DESCRIPTION
[0044] Referring now to FIGS. 1-12 , a double check valve 2 is provided that includes an inlet check valve 6 and an outlet check valve 10 positioned in a valve body 14 . The valve body 14 receives a valve cap 18 that is adapted for interconnection to a sill cock of a faucet, for example. The valve body 14 also includes a plurality of vents 22 that allow for drainage of fluids from the sill cock, the inlet check valve 6 and/or outlet check valve 10 depending on the pressure gradient within the double check valve 2 . Embodiments of the present invention thus allow fluid within the sill cock to drain from the double check valve to prevent freezing. Back flow is prevented such that when pressure at an outlet 26 of the double check valve is greater than the pressure at the inlet 30 , which is in communication with a fluid supply, a main seal 34 (or diaphragm) will cooperate with an inlet check seal 38 to prevent back flow from entering the fluid supply. Excess water then will be trapped within the inlet check valve 6 or outlet check valve 10 (when a hose is interconnected to the check valve), or be drained from the vents 22 . If no hose is interconnected, trapped fluid is able to drain from the inlet and outlet valves as well.
[0045] Referring now to FIGS. 1 and 1A , a double check valve 2 of one embodiment of the present invention is shown. Preferably, the components of double check valve 2 , which will be described in further detail below, are constructed of a rigid material commonly used in the plumbing arts, such as brass. However, one skilled in the art will appreciate other suitable materials may be utilized without deviating from the scope of the invention. The double check valve 2 includes a valve body 14 that is interconnected to a valve cap 18 . The valve cap 18 is the inlet 30 of the double check valve 2 and employs a plurality of threads 42 (or a bayonet fitting), positioned on its outer and/or inner surface thereof, for interconnection to a sill cock of a faucet. The valve body 14 is preferably a cylindrical member that may include a knurled 46 outer surface that aids in the interconnection of the double check valve 2 to a fluid source. The double check valve 2 also includes a plurality of vents 22 that allow fluid and/or air to escape from the internal volume thereof. The valve body 14 also includes a plurality of threads 42 positioned about an outlet 26 of the double check valve 2 . A hose plunger 50 is selectively interconnected to the valve body 14 and is designed to coincide with the outlet 26 of the double check valve 2 when a hose 4 is interconnected thereto. FIG. 1A illustrates an embodiment of the double check valve 2 in association with a faucet 51 , also referred to as a sill cock. The faucet 51 employs a valve 52 to control the flow of water.
[0046] Referring now to FIGS. 2 and 3 , exploded views of one embodiment of the present invention are provided. An o-ring 54 is positioned within the valve cap 18 . One of skill in the art will appreciate the sealing function provided by the o-ring 54 may be performed by a flat seal or any other sealing member, or combination thereof, without departing from the scope of the invention. The valve cap 18 may also include a plurality of wrench flats 58 for securely interconnecting the double check valve 2 to a sill cock, for example. The valve cap 18 also includes an annular jut 62 that interfaces with the main seal 34 of the double check valve 2 . Between the main seal 34 and the valve body 14 resides an inlet check body 66 that includes a lower end with a protruding, or hooked surface 70 . The inlet check body 66 receives the inlet check seal 38 on one end and an inlet check spring 74 on the other end. The inlet check spring 74 rests on an internal wall, or seat 78 , provided within the valve body 14 . Alternatively, the inlet check spring 74 may contact and outlet check body 86 . The seat 78 defines a passage 80 that allows fluid to flow from the inlet check valve 6 to the outlet check valve 10 . The valve body 14 also includes threads 42 that receive a hose.
[0047] The seat 78 is also associated with a drain spring 82 that is positioned about the outlet check body 86 . The outlet check body 86 includes a hollow portion 90 having a slot 94 bounded by a stop 98 . The stop 98 cooperates with the hooked surface 70 of the inlet check body 66 , thereby operably interconnecting the inlet check body 66 and the outlet check body 86 . The outlet check body 86 includes an outlet check seal 102 and an outlet check spring 104 positioned about a cylindrical portion 108 thereof. Finally, the outlet check body 86 includes a lower protrusion 112 that is snap fit within a hub 116 of the hose plunger 50 .
[0048] An upper surface 118 of the hose plunger 50 is engaged to the drain spring 82 wherein its lower portion is adapted to contact a hose. The hose plunger 50 also includes a lip that engages an inner surface of the valve body 14 when a hose is interconnected thereto that prevents further insertion of the hose plunger 50 into the double check valve when the hose is interconnected. The hose plunger 50 of one embodiment of the present invention is a snap fit within the valve body 14 such that the lip 120 of the hose plunger 50 engages a stop 124 provided adjacent to the outlet of the valve body 14 when a hose is not interconnected to the valve body 14 .
[0049] Referring now to FIG. 4 , the double check valve 2 of one embodiment is shown during an open flow condition. Here, the valve cap 18 is shown interconnected to the valve body 14 . The valve cap 18 may include a thumbscrew aperture 128 to receive a thumbscrew that allows a user to tightly (an often permanently) affix the double check valve 2 onto a sill cock. A main seal 34 is positioned between the annular jut 62 of the valve cap 18 and the valve body 14 . Embodiments of the present invention interference fit the valve cap 18 onto the valve body 14 . One skilled in the art, however, will appreciate that the valve cap 18 may be screwed, welded or otherwise interconnected to the valve body 14 . An o-ring 54 resides within the valve cap 18 and is adapted to provide a seal between the sill cock and the valve cap 18 .
[0050] FIG. 4 shows an open flow condition wherein the supply pressure exists but no hose is interconnected to the double check valve 2 . The hose plunger 50 is biased by the drain spring 82 such that the lip 120 of the hose plunger 50 contacts the stop 124 of the valve body 14 . Supply pressure forces the main seal 34 to deflect downwardly, which blocks fluid flow through the vents 22 . This configuration is substantially different from the V-444 configuration described above. During an open flow condition with no interconnected hose, the V-444 valve will allow fluid to escape out of the vents that wastes water. Supply pressure also forces the inlet check body 66 downwardly, which compresses the inlet check spring 74 . The supply pressure in this configuration is sufficient enough to transition the outlet check seal 102 downwardly and to compress the outlet check spring 104 to separate the outlet check seal 102 and seat 78 .
[0051] Referring now to FIG. 5 , the double check valve 2 is shown with the hose 4 interconnected during a non-flow condition. In this configuration, connection of the hose 4 , which includes a hose washer 132 , forces the hose plunger 50 , and thus the hub 116 thereof, axially upward. The upward motion of the hose plunger 50 compresses the outlet check spring 104 , which forces the outlet check body 86 upwardly such that the outlet check seal 102 engages the seat 78 . Thus, interconnection of the hose 4 completely isolates the outlet check valve 10 from the inlet check valve 6 . If any back flow causing pressure rise in the hose 4 occurs, the seal between the outlet check seal 102 and its seat 78 will prevent fluid from entering the fluid source, unless those components have failed (for example, debris lodged between the outlet check seal 102 and the seat 7 that allows for fluid infiltration). Since there is no flow from the fluid supply, the inlet check spring 74 and the inlet check body 66 will be positioned upwardly so that the inlet check seal 38 is engaged to the main seal 34 . Thus, the inlet check valve 6 is isolated from the valve cap 18 that is interconnected to the fluid source. The inlet check valve 6 is, however, in fluidic communication with the vents 22 wherein any fluid pressurized by the transitioning outlet check body 86 will exit therethrough.
[0052] Referring now to FIG. 6 , a closed flow condition is shown wherein the hose (not shown) is interconnected to the valve body 14 and the fluid supply has been opened. Here, supply pressure deflects the inner diameter of the main seal 34 downwardly such that the main seal 34 blocks the vents 22 . Supply pressure also acts on the inlet check seal 38 to force it downwardly which compresses the inlet check spring 74 . As described above, since the hose is interconnected to the valve body 14 , the hose plunger and the outlet check body 86 will be shifted upwardly. The inlet check body, however, will contact the outlet check body 86 and force it downwardly, thereby counteracting the outlet check seal and opening the passage 80 between the inlet check valve 6 and the outlet check valve 10 .
[0053] Referring now to FIG. 7 , a non-flow configuration wherein a siphon has occurred is shown subsequent to the removal of supply pressure with the hose (not shown) interconnected to the valve body 14 . A siphon condition may be caused when gravity-induced flow of the water in the hose pulls a vacuum after the supply pressure has been shut off. The vacuum within the inlet check valve 6 and the outlet check valve causes the main seal 34 and the outlet check body 86 to deflect towards the outlet of the double check valve 2 . The outlet check body 86 translates downwardly until it contacts the hub 116 of the hose plunger 50 . The inlet check spring 74 pushes the inlet check body 66 upwardly. However, the hooked surface 70 of the inlet check body 66 will engage with the stop 98 of the outlet check body 86 , thereby limiting the range of motion of the inlet check body 66 and preventing the inlet check seal 38 from closing the main seal 34 . That is, during a siphoning condition, the inlet check seal 38 will not be able to fully flatten the main seal 34 . As a result, the deflected main seal 34 will be prevented from completely blocking the vents 22 . A path between the inlet check seal 38 and the internal surface of the inlet check valve 6 will allow air from the outside of the double check valve 2 to enter through the vents 22 to break the vacuum which allows the outlet check spring 104 to relax and engage the outlet check valve 10 on the seat 78 . This in turn will allow the inlet check body 66 to transition upwardly to engage the inlet check seal 38 onto the main seal 34 to isolate the inlet check valve 6 and the outlet check valve 10 from the valve cap 18 as shown in FIG. 5 .
[0054] Referring now to FIG. 8 , a back siphonage situation is shown. Here, the hose (not shown) is interconnected to the valve body 14 and a vacuum has occurred at fluid supply that could cause contaminated fluid from the hose or double check valve 2 to enter the fluid supply. In operation, the hose forces the hose plunger 50 upwardly that compresses the drain spring 82 . The hub 116 of the hose plunger 50 also moves upwardly and forces, via the outlet check spring 104 , the outlet valve check body 86 to move upwardly so that outlet check seal 102 engages the seat 78 . The vacuum in the valve cap 18 pulls the inlet check seal upwardly to engage the main seal 34 . Thus the outlet check valve 10 is isolated from the inlet check valve 6 and the inlet check valve 6 is isolated from the cap valve 18 which is interconnected to the fluid supply, and no fluid from the hose and/or the double check valve can enter the fluid supply.
[0055] Referring now to FIG. 9 , draining of the double check valve 2 is illustrated. After the hose is removed, the drain spring 82 expands and forces the hose plunger 50 downwardly such that the lip 120 of the hose plunger 50 contacts the stop 124 of the valve body 14 . The hub 116 of the hose plunger 50 will also contact the protrusion 112 of the outlet check body 86 and pull the outlet valve body 86 downwardly, which removes the outlet check seal 102 from the outlet check seat 78 . The stop 98 of the outlet check body 86 will contact the hooked surface 70 of the inlet check body 66 and pull the inlet check seal 38 from the main seal 34 . Thus, a free flow path from the inlet check valve 6 into the outlet check valve 10 and out of the hose plunger 50 is provided. Water in the sill cock will also be able to flow through the valve cap 18 and through the inlet check valve 6 , the outlet check valve 10 and out of the hose plunger 50 . Fluid may also drain through the plurality of vents provided.
[0056] Referring now to FIG. 10 , the double check valve 2 is shown during a test. More specifically, it is one aspect of the present invention that the double check valve 2 of embodiments of the present invention can be easily tested in the field to ensure that it is in proper working condition. Here, the hose (not shown) is interconnected to the threads 42 of the valve body 14 that forces the hose plunger 50 upwardly and compresses the drain spring 82 . The hub 116 is also forced upwardly which compresses the outlet check spring 104 and forces the outlet check seal 102 against seat 78 . If the double check valve 2 is working properly the outlet check valve 10 should be isolated from the vents 22 . Fluid 134 is then added via the hose and into the outlet 26 of the double check valve 2 . If the integrity of the outlet check valve 102 and the seat 78 are adequate, no fluid will enter the inlet check valve 6 . Conversely, if the integrity between the outlet check seal 102 and the seat 78 is broken, fluid 134 will fill the inlet check valve 6 , and will exit from the plurality of vents 22 . The inlet check spring 74 will force the inlet check body 66 upwardly to place the inlet check seal 38 in contact with the main seal 34 to prevent any fluid from entering the water source during this test.
[0057] Referring now to FIGS. 11 and 12 , valve caps 18 of alternate embodiments of the present invention are provided. Here, the annular jut 62 , which interfaces with the main seal 34 and ring 136 , which interfaces with a groove 140 provided on the valve body 14 are substantially the same as those described above. However, the inlet portion 30 of the valve cap 18 includes a plurality of exterior threads 42 for threading onto sill cocks and have inwardly threads 42 . Inspection of FIGS. 11 and 12 will show that the inlets 30 of these valve caps 18 are of different diameters, thereby succinctly illustrating the scalability of the present invention.
[0058] One of skill in the art will appreciate that the valve described and shown herein may be interconnected to the sill cock via a bendable or telescoping member to provide the ability to selectively locate the valve. Alternatively, or in addition, valves as described may possess telescoping functionality as shown in U.S. Design Pat. No. D491,253 to Hansle. The valve may also employ a timer, flow regulation capabilities, etc. to control the flow of fluid therefrom. The valve may employ more than one outlet, which each may include valving as described, and may employ a combination of materials as described in Tripp. Further, the valve may be directly integrated into the sill cock instead of interconnected thereto. The system described herein may include a visual or audible alarm to notify the instance of a valve failure.
[0059] While various embodiments of the present invention have been described in detail, it will be apparent that modifications and alterations of those embodiments are also intended to be encompassed by this description. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims. For example, aspects of inventions disclosed in U.S. Patent and Published Patent Application Nos. 5,632,303, 5,590,679, 7,100,637, 5,813,428, and 20060196561, all of which are incorporated herein by this reference, which generally concern back flow prevention, may be incorporated into embodiments of the present invention. Aspects of inventions disclosed in U.S. Pat. Nos. 5,701,925 and 5,246,028, all of which are incorporated herein by this reference, which generally concern sanitary hydrants, may be incorporated into embodiments of the present invention. Aspects of inventions disclosed in U.S. Pat. Nos. 6,532,986, 6,805,154, 6,135,359, 6,769,446, 6,830,063, RE39235, 6,206,039, 6,883,534, 6,857,442 and 6,142,172, all of which are incorporated herein by this reference, which generally concern freeze-proof hydrants, may be incorporated into embodiments of the present invention. Aspects of inventions disclosed in U.S. Patent and Published Patent Application Nos. D521113, D470915, 7,234,732, 7,059,937, 6,679,473, 6,431,204, 7,111,875, D482431, 6,631,623, 6,948,518, 6,948,509, 20070044840, 20070044838, 20070039649, 20060254647 and 20060108804, all of which are incorporated herein by this reference, which generally concern general hydrant technology, may be incorporated into embodiments of the present invention. | A double check valve is provided that includes an in-line inlet check valve and an outlet check valve that cooperate to prevent back flow of fluid through the valve. The check valve also includes at least one vent that allows for fluid trapped within the check valve to drain, thereby preventing freezing of the check valve and hydrant to which it is interconnected. The check valve provided omits many superfluous components and thus is smaller and easier to install than check valves of the prior art. | 4 |
This is a divisional of application Ser. No. 08/141,353 filed Oct. 26, 1993.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus and a method for controlling a sewing machine driven by a drive such as a motor.
2. Description of the Background Art
FIG. 62 is an arrangement diagram showing a conventional sewing machine controlling apparatus disclosed in Japanese Laid-Open Patent Publication No. HEI3-14479, for example. In this drawing, the numeral 1 indicates a sewing machine, 2 denotes a motor, 3 designates a needle position detector acting as needle position detection means to detect the needle position of the sewing machine 1, 4 represents a machine pulley, 5 indicates a motor pulley, and 6 represents a belt fitted over the machine pulley 4 and the motor pulley 5 to transmit the rotation of the motor 2 to the sewing machine 1. 7 designates a stator of the motor 2, 8 denotes a rotor of the motor 2, and 9 indicates a brake for stopping the motor 2. 10 denotes a foot pedal used to operate the sewing machine 1, 11 represents a lever unit which detects the operation of the foot pedal 10, 12 designates a sewing machine control circuit serving as machine control means to control the orientation, automatic thread trimming, backtacking, etc., of a machine needle, and 13 indicates a motor speed control circuit acting as motor speed control means to control the motor 2 and the brake 9, thereby providing desired stitching speed under the operation command of the foot pedal 10 and others.
S1 indicates a stitching start signal, S2 designates a thread trimmer start signal, S3 represents a needle UP signal, VC denotes a speed command signal, SRT indicates a run signal, BK represents a brake signal, LLKO denotes a low-speed command signal, IMCO designates a middle-speed command signal, and R indicates a reverse rotation signal. It is to be understood that the stitching start signal S1 and the thread trimmer start signal S2 are input signals from the lever unit 11 to the sewing machine control circuit 12, the speed command signal VC is an input signal from the lever unit 11 to the motor speed control circuit 13, and the run signal SRT, the brake signal BK, the low-speed command signal LLKO, the middle-speed command signal IMCO and the reverse rotation signal R are command signals from the sewing machine control circuit 12 to the motor speed control circuit 13.
The operation of the conventional apparatus arranged as described above will now be described. An operation timing chart is shown in FIG. 63. Toeing down the foot pedal 10 switches the stitching start signal S1 on, outputs the run signal SRT from the sewing machine control circuit 12 to the motor speed control circuit 13, excites the stator 7 of the motor 2, and rotates the rotor 8 to drive the sewing machine 1 via the motor pulley 5, the belt 6 and the machine pulley 4.
Then, by changing the toe-down amount of the foot pedal 10, the voltage, current and frequency applied by the motor speed control circuit 13 to the stator 7 of the motor 2 are under the control of the speed command signal VC of the lever unit 11 and the position detection signal FG of the needle position detector 3 fitted to the sewing machine 1 to control the speed of the sewing machine 1 to a desired value according to the toe-down amount of the foot pedal 10.
When the foot pedal 10 is returned to a neutral position, the low-speed command signal LLKO for positioning is output by the sewing machine control circuit 12, and simultaneously, the needle UP or DOWN of the sewing machine 1 is detected under the control of the position detection signal (UP or DOWN) of the needle position detector 3, and the magnetic brake 9 is excited to stop the sewing machine 1.
Further, when the foot pedal 10 is heeled, i.e., is turned in the direction opposite to the tow-down direction, the thread trimmer start signal S2 is switched on, the machine control circuit 12 outputs the run signal SRT and the middle-speed command signal IMCO to carry out end backtacking. After the end backtacking is finished, the middle-speed command signal IMCO is switched off, the low-speed command signal LLKO is switched on, and a thread trimmer output is provided to trim the machine threads.
The needle position detector 3 outputs the needle UP position signal UP and needle DOWN position signal DN which represent the positions of the machine needle. The outputs of this needle position detector 3 and the lever unit 11 are provided to the sewing machine control circuit 12 which exercises the speed control of the motor 2 and the control of various solenoids (not shown) of the sewing machine 1.
The motor speed control circuit 13, which contains an inverter, switches between phases to reverse the motor 2 for the following reason. In the automatic thread trimmer mechanism of the sewing machine 1, since the machine threads are typically trimmed using the rotation of the machine spindle after the machine needle has moved away from a material to be sewn, risen, and reached the highest position or a top dead center, the position where the sewing machine is braked to a stop after machine thread trimming and needle position detection is considerably lower than said top dead center. Hence, when the machine needle stops at this low position if the sewing machine rotates in a forward direction only, the material moved in/out, for example, is caught by the machine needle. To prevent this, the pedal 10 is operated to perform thread trimmer operation to cut the machine threads, the needle position is then detected, and the sewing machine is braked to a stop, whereby if the machine needle stops at the low position, the motor 2 is further reversed to return the machine needle nearer to the top dead center and stop there, and therefore, even a heavy material to be stitched is not caught by the machine needle. It is to be understood that when the machine needle is not at the UP position, the needle UP signal S3 is given to run the sewing machine forward to rotate the machine needle to the UP position. When the machine needle is not at the UP position at power-on, the sewing machine is run forward to rotate the machine needle to the UP position if the needle UP signal S3 is not provided.
The operation of the sewing machine control circuit 12 will now be described in accordance with FIG. 64. The sewing machine control circuit 12 consists of microprocessor circuits (not shown) such as a CPU, ROM, RAM and I/O ports, and is under the control of software. When the pedal 10 is toed down to provide the stitching start signal S1 to a run signal input circuit 301, the run signal SRT is output from a rotation/stop command circuit 305 to the motor speed control circuit 13 via a run control circuit 300 to start the motor 2 running.
Subsequently, when the pedal 10 is returned to the neutral position, the run control circuit 300 outputs the low-speed command signal LLKO to the motor speed control circuit 13 via a speed command circuit 304, whereby the motor 2 is controlled to run at low speed.
Detecting that the sewing machine 1 has reached or exceeded a predetermined speed via a needle UP/DOWN position input circuit 302 according to the pulse width of the needle DOWN position signal DN and that the needle DOWN position signal DN has entered, the run control circuit 300 switches the run signal SRT off and switches the brake signal BK on for a given period of time via the rotation/stop command circuit 305.
Then, when the pedal 10 is heeled to switch on the thread trimmer start signal S2, the middle-speed command signal IMCO is output via the run control circuit 300 and the speed command circuit 304, whereby the motor 2 runs at middle speed, backtacking is performed, the middle-speed command signal IMCO is then switched off, and further the low-speed command signal LLKO is switched on, causing the motor 2 to run at low speed. When the needle DOWN position signal DN is switched on, the thread trimmer output T is provided by a solenoid control circuit 303 to conduct automatic thread trimming of the sewing machine 1. When the needle UP position signal UP is detected, the run signal SRT is switched off, and the brake signal BK is switched on for a given length of time via the rotation/stop command circuit 305, the solenoid control circuit 303 switches the thread trimmer output T off and a wiper output W on for a given period of time, stopping the sewing machine at a thread take-up lever top dead center. It is to be understood that the thread take-up lever top dead center indicates that the thread take-up lever (not shown), which feeds the needle thread of the sewing machine 1, is at the top position, where the thread has been fed the most and cannot be removed from the machine needle at the start of next stitching.
After the brake signal BK has been excited for a given length of time, the reverse rotation signal R is switched on and the run signal SRT is switched on to reverse the motor 2. When the needle top dead center is detected using the needle UP position signal UP, the run signal SRT is switched off and the brake signal BK is switched on for a given period of time to stop the sewing machine at the needle top dead center, and the brake signal BK is switched off. Subsequently, when the thread trimmer start signal S2 is on, the solenoid control circuit 303 outputs a presser foot UP output FU to raise the presser foot (not shown).
FIG. 65 shows an example of needle bar motion, wherein a vertical axis represents the height of the machine needle with respect to a throat plate surface (0 mm) and a horizontal axis represents the rotary angle of an arm shaft (not shown) of the sewing machine 1. As the arm shaft of the sewing machine 1 rotates, the height of the machine needle changes.
At the position of 0 degrees in FIG. 65, for example, the machine needle is at the top dead center and is out of the material, whereby the material can be removed. At the position of 180 degrees, the machine needle is at the bottom dead center. When it is desired to change the direction of the material to change the stitching direction, the machine needle stopping at this position allows the material to be turned without being offset.
At the position of 90 degrees, the machine needle sticks in the material. At the position of 100 degrees, the machine needle is located at the position of the throat plate (not shown) where the material is placed. The machine needle comes out of the throat plate surface at the position of 260 degrees and comes out of the material at the position of 270 degrees.
The UP position signal UP of the machine needle is switched on slightly in front of the thread take-up lever top dead center (at 40 degrees) and the DOWN position signal DN of the machine needle is switched on slightly in front of the needle DOWN position (at 160 degrees). The machine needle is oriented to a stop at the needle UP or DOWN position under the control of these two signals.
SUMMARY OF THE INVENTION
In the conventional sewing machine controlling apparatus arranged as described above, when the sewing machine is started with the machine needle stopping at the UP position after thread trimming or the like, the sewing machine 1 is not high in speed and does not have the force of inertia when the machine needle pierces the material as compared to the start of operation with the machine needle at the DOWN position, whereby the machine needle does not pierce a heavy material, a leather product or the like.
For this reason, the machine pulley is reversed by hand and brought near to the needle DOWN position before operation is started, whereby the material must be held by one hand at the start of stitching, workability is low, and it is dangerous to touch the machine pulley.
When the material to be sewn is a leather product, for example, in which large holes are made in seams, the holes, if positioned inaccurately from the edges of the leather, will result in unneat seams and low quality. To avoid this, the machine pulley is turned by hand to move the machine needle to a position immediately before the material, the positions of holes made by the machine needle in the leather product are determined, and operation is then started, whereby the material must be held by one hand, resulting in poor workability. In addition, if the pedal is accidentally depressed by foot during the hand-turning of the machine pulley, the sewing machine may rotate and the operator hand will be caught between the machine pulley and the belt, etc., involving danger of injury.
Also, if the machine needle is moved to the position immediately before the material once, the position where the machine needle should stick in the material cannot always be reached at one time and the machine pulley must be hand-rotated in the forward or reverse direction several times to set the position, further reducing workability.
Also, when a switch is turned on by hand to start stitching, the hand holding the material is used to turn the switch on, whereby the material moves and stitching start must be repeated many times.
Also, in jogging angle setting, a jogging angle is set by angle setting means, a jogging signal is entered to rotate the sewing machine by the jogging angle, a distance between the material and the machine needle is checked, and if the distance is too short or too long, the angle setting must be repeated many times.
Also, when the material to be stitched has been changed, the angle is re-set, the jogging signal is entered to make a rotation of the jogging angle, the distance between the material and the machine needle is checked, and if the distance is too short or too long, the angle setting must be repeated many times.
It is accordingly a first object of the present invention to overcome the above enumerated difficulties by providing a safe sewing machine controlling apparatus and method which allow the machine needle to be stopped immediately before a material by the rotation of a drive, such as a motor, to permit pre-microadjustment of the position where the machine needle sticks in the material and which allow the sewing machine to be reversed to return the machine needle to pierce even a heavy material.
A second object is to provide a sewing machine controlling apparatus and method which permit reverse-rotation needle UP for use with a blind stitching machine and which also permit reverse-rotation needle UP after backtacking when it is desired to do backtacking.
A third object is to provide a sewing machine controlling apparatus and method which keep any excess stitches from being put in a material or a finger from being stuck during needle UP operation.
A fourth object is to provide a sewing machine controlling apparatus and method which allow a next thread trimmer signal to be entered when the machine needle has stopped at the UP position and the force of piercing a material to be increased at the start of operation to pierce even a heavy material without requiring the machine pulley to be rotated by hand.
A fifth object is to provide a sewing machine controlling apparatus and method which allow a next thread trimmer start signal to be entered after thread trimming and the force of piercing a material to be increased at the start of operation to pierce even a heavy material without requiring the machine pulley to be rotated by hand.
A sixth object is to provide a sewing machine controlling apparatus and method which offer ease of determining the position of sticking the machine needle without the machine pulley being rotated by hand after thread trimming, whereby excellent workability is increased, stitching time is reduced, and the machine pulley need not be touched by hand.
A seventh object is to provide a sewing machine controlling apparatus and method which keep a material from being offset in pressing a switch by hand to avoid stitching start from being repeated many times, whereby workability is increased and stitching time is reduced.
An eighth object is to provide a sewing machine controlling apparatus and method which facilitate jogging angle setting which must be made to change the stopping position of the machine needle immediately before a new material different in thickness from the old one.
As described herein, according to the first feature of the invention, the jogging angle can be set and the machine needle can be stopped immediately before the material by the sewing machine drive so that the machine pulley need not be hand-turned, whereby safety is ensured and working efficiency is improved.
Also, according to a second feature of the invention, the application of the jogging signal allows the machine needle to be rotated in the reverse direction to a position away from the material, whereby the stitching start speed of piercing the next material is increased and the force of inertia is large enough to prevent the needle from being stopped, without piercing the material, and working efficiency is improved. Also, the torque of the sewing machine drive may be small, resulting in a low-priced apparatus.
Also, according to a third feature of the invention, the application of the jogging signal alternates forward rotation and reverse rotation, whereby the position where the material is pierced with the machine needle can be re-adjusted easily.
Also, according to the fourth embodiment of the invention, the application of the stitching start signal after the forward rotation of the jogging angle automatically rotates the sewing machine in the reverse direction once, then in the forward direction, whereby the force of piercing the material can be provided and the jogging signal need not be applied to improve working efficiency.
Also, according to the fifth embodiment of the invention, the stitching start signal causes the sewing machine to rotate in the reverse direction, come to a stop once, then rotate in the forward direction, whereby skip stitches or the like caused by the unevenly fed thread when the reverse rotation shifts directly to the forward direction can be prevented because the sewing machine rotates forward after the thread is fed evenly.
Also, according to the sixth embodiment of the invention, if the sewing machine does not rotate forward by the jogging angle when the jogging signal has been applied, the stitching start signal causes the sewing machine to start with forward rotation, not with reverse rotation, whereby working efficiency is improved.
Also, according to the seventh embodiment of the invention, after operating under the control of the stitching start signal, the sewing machine is always rotated forward by the jogging angle in the forward direction under the control of the jogging signal, whereby working efficiency is improved.
Also, according to the eighth embodiment of the invention, reverse-rotation needle UP can be achieved when the direction of the material is changed on the blind stitching machine, whereby the machine pulley need not be hand-rotated to improve working efficiency.
Also, according to the ninth embodiment of the invention, the reverse rotation signal permits reverse-rotation needle UP and the thread trimmer start signal allows end backtacking and reverse-rotation needle UP, whereby working efficiency is improved.
Also, according to the tenth embodiment of the invention, reverse-rotation needle UP is performed before the material is pierced with the machine needle and forward-rotation needle UP is done after the material has been pierced, whereby the material is not seamed or bored unlike the conventional sewing machine which always rotated forward. Also, since the machine needle always moves upward, there is no danger that the hand is pierced with the machine needle if it is under the machine needle, ensuring safety.
According to the eleventh embodiment of the invention, the material is not seamed or bored unlike the conventional sewing machine which automatically raised the needle in the forward direction at power-on. Also, the finger is not pierced.
Also, according to the twelfth embodiment of the invention, since the sewing machine is designed to rotate the jogging angle only after thread trimmer operation is performed, the needle is usually at a stop at the DOWN position before thread trimming, and if the jogging signal switch is accidentally touched, the sewing machine does not rotate when the needle need not stop immediately before the material, and if the sewing machine is jogged carelessly, for example, the machine needle is kept from coming out of the DOWN position and stopping at a position outside the material, the material does not offset when its direction is changed, neat seams are provided, and unnecessary motion is not made, whereby time can be reduced and working efficiency is improved.
Also according to the thirteenth to the fifteenth embodiments, the application of the stitching start signal at the needle UP position stop time or after thread trimming causes the machine needle to rotate in the reverse direction by the reverse rotation angle set to the reverse rotation angle setting means, then to rotate in the forward direction, whereby the speed at the time of piercing the material is increased enough to provide the force of inertia, thereby preventing the needle from stopping without piercing the material. Also, the motor torque may be small, resulting in a low-priced apparatus.
Also, according to the sixteenth embodiment, the jogging angle can be set and the machine needle can be stopped immediately before the material by the sewing machine drive, whereby the machine pulley need not be hand-turned to ensure safety and improve working efficiency.
Also, according to the seventeenth embodiment of the invention, when it is desired to change the material position or the material after the machine needle has been lowered to the position immediately before the material once, merely entering the jogging signal causes the machine needle to rotate reversely to return to the top, whereby it is easy to shift the material position or change the material.
Also, according to the eighteenth embodiment of the invention, the wiper, if any, makes contact with the machine needle when the thread is wiped by the wiper after the machine needle has stopped immediately before the material, and to prevent this, the sewing machine is stopped once at the needle UP position, the wiper is operated, and the sewing machine is rotated the jogging angle again to stop the machine needle at the position immediately before the material, whereby the wiper does not come into contact with the machine needle and the needle fall position for the next material can be adjusted easily.
Also, according to the nineteenth embodiment of the invention, the machine pulley is hand-turned until it actually reaches the stop position immediately before the material and that position is stored, whereby angle setting need not be repeated many times.
Also, according to the twentieth embodiment of the invention, the number of times when the reverse rotation signal switch is pressed is decreased to reduce working time.
Also, according to the twenty first embodiment of the invention, the reverse rotation signal switch can be omitted, resulting in a low-priced apparatus.
Also, according to the twenty second embodiment of the invention, the sewing machine is actually rotated under the control of the ultra-low speed signal, with the machine pulley untouched, to match the point of the machine needle with the position immediately before the material, whereby safety is ensured, adjustment need not be made many times, and working time is reduced.
Also, according to the twenty third embodiment of the invention, the sewing machine running at ultra-low speed can be returned under the control of the angle storage signal if it has gone beyond the destination, whereby the time for setting the position immediately before the material is reduced.
Also, according to the twenty fourth embodiment of the invention, once the angle between the material and the machine needle has been set, the stop position immediately before the material need not be re-adjusted if the thickness of the material changes, whereby working time can be reduced.
Also, according to the twenty fifth embodiment of the invention, the torque which peaks within the position where the material is pierced with the machine needle is removed as noise, whereby the material surface position can be detected reliably.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an arrangement diagram of a sewing machine controlling apparatus illustrating an embodiment of a first embodiment of the invention.
FIG. 2 is a detail drawing of a sewing machine control circuit shown in FIG. 1.
FIG. 3 is a flowchart illustrating the operation of the first embodiment of the invention.
FIG. 4 is a timing chart of the first embodiment of the invention.
FIG. 5 is a flowchart illustrating the operation of a second embodiment of the invention.
FIG. 6 is a timing chart of the second embodiment of the invention.
FIG. 7 is a timing chart of a third embodiment of the invention.
FIG. 8 is a flowchart illustrating the operation of a fourth embodiment of the invention.
FIG. 9 is a timing chart of the fourth embodiment of the invention.
FIG. 10 is a flowchart illustrating the operation of a fifth embodiment of the invention.
FIG. 11 is a timing chart of the fifth embodiment of the invention.
FIG. 12 is a timing chart of a sixth embodiment of the invention.
FIG. 13 is a timing chart of a seventh embodiment of the invention.
FIG. 14 is an arrangement diagram of a sewing machine controlling apparatus illustrating an eighth embodiment of the invention.
FIG. 15 is a diagram showing a stitching pattern of the eighth embodiment of the invention.
FIG. 16 is a detail drawing of a sewing machine control circuit shown in FIG. 14.
FIG. 17 is a flowchart illustrating the operation of the eighth embodiment of the invention.
FIG. 18 is a timing chart of the eighth embodiment of the invention.
FIG. 19 is a flowchart illustrating the operation of a ninth embodiment of the invention.
FIG. 20 is a timing chart of the ninth embodiment of the invention.
FIG. 21 is an arrangement diagram of a sewing machine controlling apparatus illustrating an embodiment of a tenth embodiment of the invention.
FIG. 22 is a detail drawing of a sewing machine control circuit shown in FIG. 21.
FIG. 23 is a flowchart illustrating the operation of the tenth embodiment of the invention.
FIG. 24 is a needle bar motion diagram of the tenth embodiment of the invention.
FIG. 25 is a timing chart at the time of reverse-rotation needle UP in the tenth embodiment of the invention.
FIG. 26 is a timing chart at the time of forward-rotation needle UP in the tenth embodiment of the invention.
FIG. 27 is a flowchart illustrating the operation of an eleventh embodiment of the invention.
FIG. 28 is a flowchart illustrating the operation of a twelfth embodiment of the invention.
FIG. 29 is an arrangement diagram of a sewing machine controlling apparatus illustrating a thirteenth embodiment of the invention.
FIG. 30 is a detail drawing of a sewing machine control circuit shown in FIG. 29.
FIG. 31 is a timing chart of the thirteenth embodiment of the invention.
FIG. 32 is a flowchart illustrating the operation of the thirteenth embodiment of the invention.
FIG. 33 is a flowchart illustrating the operation of a fourteenth embodiment of the invention.
FIG. 34 is an arrangement diagram of a sewing machine controlling apparatus illustrating a fifteenth embodiment of the invention.
FIG. 35 is a detail drawing of a sewing machine control circuit shown in FIG. 34.
FIG. 36 is a timing chart of the fifteenth embodiment of the invention.
FIG. 37 is a flowchart illustrating the operation of the fifteenth embodiment of the invention.
FIG. 38 is a timing chart of a sixteenth and seventeenth embodiment of the invention.
FIG. 39 is a flowchart illustrating the operation of the sixteenth and seventeenth embodiment of the invention.
FIG. 40 is a timing chart of the eighteenth embodiment of the invention.
FIG. 41 is a flowchart illustrating the operation of the eighteenth embodiment of the invention.
FIG. 42 is an arrangement diagram of a sewing machine controlling apparatus illustrating an nineteenth embodiment of the invention.
FIG. 43 is a detail drawing of a sewing machine control circuit shown in FIG. 42.
FIG. 44 is a flowchart illustrating the operation of the nineteenth embodiment of the invention.
FIG. 45 is a timing chart of the nineteenth embodiment of the invention.
FIG. 46 is a flowchart illustrating the operation of a twentieth embodiment of the invention.
FIG. 47 is a timing chart of the twentieth embodiment of the invention.
FIG. 48 is a flowchart illustrating the operation of a twenty-first embodiment of the invention.
FIG. 49 is a timing chart at a time when the sewing machine pulley of the twenty-first embodiment of the invention has been rotated a given angle or more.
FIG. 50 is a timing chart at a time when the sewing machine pulley of the twenty-first embodiment of the invention has been rotated less than the given angle.
FIG. 51 is an arrangement diagram of a sewing machine controlling apparatus illustrating a twenty-second embodiment of the invention.
FIG. 52 is a detail drawing of a sewing machine control circuit shown in FIG. 51.
FIG. 53 is a flowchart illustrating the operation of the twenty-second embodiment of the invention.
FIG. 54 is a timing chart of the twenty-second embodiment of the invention.
FIG. 55 is a flowchart illustrating the operation of a twenty-third embodiment of the invention.
FIG. 56 is a timing chart of the twenty-third embodiment of the invention.
FIG. 57 is an arrangement diagram of a sewing machine controlling apparatus illustrating a twenty-fourth embodiment of the invention.
FIG. 58 is a detail drawing of a sewing machine control circuit shown in FIG. 57.
FIG. 59 is a flowchart illustrating the operation of the twenty-fourth embodiment of the invention.
FIG. 60 is a timing chart of a twenty-fifth embodiment of the invention.
FIG. 61 is a flowchart illustrating the operation of the twenty fifth embodiment of the invention.
FIG. 62 is an arrangement diagram of a conventional sewing machine controlling apparatus.
FIG. 63 is a timing chart of conventional operation.
FIG. 64 is a detail drawing of a sewing machine control circuit shown in FIG. 62.
FIG. 65 is a diagram showing an example of the needle bar motion of the sewing machine.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of the invention will now be described with reference to the appended drawings. FIG. 1 is an arrangement diagram of a sewing machine controlling apparatus concerned with the present embodiment, wherein the numeral 30 indicates a jogging angle setting circuit acting as jogging angle setting means, 520 represents a sewing machine control circuit detailed in FIG. 2, and S4 designates a jogging signal entered into the sewing machine control circuit 520. A position detection signal FG from the needle position detector 3 is designed to be entered into the motor speed control circuit 13 and also into the sewing machine control circuit 520. It is to be noted that the other parts are identical to those of the conventional example in FIG. 62 and will not be described.
The operation of the apparatus according to the present embodiment will now be described. When the jogging angle is set to 90 degrees, for example, by the jogging angle setting circuit 30 and the jogging signal S4 is applied to the sewing machine control circuit 520, the sewing machine 1 runs in the forward direction by the set jogging angle and the machine needle stops immediately before the material.
When the jogging signal S4 is switched on, the run signal SRT is switched on via the run signal input circuit 301 in FIG. 2, then via the run control circuit 330 and the rotation/stop command circuit 305 to start the motor 2 running forward. At this time, the jogging angle set in the angle setting circuit 30 is compared by an angle comparison circuit 311 with the rotary angle of the sewing machine 1 entered to the needle position input circuit 312 from the position detection signal FG given by the needle position detector 3. If the rotary angle has reached or exceeded the set jogging angle, the run control circuit 330 causes the rotation/stop command circuit 305 to switch the run signal SRT off and the brake signal BK on, stopping the sewing machine 1 at the rotary position of the set jogging angle.
The above operation will be described in accordance with a flowchart in FIG. 3. At power-on or after thread trimming, a flag S4ONF for storing the ON of the jogging signal S4 has been cleared to 0, the run signal SRT to OFF, and the brake signal BK to OFF.
Starting at step 40, the processing advances from step 41 to step 42 because the flag S4ONF is still 0 at step 41. Until the jogging signal S4 turns from OFF to ON at step 42, the run signal SRT remains OFF at step 43 and the sewing machine is kept stopped. When the jogging signal S4 has turned from OFF to ON at step 42, the sequence progresses to step 44, then to step 45 since a brake timer is not on. Here, the flag S4ONF for storing the ON of the jogging signal S4 is set to 1. Also, since operation is started, the run signal SRT is switched on. At step 46, it is judged whether the jogging angle has been reached or not. If it has not been reached, the process ends and the sewing machine 1 continues rotating, awaiting the next cycle through the step 40 START (not shown).
If it has been judged at step 46 that the sewing machine 1 has rotated the jogging angle, the run signal SRT is switched off at step 47, the brake signal BK is switched on at step 48, and the brake timer is set for the brake output time at step 49. The processing returns from the END at step 55 to the START at step 40. Since the flag S4ONF is now 1, the processing shifts to step 44. As the brake timer is on at step 44, the sequence moves to step 50 where the brake timer is counted up. At step 51, it is judged whether the brake timer has exceeded a given time or not. If the brake timer has not expired, the brake signal BK is switched on at step 52. If the brake timer has expired, the brake signal BK is switched off at step 53 and the flag S4ONF is cleared to 0 at step 54. The timing chart of this operation is shown in FIG. 4.
When the jogging signal S4 is switched on, the run signal SRT is switched on and the sewing machine 1 starts rotating forward because the reverse rotation signal R is 0. It is detected that the sewing machine 1 has rotated the set jogging angle (e.g., 90 degrees) using the position detection signal FG of the needle position detector 30, the run signal SRT is switched off, and the brake signal BK is switched on to stop the machine needle at a position immediately before the material. The brake signal BK is switched off in a given time. An operator moves the material at this position to determine the position of the material to be pierced with the machine needle. When the position of the material to be pierced with the machine needle has been confirmed, the operator toes down the foot pedal 10 to enter the stitching start signal S1 into the sewing machine control circuit 520, whereby the run signal SRT is output to the motor speed control circuit 13 to cause the sewing machine 1 to perform predetermined operations as in the aforementioned conventional example. When thread trimmer operation is required, the foot pedal 10 is heeled to cause the sewing machine 1 to carry out operations as in the above-mentioned conventional example to cut the machine threads. It is to be noted that the apparatus in the present embodiment, which allows the jogging angle to be set and the needle to be stopped immediately before a fabric by the motor 2, whereby the machine pulley 4 need not be rotated by hand, safety is ensured, and working efficiency is improved.
A second embodiment of the invention will now be described. The operation of the sewing machine control circuit 520, which achieves the operation of the apparatus in the present embodiment, will be described in accordance with a flowchart shown in FIG. 5. It is to be understood that the arrangement and operation of the machine controlling apparatus are identical to those of the first embodiment (Embodiment 1) with the exception of the operation of this sewing machine control circuit and will not be described.
At power-on or after thread trimming, the flag S4ONF for storing the ON of the jogging signal S4 has been cleared to 0, a reverse rotation flag RFLAG to 0, the run signal SRT to OFF, the brake signal BK to OFF, and the reverse rotation signal R to OFF.
Starting at step 40, the processing advances from step 41 to step 42 because the flag S4ONF is still 0 at step 41. Until the jogging signal S4 turns from OFF to ON at step 42, the run signal SRT remains OFF at step 43 and the sewing machine is kept stopped. When the jogging signal S4 has turned from OFF to ON at step 42, the sequence progresses to step 60. When the reverse rotation flag RFLAG is 0, the processing proceeds to step 61, where the reverse rotation signal R is set to OFF and the sewing machine rotates forward. When the reverse rotation flag RFLAG is 1 at step 60, the sequence advances to step 62, where the reverse rotation signal R is set to ON and the sewing machine rotates reversely.
Next, the processing progresses to step 44, then to step 45 since the brake timer is not on. At step 45, the flag S4ONF is set to 1. Once the jogging signal S4 is entered, it is held until the sewing machine rotates the jogging angle.
Also, since the run signal SRT is switched on at step 45, the sewing machine 1 starts rotating. At step 46, it is judged whether the sewing machine 1 has rotated the set jogging angle or not using the position detection signal FG of the needle position detector 3 of the sewing machine 1. If it has not rotated the set angle, the sewing machine 1 continues rotating. If it has rotated the set jogging angle, the run signal SRT is switched off at step 47, the brake signal BK is switched on, and the brake timer is started. Subsequently, in a next processing beginning at step 40, since the brake timer is on at step 44, the brake timer is counted up at step 50, and it is judged at step 51 whether or not the brake time has elapsed a given time. If not, the brake signal BK is kept on at step 52. If the brake time has elapsed, the brake signal BK is switched off at step 53, the flag S4ONF is set to 0 at step 54, and the sewing machine 1 comes to a stop. At this time, the reverse rotation flag RFLAG is EXCLUSIVE ORed with 1 at step 63 to invert the value. After the first forward rotation is finished, the reverse rotation flag RFLAG is set to 1.
Accordingly, when the jogging signal S4 is then entered, the reverse rotation signal R is switched on at step 62 to rotate the sewing machine 1 reversely because the reverse rotation flag RFLAG is 1 at step 60. When sewing machine has rotated the jogging angle reversely, the run signal SRT is switched off and the brake signal BK is switched on to stop the sewing machine 1. At this time, the reverse rotation flag RFLAG is set to 0.
This operation is as detailed in FIG. 6 and will not be described. It is to be noted that when the run signal SRT is used for stitching in the forward direction with the machine needle stopping immediately before the material, the distance of piercing the material is short, the speed is not high enough when the material is pierced, and the force of inertia is small, whereby torque required to pierce the material is not provided and the sewing machine stops. However, the apparatus in the present embodiment allows the sewing machine to rotate by the jogging angle once to move the machine needle away from the material under the control of the jogging signal entered again and subsequently to rotate forward under the control of the run signal SRT, whereby the distance of piercing the material is large, the speed of piercing the material is high, and the force of inertia is therefore large to facilitate the piercing of the material.
A third embodiment of the invention will now be described. In the sewing machine controlling apparatus described in Embodiment 2, further entry of the jogging signal S4 causes the sewing machine 1 to rotate forward since the reverse rotation flag RFLAG is 0. After the sewing machine 1 has stopped, the reverse rotation flag RFLAG is inverted to 1. When the jogging signal S4 is further entered, the sewing machine 1 rotates reversely because the RFLAG is 1. Accordingly, every time the jogging signal S4 is entered, the sewing machine 1 alternates between forward rotation and reverse rotation. The timing chart of this operation is shown in FIG. 7. It is to be noted that the present embodiment allows the position where the material is pierced with the machine needle to be re-adjusted to improve working efficiency.
A fourth embodiment of the invention will now be described. Operation performed at the application of the stitching start signal S1 will be described with reference to FIG. 8. When a flag S1F, which stores the ON of the stitching start signal S1, is 0 at step 70, the processing moves on to step 71 once. If the stitching start signal S1 is off at step 71, the processing advances to step 41, where the operation as in Embodiment 3 shown in FIG. 7 is performed. When the stitching start signal S1 has turned from OFF to ON at step 71, the sequence progresses to step 72, where the run signal SRT is switched on and the flag S1F is set to 1. At step 73, it is judged whether the reverse rotation flag RFLAG is 1 or not. If it is 1, the reverse rotation signal R is set to ON at step 74 and the sewing machine 1 rotates reversely. If the reverse rotation flag RFLAG is 0 at step 73, the sewing machine 1 rotates forward, not reversely. At step 75, it is judged whether the sewing machine 1 has rotated the set jogging angle in the reverse direction. If the jogging angle has not been reached, the sequence advances to step 77. If the set jogging angle has been reached, the reverse rotation flag RFLAG is set to 0 and the reverse rotation signal R is switched off to run the sewing machine 1 forward. At step 77, it is monitored whether or not the stitching start signal S1 has turned from ON to OFF. If it has changed from ON to OFF, stop processing is performed at step 78. If it has been judged at step 79 that the stop processing is complete, the flag S1F is set to 0 at step 69.
Accordingly, when the stitching start signal S1 is switched on with the sewing machine 1 stopping at the position of 90 degrees after rotating by the jogging angle forward under the control of the jogging signal S4, the sewing machine 1 is rotated reversely by the jogging angle, then rotates forward and stitches the material. Therefore, when the stitching start signal S1 is applied with the needle stopping immediately before the material, the sewing machine 1 rotates reversely once and then operates, thereby eliminating a problem that the sewing machine 1 stops without piercing the material.
When the machine needle is at a stop at the needle UP position, i.e., 0 degrees, because the jogging signal S4 has not been provided or an even number of jogging signals S4 have been entered, the sewing machine 1 does not rotate reversely but rotates forward once since the reverse rotation flag RFLAG is 0, whereby extra reverse rotation is not made and working efficiency is high. The timing chart of this operation is shown in FIG. 9.
A fifth embodiment of the invention will now be described. The operation of the sewing machine control circuit 520 concerned with the present embodiment will be described with reference to a flowchart in FIG. 10. When the flag S1F, which stores the ON of the stitching start signal S1, is 0 at step 70, the processing proceeds to step 71. It is judged at step 71 whether or not the stitching start signal S1 has turned from OFF to ON. If it has turned from OFF to ON, the processing advances to step 80. When a delay timer is not on, the sequence progresses to step 72, where the run signal SRT is switched on and the flag S1F is set to 1.
At step 73, it is judged whether the reverse rotation flag RFLAG is 1 or not. If it is 1, the processing moves on to step 74, where the reverse rotation signal R is switched on to rotate the sewing machine reversely. If the reverse rotation flag RFLAG is 0, the reverse rotation flag R is switched off to run the sewing machine 1 forward. At step 75, it is judged whether the sewing machine 1 has rotated the set jogging angle. If the jogging angle has not been reached, the sewing machine continues reverse rotation. If the sewing machine has made the reverse rotation of the set jogging angle, the run signal SRT is switched off, the brake signal BK is switched on, the reverse rotation flag RFLAG is cleared to 0, and the brake timer and the delay timer, which sets a short stop time, are started.
Next, since the delay timer is on at step 80, the run signal SRT is switched off at step 83 and the delay timer is counted up at step 84. At step 85, it is judged whether or not the delay timer has been counted up. If not, the processing advances to step 86. If the delay time has elapsed, the sequence progresses to step 72, where operation is started. Since the reverse rotation flag RFLAG is 0 at step 73, the sequence moves on to step 81, where the reverse rotation signal R is switched off to make a forward rotation. The brake timer is counted up at step 86 and it is judged at step 87 whether the brake time has elapsed or not. If not, the brake signal BK is switched on and the reverse rotation signal R is also switched on at step 88 and the sewing machine is at a stop. After the brake time has elapsed, the brake signal BK is switched off and the reverse rotation signal R is also switched off at step 89. Then, since the delay timer has expired, the processing advances from step 80 to step 72, where the sewing machine 1 performs forward rotation.
Accordingly, after making reverse rotation under the control of the stitching start signal S1, the sewing machine stops once, then rotates forward. The timing chart of this operation is shown in FIG. 11. According to the present embodiment, the sewing machine does not shift directly from reverse rotation to forward rotation, preventing the occurrence of skip stitches, etc., due to the unevenly fed machine thread.
A sixth embodiment of the invention will now be described. FIG. 12 shows operation wherein the jogging signal S4 has not been provided in the sewing machine controlling method described in Embodiment 5. When the stitching start signal S1 is entered, the run signal SRT is switched on and forward rotation is performed because the reverse rotation signal R is off. The reason is that since the inversion of the reverse rotation flag RFLAG at step 63 in FIG. 10 is not made when the jogging signal S4 is not given, the reverse rotation signal RFLAG is 0, whereby the reverse rotation flag RFLAG is judged to be 0 at step 73 and the reverse rotation signal R is switched off at step 81 to start the sewing machine running in the forward direction and therefore working efficiency is improved.
A seventh embodiment of the invention will now be described. FIG. 13 shows that operation starts with forward rotation whenever the jogging signal S4 is entered after the sewing machine 1 has run under the control of the stitching start signal S1 in the sewing machine controlling method described in Embodiment 5. Switching on the jogging signal S4 rotates the sewing machine in the forward direction, independently of whether the sewing machine 1 has jogged in the forward direction or in the reverse direction before the stitching start signal S1 was entered. The reason is that since the reverse rotation flag RFLAG is cleared at step 82 at the input time of the stitching start signal S1, the reverse rotation flag RFLAG is 0 at step 60 when the next jogging signal S4 is switched on, and therefore the reverse rotation signal R is switched off at step 61.
When the jogging signal S4 is entered, the apparatus according to this embodiment always rotates the jogging angle in the forward direction, improving working efficiency.
An eighth embodiment of the invention will now be described. FIG. 14 is an arrangement diagram of a sewing machine controlling apparatus concerned with the present embodiment, wherein 32 indicates a reverse rotation angle setting circuit serving as reverse rotation angle setting means, S5 designates a reverse rotation signal, and 521 represents a sewing machine control circuit detailed in FIG. 16. When a material 98 as shown in FIG. 15 is to be stitched by a blind stitching machine, for example, start backtacking is done at portion 90 and first straight stitching is made at portion 91 under the control of the stitching start signal S1. When the stitching start signal S1 is switched off, the sewing machine stops at the needle DOWN position once at portion 92, but the blind stitching machine does not allow the direction of the material to be changed unless reverse-rotation needle UP is carried out. Accordingly, the reverse rotation signal S5 is switched on at portion 92 to perform reverse-rotation needle UP. It is to be understood that reverse-rotation needle UP indicates that the machine needle is raised in the reverse rotation.
Likewise, second, third and fourth straight stitchings are done at portions 93, 95 and 97, respectively. As at portion 92, the reverse-rotation needle UP is performed at portions 94 and 96 to change the direction of the material. Under the control of the thread trimmer start signal S2, end backtacking is carried out at portion 99, which is followed by reverse-rotation needle UP at portion 200 because the material 98 cannot be removed from the sewing machine 1 without doing the reverse-rotation needle UP. Therefore, reverse-rotation needle UP is performed by the reverse rotation signal S5, and end backtacking and reverse-rotation needle UP are done by the jogging signal.
The operation of the sewing machine control circuit 521 will now be described in accordance with a block diagram in FIG. 16. When the reverse rotation signal S5 is switched on, the run control circuit 310 switches the run signal SRT on and the reverse rotation signal R on via the run signal input circuit 301 to start the motor 1 reversing.
At this time, the reverse rotation angle set to the reverse rotation angle setting circuit 32 is compared by the angle comparison circuit 311 with the rotary angle of the sewing machine 1 entered into the needle position input circuit 312 from the needle position detection signal FG given by the needle position detector 3. When the sewing machine 1 has rotated the set reverse rotation angle or more in the reverse direction, the run control circuit 310 causes the rotation/stop command circuit 305 to switch the run signal SRT off and the brake signal BK on to stop the sewing machine 1.
FIG. 17 is a software flowchart for said reverse rotation needle UP. In FIG. 17, S5ONF indicates a flag which stores that the reverse rotation signal S5 has been switched on once. At step 100, it is judged whether the flag S5ONF is 1 or 0. If it is 0, the processing goes forward to step 101. If the reverse rotation signal S5 does not turn from OFF to ON, the run signal SRT is switched off at step 43 to stop the sewing machine 1. When the reverse rotation signal S5 has turned from OFF to ON at step 101, the sequence advances to step 44. When the brake timer is not on, the sequence proceeds to step 102, where the flag S5ONF is set to 1, the reverse rotation signal R is switched on and the run signal SRT is switched on to rotate the sewing machine 1 reversely. At step 46, it is judged whether or not the sewing machine 1 has reversed the set reverse rotation angle. If not, the sewing machine 1 performs reverse rotation. If the sewing machine 1 has reversed the set reverse rotation angle, the processing progresses to step 47, where the run SRT signal is switched off and the brake signal BK is switched on. At step 49, the brake timer is started.
Since the brake timer is on at step 44, the sequence moves on to step 50, where the brake timer is counted up. At step 51, it is judged whether or not the brake time has elapsed. If not, the brake signal BK is switched on at step 52. If the brake time has elapsed, the brake signal BK is switched off at step 53, the flag S5ONF is set to 0 at step 103, and the reverse rotation signal R is switched off at step 104. As a result, the reverse rotation signal S5 causes the sewing machine 1 to reverse the set reverse rotation angle and come to a stop. This timing chart is shown in FIG. 18. After the sewing machine 1 has reversed the reverse rotation angle set to the reverse rotation angle setting circuit 32, the operator toes down the foot pedal 10 to enter the stitching start signal S1 into the sewing machine control circuit 520, and as in said conventional example, the run signal SRT is output to the motor speed control circuit 13 and the sewing machine 1 performs predetermined operation. When thread trimmer operation is required, heeling the foot pedal 10 causes the sewing machine 1 to perform the operation as in said conventional example to cut the machine threads. The apparatus in the present embodiment allows the reverse-rotation needle UP operation to be performed when the direction of the material is changed on the blind stitching machine, improving working efficiency.
A ninth embodiment of the invention will now be described. FIG. 19 is a software flowchart of the sewing machine control circuit 521 concerned with Embodiment 9. This mainly represents the processing performed at portions 99 and 200 in FIG. 15. At step 110, it is judged whether the sewing machine 1 is being run or not. If the sewing machine 1 is being run, operation by the reverse rotation signal S5 is not performed. If the sewing machine 1 is at a stop, the processing proceeds to step 111, where it is judged whether or not the sewing machine 1 is at a stop after it has run once. If not, the sequence advances to step 118, where reverse rotation needle UP processing is performed when the reverse rotation signal S2 is entered. If the sewing machine 1 is at a stop after it has run once, the processing progresses to step 100. If the flag S2ONF, which stores that the reverse rotation signal S5 has switched on once, is 1, the processing moves on to step 113. If the flag S2ONF is 0, the sequence moves forward to step 101. When the reverse rotation signal S5 has not turned from OFF to ON, the processing advances to step 118. When the reverse rotation signal S5 has turned from OFF to ON, the flag S2ONF is set to 1 at step 112. At step 113, it is judged whether or not end backtacking has finished. If not, the sequence proceeds to step 114, where end backtacking processing is done. If end backtacking has ended at step 113, the sequence advances to step 115, where it is judged whether or not reverse rotation needle UP has ended. If not, reverse rotation needle UP is performed. It reverse rotation needle UP has finished, the flag S2ONF is set to 0.
As described above, when the reverse rotation signal S5 is on, end backtacking is done, reverse rotation needle UP follows, and after a stop, the material can be removed. FIG. 20 shows the timing chart of the above operation. The apparatus in the present embodiment allows either the reverse-rotation needle UP or the end backtacking and reverse-rotation needle UP to be done, improving working efficiency.
A tenth embodiment of the invention will now be described. FIG. 21 shows a sewing machine controlling apparatus concerned with the present embodiment which operates under the control of a second needle UP signal. Unlike the needle UP signal S3 in said conventional apparatus, this second needle UP signal raises the machine needle from its then position independently of the rotation direction of the machine needle and will be described later in detail. In this drawing, 522 indicates a sewing machine control circuit detailed in FIG. 22 and S6 is a second needle UP signal. The other parts are identical to those in the conventional apparatus shown in FIG. 64 and will not be described. It is to be noted that the sewing machine control circuit 522 is different in operation sequence of the run control circuit 320 from the one in the conventional example in FIG. 64.
FIG. 23 is a software flowchart of the sewing machine control circuit 522, wherein S6ONF is a flag which stores whether or not the second needle UP signal S6 has turned on once. If the flag S6ONF is 0 at step 120, the processing advances to step 121. When the second needle UP signal S6 has turned from OFF to ON, the sequence proceeds to step 122, where it is judged whether or not the needle UP signal UP is on. If not on, the run signal SRT is switched on at step 123 and the flag S6ONF is set to 1 at step 124. When the machine needle is in a range from the UP position to the DOWN position in the forward rotation direction, i.e., in area A in FIG. 24, at step 125, the reverse rotation signal R is switched on at step 126. When the machine needle is in a range from the DOWN position to the UP position in the forward rotation direction, i.e., in area B in FIG. 24, the reverse rotation signal R is switched off at step 127. Since the flag S6ONF is 1 at step 124, the sequence then moves to step 44 at step 120. Since the brake timer is not on, the processing progresses to step 128, where the sewing machine rotates under the control of the reverse rotation signal R set at step 126 or 127 until the UP position signal UP is switched on.
FIG. 25 is a timing chart at a time when the machine needle is in the range from the UP position to the DOWN position in the forward rotation direction. Namely, when the machine needle is in area A in FIG. 24, the reverse rotation signal R is switched on at step 126, whereby the machine needle is rotated in the reverse direction and stops at the UP position. FIG. 26 is a timing chart at a time when the machine needle is in the range from the DOWN position to the UP position in the forward rotation direction. Namely, when the machine needle is in area B in FIG. 24, the reverse rotation signal R is switched off at step 127, whereby the machine needle is rotated in the forward direction and stops at the UP position. When stitching, for example, is started after the machine needle has stopped at the UP position, the operator toes down the foot pedal 10 to enter the stitching start signal S1 into the sewing machine control circuit 520, and as in said conventional example, the run signal SRT is output to the motor speed control circuit 13 and the sewing machine 1 performs predetermined operation. When thread trimmer operation is required, heeling the foot pedal 10 causes the sewing machine 1 to perform the operation as in the conventional example to cut the machine threads. The apparatus in the present embodiment allows reverse rotation needle UP to be performed before the material is pierced with the machine needle and forward rotation needle UP to be performed after the material is pierced with the machine needle, thereby preventing the material from being seamed or bored.
An eleventh embodiment of the invention will now be described. FIG. 27 is a software flowchart of the sewing machine control circuit 522 concerned with Embodiment 11, wherein a flag PONF which indicates whether or not needle is in the up position immediately after power-on is initialized to 0, at power-on. Since the flag PONF is initially 0 at step 130 the processing progresses to step 122, where if the needle UP position signal UP is on, the flag PONF is set to 1 at step 131, whereby needle UP processing is not performed and is regarded as complete.
When the needle is not in the UP position at step 122, the run signal SRT is switched on at step 123 and the flag S6ONF is set to 1. If the machine needle is in the range from the UP position to the DOWN position in the forward rotation direction at step 125, the reverse rotation signal R is switched on at step 126 to raise the needle in the reverse rotation direction. When the machine needle is in the range from the DOWN position to the UP position in the forward rotation direction, the reverse rotation signal R is switched off at step 127 to raise the needle in the forward rotation direction. After needle UP processing is finished, the flag PONF is set to 1 at step 132 and it is stored that the needle UP immediately after power-on is complete to accept only needle UP performed under the control of the second needle UP signal S6 thereafter.
The apparatus in the present embodiment prevents the material from being seamed or bored at power-on.
An embodiment of a twelfth invention will now be described. FIG. 28 is a software flowchart of the sewing machine control circuit 522 concerned with Embodiment 12, wherein it is judged at step 140 whether or not the sewing machine 1 has stopped after thread trimming, and the jogging signal S4 is made valid only when the sewing machine has stopped after thread trimming. The other parts are identical to those of Embodiment 1 described in FIG. 3. According to the apparatus in this embodiment, when the machine needle need not be stopped immediately before the material, the machine needle does not rotate if the jogging signal S4 switch is touched accidentally, whereby the sewing machine is not jogged carelessly.
An embodiment of a thirteenth invention will now be described. FIG. 29 is an arrangement diagram of a sewing machine controlling apparatus concerned with the present embodiment, wherein 523 indicates a sewing machine control circuit which is detailed in FIG. 30. Referring to FIGS. 29 and 30, switching the stitching start signal S1 on causes the run control circuit 340 to switch the run signal SRT on and the reverse rotation signal R on via the run signal input circuit 301 to start the motor 2 running in the reverse direction. At this time, the reverse rotation angle set to the reverse rotation angle setting circuit 32 is compared by the angle comparison circuit 311 with the rotary angle of the sewing machine 1 provided by entering the position detection signal FG from the needle position detector 3 into the needle position input circuit 312. When the sewing machine has rotated the set reverse rotation angle or more in the reverse direction, the run control circuit 340 causes the rotation/stop command circuit 305 to switch the reverse rotation signal R off to switch the motor 2 to the forward rotation.
FIG. 31 is a timing chart of the above operation, wherein the machine needle is at a stop at 40 degrees, i.e., at the thread take-up lever top dead center. When the stitching start signal S1 is switched on at this time, the run signal SRT is switched on to start the sewing machine 1 running. At this time, the reverse rotation signal R is switched on and the sewing machine 1 makes the reverse rotation of the reverse rotation angle (e.g., 90 degrees) set to the reverse rotation angle setting circuit 32 at predetermined speed.
After the sewing machine 1 has reversed the set angle, the reverse rotation signal R is switched off and the sewing machine 1 rotates in the forward direction. The forward rotation speed at this time corresponds to the speed command signal VC proportional to the toe-down degree of the pedal 10.
FIG. 32 is a software flowchart of a sewing machine control circuit 523 concerned with Embodiment 13. When the sewing machine 1 is at a stop, a run flag S1F is 0. Beginning with START at step 38, the processing of this routine is started. At step 39, the reverse rotation angle is read from the reverse rotation angle setting circuit 32. If the sewing machine is at a stop at step 40, the sequence advances to step 41 since the run flag S1F is 0. At step 41, the processing waits for the stitching start signal S1 to be switched on. If it is not switched on, the reverse rotation flag RFLAG is set to 1 at step 42. When the stitching start signal S1 is switched on at step 41, the sequence proceeds to step 43. It is judged at step 43 whether or not the machine needle is at a stop at the UP position. If it is not at the UP position, the processing progresses to step 54, where the reverse rotation flag RFLAG is cleared to 0. Since the run signal SRT is switched on at step 44, the sewing machine 1 starts rotating. The run FLAG S1F is also set to 1.
Since the reverse rotation flag RFLAG is 0 at step 45, the reverse rotation signal R is switched off at step 48, whereby the sewing machine rotates in the forward direction, not in the reverse direction.
When the machine needle is at a stop a the UP position at step 43, the reverse rotation flag RFLAG is 1 at step 45, the processing moves on to step 46, where the reverse rotation signal R is switched on to rotate the sewing machine in the reverse direction. At step 47, it is judged whether the sewing machine has reversed the set reverse rotation angle or not. Until the sewing machine 1 reverses the set reverse rotation angle, the processing advances to step 49, where the sewing machine continues reverse rotation.
When the sewing machine has reversed the set reverse rotation angle at step 47, the sequence proceeds to step 48, where the reverse rotation flag RFLAG is set to 0 and the reverse rotation signal R is switched off, whereby the sewing machine 1 that was rotating in the reverse direction changes the direction to rotate in the forward direction. If the stitching start signal S1 remains on at step 49, the sewing machine 1 continues operation.
When the stitching start signal S1 is switched off at step 49, stop processing is performed at step 50, the sewing machine 1 rotates until it reaches the needle UP or DOWN position, and the sewing machine 1 reaches the needle position at step 51. When the stop processing ends, the run signal SRT is switched off and the run flag S1F is reset to 0 at step 52 to stop the sewing machine 1. This routine ends at step 53 and starts at step 38 again.
According to the apparatus of this embodiment, when the sewing machine 1 is at a stop at the needle UP position or after it has trimmed the threads, the sewing machine 1 reverses the set reverse rotation angle and then rotates in the forward direction, whereby the speed of piercing the material can be increased.
A fourteenth embodiment of the invention will now be described. An arrangement diagram concerned with a sewing machine controlling apparatus of Embodiment 14 is identical to the one in FIGS. 29 and 30 described in said Embodiment 13 and will not be described.
FIG. 33 is a software flowchart of the sewing machine controlling apparatus concerned with Embodiment 14. In this drawing, while the sewing machine 1 is at a stop, the run flag S1F is 0. Beginning with START at step 38, the processing of this routine is started. At step 39, the reverse rotation angle is read from the reverse rotation angle setting circuit 32.
If the sewing machine is at a stop at step 40, the sequence advances to step 41 since the run flag S1F is 0. At step 41, the processing waits for the stitching start signal S1 to be switched on. If it is not switched on, the reverse rotation flag RFLAG is set to 1 at step 42.
When the stitching start signal S1 is switched on at step 41, the sequence proceeds to step 60.
It is judged at step 60 whether the sewing machine has trimmed the threads or not. If not, the processing progresses to step 54, where the reverse rotation flag RFLAG is cleared to 0. Since the run signal SRT is switched on at step 44, the sewing machine 1 starts rotating. The run flag S1F is also set to 1. The reverse rotation flag RFLAG is 0 at step 45 and the reverse rotation signal R is switched off at step 48, whereby the sewing machine 1 rotates in the forward direction, not in the reverse direction.
When the machine needle is at a stop at the UP position, the reverse rotation flag RFLAG is 1 at step 45, and the processing moves on to step 46, where the reverse rotation signal R is switched on to rotate the sewing machine 1 in the reverse direction.
At step 47, it is judged whether the sewing machine has reversed the set reverse rotation angle or not. Until the sewing machine 1 reverses the set reverse rotation angle, the processing advances to step 49, where the sewing machine 1 continues reverse rotation.
When the sewing machine has reversed the set reverse rotation angle at step 47, the sequence proceeds to step 48, where the reverse rotation flag RFLAG is set to 0 and the reverse rotation signal R is switched off, whereby the sewing machine 1 that was rotating in the reverse direction changes the direction to rotate in the forward direction.
If the stitching start signal S1 remains on at step 49, the sewing machine 1 continues operation. When the stitching start signal S1 is switched off at step 49, stop processing is performed at step 50, the sewing machine 1 rotates until the machine needle reaches the UP or DOWN position, and the sewing machine 1 reaches the needle UP or DOWN position at step 51. When the stop processing ends, the run signal SRT is switched off and the run flag S1F is reset to 0 at step 52 to stop the sewing machine 1. This routine ends at step 53 and restarts at step 38. The apparatus of this embodiment allows the machine needle to stop immediately before the material, whereby the machine pulley 4 need not be rotated by hand.
A fifteenth embodiment of the invention will now be described. FIG. 34 is an arrangement diagram of a sewing machine controlling apparatus concerned with this embodiment, wherein 524 indicates a sewing machine control circuit detailed in FIG. 35 and S4 denotes a jogging signal. It is to be understood that the other parts are identical to those of Embodiment 1 shown in FIG. 1 and will not be described.
The operation of the sewing machine control circuit 524 will be described in accordance with a block diagram shown in FIG. 35. When the jogging signal S4 is switched on, the run control circuit 350 causes the run signal SRT to be switched on via the run signal input circuit 301, the sewing machine 1 to start rotating, and the thread trimmer output T to be output from the solenoid control circuit 303.
Starting at a point when the sewing machine 1 has detected the needle UP position signal UP of the needle position detector 3 from the needle UP/DOWN position input circuit 302, the jogging angle (e.g., 35 degrees) set to the angle setting circuit 30 is compared by the angle comparison circuit 311 with the rotary angle of the sewing machine 1 entered from the position detection signal FG given by the needle position detector 3 via the needle position input circuit 312. When the sewing machine 1 has reached or exceeded the set jogging angle, the run control circuit 350 causes the rotation/stop command circuit 305 to switch the run signal SRT off and the brake signal BK on to stop the sewing machine 1 at the set jogging angle.
Operation will now be described in accordance with a timing chart in FIG. 36. When the jogging signal S4 is switched on, the run signal SRT is output to start the sewing machine 1 rotating and the thread trimmer output T is output to cut the threads. When the needle UP position signal UP is switched on, the thread trimmer output T is switched off and a jogging command flag S4ONF is set to 1 to start jogging. When the sewing machine 1 has rotated the set jogging angle, the run signal SRT is switched off and the brake signal BK is output for a certain period of time to stop the sewing machine 1, and the jogging command flag S4ONF is set to 0.
Accordingly, after thread trimming, the machine needle automatically rotates the jogging angle set to the jogging angle setting circuit 30 in the forward direction, starting at the needle UP position, and comes to a stop.
When, after the stop, the presser foot is raised, the material sewn is removed, and the material to be stitched next is inserted, where to start stitching the next materials made clear because the machine needle is immediately before the material.
Operation will now be described in accordance with a flowchart in FIG. 37. Beginning with step 60, it is judged at step 61 whether or not the sewing machine 1 has operated once. If not, no processing is performed at END of step 79 and the sequence is finished. If it has been judged at step 61 that the sewing machine 1 has operated once, the sequence advances to step 62. If a thread trimmer flag TRIMF is 1, the sequence proceeds to step 64. If the thread trimmer flag TRIMF is 0 at step 62, the sequence progresses to step 63, where it is judged whether or not the jogging signal S4 is on. If it is off, no operation is performed and the sequence moves on to END of step 79. If the jogging signal S4 is on, the sequence proceeds to step 64, where the thread trimmer flag TRIMF is set to 1.
At step 65, where thread trimmer processing is carried out, the thread trimmer output T is provided and the sewing machine 1 is rotated up to the needle UP position. At step 66, it is judged whether or not the machine needle has reached the UP position. If not, the thread trimmer processing is continued. If the machine needle has reached the UP position once, the sequence advances to step 67. If the brake timer is not on, the sequence proceeds to step 68, where the flag S4ONF for storing that jogging processing has initiated is set to 1.
Also, the run signal SRT is switched on to start the operation of the sewing machine 1. At step 69, it is judged whether or not the jogging angle has been reached. If not, the sewing machine keeps rotating.
If it has been judged at step 69 that the jogging angle has been rotated, the run signal SRT is switched off at step 70, the brake signal BK is switched on at step 71, and the brake timer is set for the brake output time at step 72. The sequence returns from END of step 79 to START of step 60 and shifts to step 64 since the thread trimmer flag TRIMF is now 1. Because the machine needle has reached the UP position once at step 66, the processing shifts to step 67. Since the brake timer is on at step 67, the processing shifts to step 73, where the brake timer is counted up. At step 74, it is judged whether or not the brake timer has exceeded the given time. If the brake timer has not expired, the brake signal BK is switched on at step 75. If the brake timer has expired, the brake signal BK is switched off at step 76, the flag S4ONF is cleared to 0 at step 77, and the thread trimmer flag TRIMF is cleared to 0 at step 78. It is to be understood that stitching start or thread trimmer start is made as described in said conventional example and will not be described here.
A sixteenth embodiment of the invention and a seventeenth embodiment of the invention will now be described. The arrangement of an apparatus in the present embodiment is identical to that in Embodiment 15 and will not be described. FIG. 38 illustrates the operation of a sewing machine controlling apparatus concerned with Embodiment 16, showing the operation which begins with a stop at the needle UP position after thread trimming.
When the jogging signal S4 is switched on in this status, the run signal SRT is switched on and the reverse rotation signal R is on the forward rotation side, whereby the sewing machine 1 starts forward rotation. Since the jogging command flag S4ONF is 1 at this time, the sewing machine 1 rotates by the jogging angle set in the jogging angle setting circuit 30 (e.g., 35 degrees) in the forward direction, whereby the run signal SRT is switched off, the reverse rotation flag RFLAG is inverted to 1, and the brake signal BK is switched on to stop the machine needle at a position immediately before the material. The operator moves the material at this position to set the position of the material to be pierced with the machine needle.
Further, when the jogging signal S4 is switched on again, the run signal SRT is switched on, the reverse rotation signal R is set to the reverse rotation side because the reverse rotation flag RFLAG is 1, and the sewing machine 1 starts reverse rotation. Since the jogging command flag S4ONF is 1 at this time, rotating the sewing machine 1 by the angle set to the jogging angle setting circuit 30 (90 degrees in the figure) in the reverse direction causes the run signal SRT to be switched off, the reverse rotation flag RFLAG to be inverted to 0, and the brake signal BK to be switched on, whereby the sewing machine 1 is reversed to the needle UP position and brought to a stop.
When the material is stitched in the forward rotation under the control of the stitching start signal S1 after the machine needle has been stopped immediately before the material, the distance of piercing the material is short and the speed of piercing the material is not high enough to provide the sufficient force of inertia, whereby the torque required to pierce the material is not provided and the sewing machine 1 comes to a stop. To prevent this, if the jogging signal S4 is switched on again to rotate the machine needle by the jogging angle to move away from the material once and subsequently the needle is rotated in the forward direction under the control of the stitching start signal S1, the distance of piercing the material is increased and the speed of piercing the material is increased to provide larger force of inertia, whereby the material can be pierced.
The sewing machine control circuit 524 which has achieved this operation will now be described in accordance with a flowchart in FIG. 39.
At power-on or after thread trimming, the flag S4ONF for storing that the jogging processing has started is initialized to 0, the reverse rotation flag RFLAG to 0, the run signal SRT to OFF, the brake signal BK to OFF, and the reverse rotation signal R to OFF.
Starting at step 80, it is judged at step 81 whether the sewing machine 1 has done thread trimming or not. If not, the sequence proceeds to step 103. If the sewing machine 1 has already done thread trimming, the sequence progresses to step 83 because the S4ONF is still 0 at step 82. Until the jogging signal S4 turns from OFF to ON at step 83, the run signal SRT is OFF at step 84, whereby the sewing machine 1 remains stopped. If the jogging signal S4 is on at step 85, presser foot UP processing is performed at step 86. If the jogging signal S4 is off at step 85, presser foot DOWN processing is performed at step 87. If the jogging signal S4 has turned from OFF to ON at step 83, the sequence proceeds to step 88. If the reverse rotation flag RFLAG is 0, the sequence advances to step 89, where the reverse rotation signal R is set to OFF, whereby the sewing machine 1 rotates in the forward direction. If the reverse rotation flag RFLAG is 1 at step 88, the sequence moves on to step 90, where the reverse rotation signal R is set to ON, whereby the sewing machine 1 rotates in the reverse direction.
Next, the processing advances to step 91. Since the brake timer is not on, the processing moves forward to step 92, where the flag S4ONF is set to 1, and once the jogging signal S4 is entered, it is held until the sewing machine 1 finishes the rotation of the jogging angle.
Since the run signal SRT is set to ON at step 92, the sewing machine 1 starts rotating. At step 93, it is judged whether or not the sewing machine 1 has rotated the set jogging angle using the position detection signal FG of the needle position detector 3 of the sewing machine 1. If not, the sewing machine keeps rotating. If it has rotated the set jogging angle, the run signal SRT is switched off at step 94, the brake signal BK is switched on, and the brake timer is started. Thereafter, since the brake timer is on at step 91, the brake timer is counted up at step 97 and it is judged at step 98 whether the given brake time has elapsed or not. If not, the brake signal BK is kept on at step 99. After the brake time has elapsed, the brake signal BK is switched off at step 100, the flag S4ONF is set to 0 at step 101, and the sewing machine 1 stops. At this time, the reverse rotation flag RFLAG is EXCLUSIVE ORed with 1 to invert the value. After the first forward rotation is over, the reverse rotation flag RFLAG is set to 1.
Accordingly, when the jogging signal S4 is entered next, the reverse rotation flag RFLAG is 1 at step 88, whereby the reverse rotation signal R is switched on at step 90 to run the sewing machine 1 in the reverse direction. When the sewing machine 1 has reversed by the jogging angle, the run signal SRT is switched off and the brake signal BK is switched on to stop the sewing machine 1. At this time, the reverse rotation flag RFLAG is set to 0.
When the jogging signal S4 is further entered, the sewing machine 1 rotates forward because the reverse rotation flag RFLAG is 0. After a stop, the reverse rotation flag RFLAG is inverted to 1. When the jogging signal S4 is further entered, the sewing machine 1 rotates reversely because the reverse rotation flag RFLAG is 1. Therefore, every time the jogging signal S4 is entered, the sewing machine 1 alternates between forward rotation and reverse rotation. This allows the position where the material is pierced with the machine needle to be re-adjusted.
At step 103, it is judged whether the jogging signal S4 has been entered or not. If not, the sequence is terminated at END of step 105 with no further operation being performed. If the jogging signal S4 has been entered, thread trimmer processing is performed.
An eighteenth embodiment of the invention will now be described. The arrangement of the apparatus in this embodiment is identical to that of said Embodiment 16 and will not be described.
Assuming that the jogging angle of 35 degrees, for example, has been set to the jogging angle setting circuit 30 in FIG. 34, operation will be described in accordance with a timing chart in FIG. 40. It is to be understood that switching the thread trimmer start signal S2 on causes the run signal SRT to be output, the sewing machine 1 to start rotating, and the thread trimmer output T to be provided to cut the threads. When the needle UP position signal UP is switched on, the thread trimmer output T is switched off, the run signal SRT is switched off, the brake signal BK is output for a given length of time, and a wiper output W for thread wiping is provided for a predetermined period of time. When the brake signal BK is switched off in a given period of time, the run signal SRT is switched on and the jogging command flag S4ONF is set to 1 to start jogging. When the sewing machine has rotated by the set jogging angle, the run signal SRT is switched off and the brake signal BK is output for a predetermined length of time to make a stop, and the jogging command flag S4ONF is set to 0.
Accordingly, after thread trimming, the sewing machine 1 stops for a given time and performs wiper operation, and the machine needle automatically rotates the jogging angle set to the jogging angle setting circuit 30 in the forward direction, starting at the needle UP position, and comes to a stop.
When, after the stop, the presser foot is raised, the material sewn is removed, and the material to be stitched next is inserted, where to start stitching the material next is made clear because the machine needle is immediately before the material.
Operation will now be described in accordance with a flowchart in FIG. 41. Beginning with step 60, it is judged at step 61 whether the sewing machine 1 has operated once. If not, no processing is performed at END of step 79 and the sequence is finished.
If it has been judged at step 61 that the sewing machine 1 has operated once, the sequence advances to step 62. If the thread trimmer flag TRIMF is 1, the sequence proceeds to step 64. If the thread trimmer flag TRIMF is 0 at step 62, the sequence progresses to step 63, where it is judged whether or not the thread trimmer start signal S2 is on. If it is off, no operation is performed and the sequence moves on to END of step 79.
If the thread trimmer start signal S2 is on, the sequence proceeds to step 64, where the thread trimmer flag TRIMF is set to 1. At step 65, thread trimmer processing is carried out, the thread trimmer output T is provided, and the sewing machine 1 is rotated up to the needle UP position. At step 66, it is judged whether or not the machine needle has reached the UP position. If not, the thread trimmer processing is continued.
If it has been judged at step 66 that the machine needle has reached the UP position once, the sequence advances to step 400, where it is judged whether or not the brake timer is on the first time. If so, the sequence proceeds to step 401, where it is judged whether the wiper is on or not. If the wiper is on, the processing progresses to step 402, where the wiper output W is switched on. If the wiper is not on, the sequence proceeds to step 403, where the wiper output is switched off and the processing moves on to step 73. When the first brake time has ended, the sequence progresses to step 67. If the brake timer is not on the second time, the sequence proceeds to step 68. Here, a flag S01ONF for storing that the jogging processing has initiated is set to 1.
Also, the run signal SRT is switched on to start the sewing machine 1 running. At step 69, it is judged whether or not the jogging angle has been reached. If not, the sewing machine 1 keeps rotating.
If it has been judged at step 69 that the jogging angle has been rotated, the run signal SRT is switched off at step 70, the brake signal BK is switched on at step 71, and the brake timer is set for the brake output time at step 72. The sequence returns from END of step 79 to START of step 60 and shifts to step 64 since the thread trimmer flag TRIMF is 1 at this time. Because the machine needle has reached the UP position once at step 66, the processing shifts to step 67. Since the brake timer is on at step 67, the processing shifts to step 73, where the brake timer is counted up. At step 74, it is judged whether or not the brake timer has exceeded the given time. If the brake timer has not expired, the brake signal BK is switched on at step 75. If the brake timer has expired, the brake signal BK is switched off at step 76, the flag S4ONF is cleared to 0 at step 77, and the thread trimmer flag TRIMF is cleared to 0 at step 78. According to the apparatus in the present embodiment, the wiper, if any, makes contact with the machine needle when the thread is wiped by the wiper after the machine needle has stopped immediately before the material, and to prevent this, the sewing machine 1 is stopped once at the needle UP position, the wiper is operated, and the sewing machine 1 is rotated by the jogging angle again to stop the machine needle at the position immediately before the material, whereby the wiper does not come into contact with the machine needle and the needle fall position for the next material can be adjusted easily.
A nineteenth embodiment of the invention will now be described. FIG. 42 is an arrangement diagram of a sewing machine controlling apparatus concerned with the present embodiment, wherein 300 indicates an angle setting circuit acting as angle setting means, 525 represents a sewing machine control circuit, and S7 denotes an angle storage signal. It is to be understood that the other parts are identical to those in previous embodiments and will not be described.
FIG. 43 is a block diagram showing said sewing machine control circuit 525, and FIG. 44 is a flowchart of software incorporated in the sewing machine control circuit 525. Control is exercised in accordance with this flowchart when the angle storage signal S7 is entered. It is to be understood that FIG. 45 is an operation timing chart. In this embodiment, switching on the angle storage signal S7 causes an angle measurement circuit 362 to start angle measurement, and turning the machine pulley 4 by hand counts the angle. By switching the angle storage signal S7 on again, the angle measurement is terminated and the angle measured is transferred from the angle measurement circuit 362 to the angle setting circuit 300 and is stored there.
Operation will now be described in accordance with the flowchart in FIG. 44 and the timing chart in FIG. 45.
Starting at step 500, it is judged at step 501 whether the angle storage signal S7 has switched on or not. If the signal is off, the sequence proceeds to step 505 and no operation is performed. If the angle storage signal S7 is on at step 501, the sequence progresses to step 502, where the rotary angle is measured. Further at step 503, it is judged again whether the angle storage signal S7 has switched on or not. If not on, the sequence moves on to step 505. If on, the sequence advances to step 504, where the rotary angle measured is transferred and stored to the angle setting circuit 300.
According to the apparatus in this embodiment, the machine needle rotates reversely to return upward when it is desired to change the position of the material or change the material after the machine needle has been lowered to a position immediately before the material, whereby it is easy to shift the position of the material or to change the material. It is to be noted that the stitching start or thread trimmer start operation is identical to those described in said conventional example and will not be described here.
A twentieth embodiment of the invention will now be described. The arrangement of the apparatus in this embodiment is identical to that in Embodiment 19 and will not be described.
After the threads have been trimmed by the thread trimmer start signal S2, the-sewing machine 1 enters a rotary angle measurement mode, wherein the angle of the machine pulley 4 hand-turned is measured. When the angle storage signal S7 is switched on, the rotary angle measured is transferred and stored to the angle setting circuit 300.
The operation of the apparatus concerned with Embodiment 19 will now be described in accordance with a flowchart in FIG. 46 and a timing chart in FIG. 47. Starting at step 510, it is judged at step 511 whether the sewing machine 1 has finished thread trimming or not. If not, the sequence advances to END of step 515 and no further operation is performed.
If the sewing machine 1 has done thread trimming at step 511, the rotary angle is measured at step 512. If the angle storage signal S7 has switched on at step 513, the rotary angle measured is transferred and stored to the angle setting circuit 300. If the angle storage signal S7 is not on at step 513, the processing advances to step 515 and the angle is not stored.
According to the apparatus in this embodiment, the machine pulley 4 is hand-turned and the machine needle is actually brought to the stop position immediately before the material to store that position, whereby angle setting need not be repeated many times.
A twenty-first embodiment of the invention will now be described. The arrangement of the apparatus in this embodiment is also identical to that in said Embodiment 18 as in Embodiment 19 and will not be described.
After the threads have been cut under the control of the thread trimmer start signal S2 in this embodiment, the sewing machine 1 goes into a rotary angle measurement mode, wherein the angle of the machine pulley 4 hand-turned is measured. When the angle storage signal S7 is switched on, the rotary angle measured is compared with a given value. If it is less than the given value, the sewing machine 1 rotates in the forward direction by the jogging angle set by the angle setting circuit 300 and comes to a stop. If the rotary angle measured is equal to or more than the given value, it is measured and transferred and stored to the angle setting circuit 300.
The operation of the apparatus concerned with this Embodiment 21 will now be described in accordance with a flowchart in FIG. 48 and timing charts in FIGS. 49 and 50.
Starting at step 520, it is judged at step 521 whether the sewing machine 1 has finished thread trimming or not. If not, the sequence advances to END of step 527 and no operation is performed.
If thread trimming has been done at step 521, the processing goes forward to step 522, where the measurement of the rotary angle is initiated. At step 523, it is judged whether the jogging signal S4 has turned on or not. If not on, the sequence progresses to END of step 527.
If the jogging signal S4 has turned on at step 523, the sequence proceeds to step 524, where it is judged whether the rotary angle of the sewing machine 1 is equal to or more than a given value. If it is less than the given value, the sequence progresses to step 526, where the sewing machine 1 rotates forward by the jogging angle set by the angle setting circuit 300 and comes to a stop as shown in the timing chart in FIG. 49.
If that angle is not less than the given value, the sequence progresses to step 525, where the rotary angle measured is transferred and stored to the angle setting circuit 300 as shown in the timing chart in FIG. 50. The apparatus in this embodiment is lower in the number of entering the reverse rotation signals S5 and thus shorter in working time than the apparatus concerned with.
A twenty-second embodiment of the invention will now be described. FIG. 51 is an arrangement diagram of a sewing machine controlling apparatus according to the present embodiment, wherein 526 indicates a sewing machine control circuit detailed in FIG. 52, S8 designates an ultra-low speed input signal, and S9 denotes an ultra-low speed reverse rotation input signal.
In the present embodiment, when the ultra-low speed input signal S8 is entered in FIG. 51, the sewing machine 1 rotates forward at ultra-low speed (0.1 to 50 revolutions/second) lower than the low speed (100 to 300 revolutions/second) of the conventional sewing machine, the rotary angle is measured, and when the ultra-low speed input signal S8 is switched off, the rotary angle measured is transferred and stored to the angle setting circuit 300.
The operation of the apparatus in the present embodiment will now be described in accordance with a block diagram in FIG. 52. When the Ultra-low speed input signal S8 is entered into the run signal input circuit 301 of the sewing machine control circuit 526, an ultra-low speed command signal VLKO is output from the speed command circuit 304 via a run control circuit 370, and further the run signal SRT is output from the rotation/stop command circuit 305 to run the motor 2 at ultra-low speed. At the same time, the run control circuit 370 commands the angle measurement circuit 362 to measure the angle. This starts the measurement of the angle.
When the ultra-low speed input signal S8 is switched off, the run signal input circuit 301 commands the ultra-low speed command signal VLKO to be set to 0 by the speed command circuit 304 via the run control circuit 370 and the rotation/stop command circuit 305 switches the run signal SRT off and outputs the brake signal BK for a given time to stop the sewing machine 1. Simultaneously, the run control circuit 370 exercises control to cause the angle measurement circuit 362 to stop the measurement of the angle and transfer the angle measured to the angle setting circuit 300, whereby the jogging angle is stored to the angle setting circuit 300. Subsequently, when the stitching start signal S1 is entered, the sewing machine 1 rotates by the jogging angle stored in the angle setting circuit 300 and comes to a stop.
The operation of the apparatus in the present embodiment will be described in accordance with a flowchart in FIG. 53. Starting at step 600, it is judged at step 601 whether the ultra-low speed input signal S8 has turned from ON to OFF. If not, the sequence advances to step 603, where it is judged whether the ultra-low speed input signal S8 is on or not. If the ultra-low speed input signal S8 is on, the sequence moves to step 604, where the ultra-low speed command signal VLKO is set to 1 and the run signal SRT is switched on, whereby the sewing machine 1 rotates at ultra-low speed and the rotary angle is measured at step 605.
If the ultra-low speed input signal S8 has turned from ON to OFF at step 601, the ultra-low speed command signal VLKO is set to 0, the run signal SRT is switched off, and the brake signal BK is switched on for a given time at step 602 to stop the sewing machine 1, and the rotary angle measured is transferred and stored to the angle setting circuit 300. It is to be understood that the stitching start or thread trimmer start operation is identical to that described in said conventional example and will not be described here.
When the ultra-low speed input signal S8 is switched on in a timing chart in FIG. 54, the run signal SRT and the ultra-low speed command signal VLKO are output to run the sewing machine 1 at ultra-low speed and measure the rotary angle beginning with the start of operation.
When the ultra-low speed input signal S8 is switched off, the run signal SRT and the ultra-low speed command signal VLKO are switched off, the brake signal BK is switched on for a given time, and the angle measured is transferred and stored to the angle setting circuit 300. By switching the ultra-low speed input signal S8 on again when the point of the machine needle has not reached the immediately-before-the-material position which was the destination, the sewing machine 1 rotates at ultra-low speed similarly and the rotary angle is counted in addition to the previous angle. When the ultra-low speed input signal S8 is switched off, the sewing machine 1 stops and the angle measured is transferred and stored to the angle setting circuit 300 similarly. It is to be understood that the stitching start or thread trimmer start operation is identical to that described in said conventional example and will not be described here.
A sewing machine controlling apparatus concerned with a twenty-third embodiment of the invention will now be described. In this embodiment, the arrangement of the sewing machine controlling apparatus is identical to that in Embodiment 22 in FIGS. 51 and 52 and will not be described. When the ultra-low speed input signal S8 is entered in FIG. 51, the sewing machine 1 rotates forward at ultra-low speed, the rotary angle is measured, and when the ultra-low speed input signal S8 is switched off, the rotary angle measured is transferred and stored to the angle setting circuit 300. When the ultra-low speed reverse rotation input signal S9 is entered, the sewing machine 1 rotates reversely at ultra-low speed, the rotary angle is measured, and when the ultra-low speed reverse rotation input signal S9 is switched off, a difference between the forward and reverse rotation angles is calculated and the rotary angle measured is transferred and stored to the angle setting circuit 300.
The operation of the apparatus in the present embodiment will now be described in accordance with the block diagram in FIG. 52. The operation at a time when the ultra-low speed input signal S8 is entered is identical to that in Embodiment 22. When the ultra-low speed reverse rotation signal S9 is entered into the run signal input circuit 301 of the sewing machine control circuit 526, the ultra-low speed command signal VLKO is output from the speed command circuit 304 via the run control circuit 370, further the run signal SRT is output from the rotation/stop command circuit 305, and the reverse rotation signal R is switched on to run the sewing machine 1 in the reverse direction at ultra-low speed.
At the same time, the run control circuit 370 commands the angle measurement circuit 362 to measure the angle. This starts the measurement of the angle.
When the ultra-low speed reverse rotation input signal S9 is switched off, the run signal input circuit 301 commands the ultra-low speed command signal VLKO to be switched off by the speed command circuit 304 via the run control circuit 370 and the rotation/stop command circuit 305 switches off the run signal SRT and the reverse rotation signal R and outputs the brake signal BK for a given time to stop the sewing machine 1.
Simultaneously, the run control circuit 370 exercises control to cause the angle measurement circuit 362 to stop the measurement of the angle and transfer the angle measured to the angle setting circuit 300, whereby the jogging angle is stored to the angle setting circuit 300. Subsequently, when the jogging signal S4 is entered, the sewing machine 1 rotates by the jogging angle stored in the angle setting circuit 300 and comes to a stop.
The operation of the apparatus given in Embodiment 23 will be described in accordance with a flowchart in FIG. 55. Starting at step 610, it is judged at step 611 whether or not the ultra-low speed input signal S8 has turned from ON to OFF. If not, the sequence advances to step 613, where it is judged whether the ultra-low speed input signal S8 is on or not. If the ultra-low speed input signal S8 is on, the sequence moves to step 614, where the ultra-low speed command signal VLKO is switched on, the run signal SRT is switched on, and the reverse rotation signal R is switched off, whereby the sewing machine 1 rotates forward at ultra-low speed and the rotary angle is measured at step 615.
If the ultra-low speed input signal S8 has turned from ON to OFF at step 611, the ultra-low speed command signal VLKO is switched off, the run signal SRT is switched off, and the brake signal BK is switched on for a given time at step 612 to stop the sewing machine 1 and to transfer and store the rotary angle measured to the angle setting circuit 300.
At step 616, it is judged whether the ultra-low speed reverse rotation input signal S9 has turned from ON to OFF. If not, the sequence advances to step 618, where it is judged whether the ultra-low speed reverse rotation input signal S9 is on or not. If the ultra-low speed reverse rotation input signal S9 is on, the sequence moves to step 618, where the ultra-low speed command signal VLKO is switched on, the run signal SRT is switched on, and the reverse rotation signal R is set to 1, whereby the sewing machine 1 reverses at ultra-low speed and the rotary angle is measured at step 620.
If the ultra-low speed reverse rotation input signal S9 has turned from ON to OFF at step 616, the ultra-low speed command signal VLKO is switched off, the run signal SRT is switched off, and the brake signal BK is switched on for a give time at step 617 to stop the sewing machine 1 and to transfer and store the rotary angle measured to the angle setting circuit 300.
When the ultra-low speed input signal S8 is first switched on in a timing chart in FIG. 56, the run signal SRT and the ultra-low speed command signal VLKO are switched on and the reverse rotation signal R is switched off to run the sewing machine 1 forward at ultra-low speed and measure the rotary angle beginning with the start of operation.
When the ultra-low speed input signal S8 is switched off, the run signal SRT and the ultra-low speed command signal VLKO are switched off, the brake signal BK is switched on for a given time, and the angle measured is transferred and stored to the angle setting circuit 300. By switching on the ultra-low speed reverse rotation input signal S9 when the point of the machine needle is lower than the immediately-before-the-material position which was the destination, the sewing machine 1 reverses at ultra-low speed and the rotary angle is subtracted in addition to the previous angle. When the ultra-low speed reverse rotation input signal S9 is switched off, the sewing machine 1 stops and the angle measured is transferred and stored to the angle setting circuit 300 similarly. According to the apparatus in the present embodiment, the sewing machine 1 can be actually rotated under the control of the ultra-low speed input signal to match the point of the machine needle with the position immediately before the material, with the machine pulley 4 untouched, whereby a safe apparatus is provided.
A sewing machine controlling apparatus concerned with a twenty-fourth embodiment of the invention will now be described. FIG. 57 is an arrangement diagram illustrating the sewing machine controlling apparatus concerned with the present embodiment, wherein 527 indicates a sewing machine control circuit which is detailed in FIG. 58.
In this embodiment, when the stitching start signal S1 is entered into the run signal input circuit 301 in FIG. 58, it passes through the run control circuit 380 and reaches the rotation/stop command circuit 305, which then outputs the run signal SRT to run the sewing machine 1 at the speed under the control of the speed command signal VC according to the toe-down degree of the pedal 10.
During the rotation of the sewing machine 1, speed deviation between the speed command signal VC and the rotary speed of the sewing machine 1, which has been converted by the speed detection circuit 381 from the position detection signal FG of the needle position detector 3 entered via the needle position input circuit 312, is operated on by a deviation operation circuit 382. When the speed deviation is large, i.e., when the load of the sewing machine 1 has increased, peak torque, i.e., the time when the material is pierced, is detected by a peak detection circuit 383. When the peak torque is detected by the peak detection circuit 383, the rotary angle at which the torque peaked is measured by the angle measurement circuit 362. The material-to-machine needle angle at the time of immediately-before-the-material stop set to the angle setting circuit 300 is subtracted from the rotary angle at which the torque peaked, and the result of subtraction is stored into the jogging angle area of the angle setting circuit 300.
When the jogging signal S4 is entered after the machine needle has stopped at the UP position, the sewing machine 1 rotates the jogging angle stored and the needle point of the sewing machine 1 stops at a position immediately before the material.
FIG. 59 is an operation flowchart of the sewing machine controlling apparatus 527 according to the present embodiment.
Starting at step 700, it is judged at step 701 whether the stitching start signal S1 is on or not. If it is on, the processing advances to step 702, where the run signal SRT is switched on to start the sewing machine 1 running. At step 703, a difference between the speed command signal VC and a speed feedback signal VF, i.e., speed deviation VD, is operated on.
At step 704, the peak of the speed deviation VD is detected. When the torque peaks, the material-to-machine needle angle at the time of immediately-before-the-material stop is subtracted from the rotary speed of the sewing machine 1 at which the torque peaks, i.e., the angle at a time when the material is pierced, at step 705. At step 706, the result of subtraction is transferred and stored to the angle setting circuit 300.
If the stitching start signal S1 is not on at step 701, the run signal SRT is switched off to stop the sewing machine 1.
FIG. 60 is an operation timing chart. When the pedal 10 is toed down, the stitching start signal S1 is switched on. As the speed command signal VC increases according to the toe-down degree of the pedal 10, the speed control circuit 13 runs the motor 2 to exercise feedback control so that the speed of the sewing machine 1 matches the speed command signal VC.
When the machine needle point has reached the surface of the material, the peak torque is generated and the speed feedback signal VF reduces slightly. The speed deviation VD between this reduced speed feedback signal VF and the speed command signal VC peaks when the material is pierced with the machine needle. The material-to-machine needle angle at the time of immediately-before-the-material stop in the angle setting circuit 300 is subtracted from the angle at the time of piercing the material from the angle measurement circuit 362, and the result of subtraction is transferred and stored to the jogging angle area of the angle setting circuit 300. When the material-to-needle angle is preset, the apparatus according to the present embodiment does not require the immediately-before-the-material stop position to be re-adjusted if the thickness of the material changes. It is to be noted that the stitching start or thread trimmer start operation is as described in said conventional example and will not be described here.
A sewing machine controlling apparatus concerned with a twenty-fifth embodiment of the invention will now be described. In this embodiment, the arrangement diagram of the sewing machine controlling apparatus is identical to that in FIG. 57 of Embodiment 23 and will not be described.
In this Embodiment 25, when the stitching start signal S1 is entered into the run signal input circuit 301 in FIG. 58, it passes through the run control circuit 380 and reaches the rotation/stop command circuit 305, which then outputs the run signal SRT to run the sewing machine 1 at the speed under the control of the run signal SRT according to the toe-down degree of the pedal 10.
During the rotation of the sewing machine 1, speed deviation between the speed command signal VC and the rotary speed of the sewing machine 1, which has been converted by the speed detection circuit 381 from the position detection signal FG of the needle position detector 3 entered via the needle position input circuit 312, is operated on by the deviation operation circuit 382. When the speed deviation is large, i.e., when the load of the sewing machine 1 has increased, peak torque, i.e., the time when the material is pierced, is detected by the peak detection circuit 383. When the peak torque is detected by the peak detection circuit 383 and the machine needle is in the range from the UP position to the DOWN position, the rotary angle at which the torque peaked is measured by the angle measurement circuit 362. The material-to-machine needle angle at the time of immediately-before-the-material stop set to the angle setting circuit 300 is subtracted from the rotary angle at which the torque peaked, and the result of subtraction is stored into the jogging angle area of the angle setting circuit 300.
When the jogging signal S4 is entered after the machine needle has stopped at the UP position, the sewing machine 1 rotates the jogging angle stored and the needle point of the sewing machine 1 stops at a position immediately before the material.
FIG. 61 is an operation flowchart of the sewing machine controlling apparatus 527 according to the present embodiment 23. Starting at step 710, it is judged at step 711 whether the stitching start signal S1 is on or not. If it is on, the processing advances to step 712, where the run signal SRT is switched on to start the sewing machine 1 running. At step 713, a difference between the speed command signal VC and the speed feedback signal VF, i.e., speed deviation VD, is operated on. At step 714, it is judged whether or not the machine needle is in the range from the UP position to the DOWN position. If the needle is in that range, the sequence progresses to step 715. If not, the sequence proceeds to step 718.
At step 715, the peak of the speed deviation VD is detected. When the torque peaks, the material-to-machine needle angle at the time of immediately-before-the-material stop is subtracted from the rotary speed of the sewing machine 1 at which the torque peaks, i.e., the angle at a time when the material is pierced, at step 716. At step 717, the result of subtraction is transferred and stored to the angle setting circuit 300.
If the stitching start signal S1 is not on at step 711, the run signal SRT is switched off to stop the sewing machine 1.
FIG. 60 is an operation timing chart. When the pedal 10 is toed down, the stitching start signal S1 is switched on. As the speed command signal VC increases according to the toe-down degree of the pedal 10, the speed control circuit 13 runs the motor 2 to exercise feedback control so that the speed of the sewing machine 1 matches the speed command signal VC.
When the machine needle point has reached the surface of the material, the peak torque is generated and the speed feedback signal VF reduces slightly. The speed deviation VD between this reduced speed feedback signal VF and the speed command signal VC peaks when the material is pierced with the machine needle. The material-to-machine needle angle at the time of immediately-before-the-material stop in the angle setting circuit 300 is subtracted from the angle at the time of piercing the material from the angle measurement circuit 362, and the result of subtraction is transferred and stored to the jogging angle area of the angle setting circuit 300.
To prevent the peak torque generated to pull the machine thread when the machine needle rises except when the material is pierced from being misrecognized, a flag UDF indicating that the needle is in the range from the UP position to the DOWN position is provided so that the angle at the peak torque time may only be read when the flag UDF is 1. According to the apparatus in this embodiment, the torque which peaks within the position where the material is pierced with the machine needle is removed as noise, whereby the fabric surface position can be detected reliably.
The needle position detector 3 for detecting the rotary angle of the sewing machine 1 in each of the previous embodiments is not limited to the one provided on the machine shaft and may be provided on the motor shaft, for example, to calculate the angle of the machine shaft according to the pulley ratio.
Also, the motor 2 and the sewing machine 1 designed to be driven via the belt 6 may be coupled directly. Further, the two signals, the needle UP position signal UP and the needle DOWN position signal DN, which were used for calculation, may be replaced by one signal, i.e., the position detection signal FG of the needle position detector 3. Also, the one angle of the needle bar, i.e., the jogging angle or the reverse rotation angle, may be separately provided for forward rotation and reverse rotation.
Also, in addition to the jogging angle and the reverse rotation angle set individually, another signal indicating the stop position may be provided for the needle position detector 3. Also, the reverse rotation angle set may be substituted by the needle UP position signal UP, the needle DOWN position signal DN, or the needle position signal.
The one jogging angle or one reverse rotation angle set may be two or more and selecting means may be provided to select from among those set. The jogging angle setting circuit or the reverse rotation angle setting circuit may be comprised of a seven-segment LED and a switch or may use a variable resistor. | A sewing machine having a motor drive operating in response to a controller to rotate in forward and reverse rotation directions. A jogging angle may be set and the drive operated automatically for rotation in forward and/or reverse directions as a function of various operating conditions so that the needle is stopped in an optimum position for piercing a material. | 3 |
FIELD OF THE INVENTION
The invention relates to stabilizer pads for earth moving vehicles. More particular, the invention pertains to an apparatus for preventing a pivotally mounted, two-way stabilizer pad from reversing its orientation under its own weight.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,889,362 discloses a reversible stabilizer pad for earth moving vehicles having a generally flanged first surface for engagement with gravel and soft earth, for example, and a resilient surface for engagement with concrete or asphalt. This patent describes the use of rubber pads on one side of the stabilizer pad for ground contact when the vehicle is on a finished surface, such as concrete or asphalt, and flanges with grouser points on the opposite side of the stabilizer pad for ground contact when the machine is on an unfinished but hard ground surface that requires that the pads dig into the surface in order better anchor and stabilize the machine when encountering difficult digging conditions. The flanged side of the pad is unsuitable for contact with finished surfaces since it could damage and/or mar such surfaces. The stabilizer pad is pivotally mounted to the end of an hydraulically operated arm such that the pad may be rotated to contact the ground with either the rubber pad side or the flange side facing down to contact the ground surface.
When the earth moving vehicle is moved into position, if extra stability is needed, the stabilizer arms, on which the pads are mounted, are hydraulically operated to move from a retracted position, in which the arms generally extend upwardly and out of the way, to a use position, in which the arms extend downwardly at an angle with the pads contacting the ground surface. The arms and pads, of course, are positioned to provide extra stability to the vehicle. When the vehicle is to be moved, the arms are lifted back to the retracted position, the vehicle is moved to a new operating location and the stabilizer arms are brought down into the use position again, if necessary.
In prior stabilizer pad constructions such as the one described in U.S. Pat. No. 4,889,362, there has been a tendency for the pad to self-flip when the earth moving machine pad support arm is lifted. The self-flipping problem relates primarily to flipping from flanged side down to rubber pad side down because the rubber pad side is typically much heavier than the flange side. When the pad inadvertently flips sides, an operator must manually flip the pad back so that the proper side is facing down. Frequently, however, the operator does not realize that the pad has self-flipped or, even if he/she realizes it, does not bother to fix it. Accordingly, the machine is used with the wrong side of the stabilizer pad in contact with the ground surface, which could result in increased hazard as well as increased wear of the rubber pads, leading to premature need for replacement. The self-flipping of the pad can be remedied with a securing or engaging bolt that is required to be secured in each position of the pad and to be disassembled and re-secured when the position of the pad is to be changed. This becomes time consuming and furthermore may involve parts that are easily lost. Further, the operator simply may not use the securing pin or bolt.
U.S. Pat. No. 4,889,362 discloses an automatically operatable latch that is adapted to rotate into an engagement with the pad when the pad is in a ground engaging surface, and furthermore adapted to automatically rotate by gravitational force out of engagement with the pad when the arm of the earth moving machine that supports the pad is lifted. In this way, when the support arm is lifted, the latch disengages from the pad and the pad is easily rotated to its opposite position. It has been found, however, that rocks, gravel and other debris frequently get caught in the automatic latch disclosed in U.S. Pat. No. 4,889,362 which can prevent the latch from releasing when the arm is lifted. In many stabilizer constructions, however, the pad must rotate to some extent when the arm is lifted in order to allow the piston of the arm to retract into the cylinder. Failure of the latch to release can thus result in damage to the arm or pad.
It is an object of the present invention to provide an improved stabilizer pad/arm construction for an earth moving machine.
It is a further object of the present invention to provide a stabilizer pad/arm construction for an earth moving machine which will not flip sides unintentionally.
It is another object of the present invention to provide a self-flip prevention mechanism which can be easily added to virtually any stabilizer pad/arm construction.
It is yet one more object of the present invention to provide a stabilizer pad/arm construction for an earth moving machine which will not jam.
SUMMARY OF THE INVENTION
The invention is a stabilizer pad/arm construction for use with earth moving equipment. The stabilizer pad is coupled to the stabilizer arm so as to be pivotable about an axis of rotation. The stabilizer pad has a plate having first and second faces adapted to provide optimal contact patches with the ground, one side being particularly adapted for contacting soft earth or gravel and the other side particularly adapted for contacting asphalt, concrete or another hard surface. The stabilizer pad is rotatable about the pivot in order to be able to contact the ground with either side facing the ground.
In order to prevent the pad from accidentally rotating under its own weight so as to switch ground contact sides when the arm is lifted, the pad is coupled to the arm such that, in order for the pad to flip sides, the arm must pass through a channel defined by side walls of the pad. A steel plate is coupled transversely to the arm to define two small gaps between the side walls and the edges of the steel plate. A rubber strip slightly longer than the steel plate as well as the channel is sandwiched between the arm and the steel plate and, when the pad is rotated to a certain position relative to the arm, the rubber strip contacts the side walls of the pad. The thickness of the pad is greater than the width of the gaps between the edge of the steel plate and the side walls. Accordingly, when the pad is rotated in a direction such that the pad enters the gap before the steel plate, the edges of the strip which extend beyond the edges of the plate bend upward and get trapped or jammed in the gap between the edge of the plate and the side wall. Since the strip is thicker than the gap, it is compressed and provides a high frictional resistance to further rotation of the pad relative to the arm in that direction. Frictional resistance is a function of the thickness of the pad relative to the thickness of the gap and the frictional coefficient of the surface of the pad and the side walls. The frictional resistance is selected such that the weight of the pad is insufficient to overcome the frictional resistance to further rotation, but small enough to allow the friction to be overcome with additional manual pressure when it is desired to flip the pad over.
Alternately or additionally, the strip may be resilient but relatively stiff so as to resist the bending necessary for the strip to fold inwardly on itself and fit through the gaps.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a fragmentary view of a typical loader/backhoe having stabilizer pads of the prior art secured thereto.
FIG. 2 is a perspective view of the stabilizer pad and arm of FIG. 1 in a gravel or dirt engaging position.
FIG. 3 is a side elevational view of the stabilizer pad and arm construction in the position of FIG. 2.
FIG. 4 is a bottom plan view of a stabilizer pad of FIGS. 1-3 shown uncoupled from a stabilizer arm.
FIG. 5 is a sequential diagram illustrating the prior art problem of stabilizer pad self-flipping.
FIG. 6 is a fragmentary view of the stabilizer pad of the present invention coupled to a stabilizer arm.
FIG. 7 is a schematic cross-sectional end view taken along line 7 of FIG. 6 showing the pad in a gravel contacting position.
FIG. 8 is a schematic cross-sectional end view similar to FIG. 7 showing the arm and pad in a second relative rotational position.
FIG. 9 is a schematic cross-sectional end view similar to FIG. 7 showing the arm and pad in a third relative rotational position.
FIG. 10 is a schematic cross-sectional end view similar to FIG. 7 showing a first alternative embodiment of the present invention.
FIG. 11 is a cross-sectional end view similar to FIG. 7 showing a second alternative embodiment of the present invention.
FIG. 12 is a cross-sectional end view similar to FIG. 7 showing a third alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a fragmentary view of a typical loader/backhoe 10 having a shovel mechanism 12, stabilizer arms 14 and 16, and associated stabilizer pads 18 and 20, respectively. Hydraulic piston 15 may operate each of the stabilizer arms 14 and 16 independently. When the equipment is being moved, the pistons associated with each cylinder are withdrawn so that the support arms pivot and are thus elevated above ground level. As the arms are pivoted upwardly, it is in that position that the pads may then be reversed. When support arms are to be used, the piston associated with each of the cylinders are extended to the position shown in FIG. 1 for ground engagement.
With reference to FIGS. 2 and 3, the stabilizer pad 18 generally includes a flat plate 22 that has extending normal to the surface thereof the flanges 24 and 26, both extending on one side from the surface of plate 22. The stabilizer pad is also provided with supporting webs or ribs 25, one associated with each flange. These provide additional support for the flanges 24 and 26. The plate 22 is notched at 30 between flanges 24 and 26 such as illustrated in FIG. 4. The plate is notched so as to accommodate the arm 14 and to enable the reversible rotation of the stabilizer pad. The arm 14 includes a journal end for accommodating pin 34. Pin 34 also fits within holes 35 and 36 of flanges 24 and 26, respectively. The pin 34 may be secured in place by means of a typical cotter pin as illustrated in FIG. 3, or the pin 34 may be threaded to accommodate a nut. FIG. 2 most clearly illustrates the resilient side of the reversible stabilizer pad. The resilient side of the pad is in the form of three laminated pads 40.
The drawings illustrate the basic components comprising the stabilizer member resilient pad structure. This includes the angle irons 44 and 48. Both angle irons include a base leg and an upright leg. Each of the upright legs has holes therein for receiving the elongated securing pins 50. The laminated pads are secured to the plate 22 by means of a series of bolts 53 each having associated nuts 55.
FIG. 5 illustrates a sequence of events as a support arm 114 is lifted. In the bottom position, the pad is illustrated with its flanged web in contact with the ground surface. In the top position it is noted that the pad has now self-flipped so that the resilient side of the pad is facing substantially downwardly. The support arm 114 may be lifted in a rather jerky motion. Because of certain inertia, the pad is apt to flip on its own. This is undesirable because, typically at a construction or other site at which earth moving equipment is being used, the ground surface is relatively consistent, either being soft, so that one desires the flanged side to be facing down, or hard, so that one desires the laminated side to be facing down. At such a site, the earth moving equipment typically is moved many times, requiring stabilizer arms to be retracted upwardly so that the earth moving machine can be moved and the stabilizer arms to be put down again with the same side facing down. Only when the ground surface changes, a relatively rare occurrence, is it desired that the stabilizer pad flip over.
Although the pad does not tend to self-flip from the rubber side to the flanged side, because the rubber side of the pad is considerably heavier than the flanged side, the pad does tend to self-flip from the flanged side to the rubber pad side.
In the sequence of FIG. 5, which should be viewed from the bottom up, the pad is shown engaging the ground surface at the bottom of the figure. As the arm 114 is raised, there is an inertia force in the direction of arrow 127. This same inertia force is also illustrated in the middle position illustrated in FIG. 2 wherein the pad is illustrated as now having been half-flipped upon a raising of the support arm 114. The top position in FIG. 4 illustrates the pad now completely reversed. When the arm 114 is now lowered again, the wrong surface will be facing downward and will engage the ground since the pad has self-flipped.
The present invention provides a stabilizer pad/arm construction which eliminates the self-flipping problem. Further, virtually any other stabilizer pad/arm construction can be easily and inexpensively modified to the construction of the present invention to eliminate the problem of self-flipping.
A preferred embodiment of the invention will now be described in detail with reference to FIGS. 6-9. The pad 18 comprises a steel plate 22 which is adapted to contact the ground with either side of the plate facing downwards. In FIG. 6, the side having flanges 24 for contact with soft earth is facing downward and the side bearing rubber pads 40 is facing upwardly. The stabilizer arm 14 extends in channel 30 (best seen in FIGS. 7, 8 and 9) and is pivotally coupled to the pad 18 in the manner best illustrated by FIG. 3 and discussed above. A steel plate 70 and a high friction, resilient strip 72 are fixed to the arm by a partially threaded U bolt 74. As best seen in FIGS. 7-9, the U bolt 74 surrounds the arm 14 and engages holes through the plate 70. Threaded nuts 76 engage the threaded ends of the U bolts to secure the plate to the U bolt around the arm. The strip 72 is sandwiched between upper surface 14a of the arm 14 and the lower surface 70a of the plate 70. The strip is formed of rubber or another flexible, abrasion resistant, material, such as spring tempered metal or neoprene. Preferably, the material also has a relatively high coefficient of friction, e.g., rubber or neoprene. The steel plate 70 is of a length, d, which is greater than the width, g, of the arm yet smaller than the width, e, of the channel 30. The rubber strip 72 is of a length, f, greater than the width, e, of the channel such that, when the arm is rotated into the channel the rubber strip 72 does not fit through the channel with the rubber strip 72 in its fully extended horizontal position, as best seen in FIG. 7. Since the length, d, of the plate 70 is less than the width, e, of the channel, small gaps 80 of width a (see FIG. 8) exist between the edges 70a and 70b of the steel plate 70 and the side walls 24a and 26a of the channel 30. The thickness, c, of the rubber strip 72 is greater than the width, a, of gaps 80. The strip 72 is preferably rubber such that it has a surface or relatively high friction, is compressible in the direction of its thickness, c, and can be flexed under force in the direction of the arrows 73 in FIG. 7.
When the arm and pad are in the relative rotational relationship shown in FIG. 7, the pad can be forced to rotate further into the position shown in FIG. 8 (rotated counterclockwise in the view of FIG. 6) such that the end portions of the rubber strip 72 which extend beyond the edges 70a and 70b of the plate 70 flex upwardly and become trapped between the side walls 24a and 26a and the edges 70a and 70b of the plate 70, providing a frictional resistance to further rotation in that direction. The particular thickness, c, of the rubber pad 72 and/or its surface coefficient of friction is selected such that the inertia of the pad itself towards self-flipping cannot overcome the frictional resistance, but application of manual pressure to further rotate the pad in the counterclockwise direction can overcome the frictional resistance to rotation in that direction. Accordingly, someone wishing to flip the pad so that the rubber side faces down can do so easily, but the pad will not be able to self-flip accidentally under solely its own inertia.
Typically, stabilizer pads are likely to self-rotate only from flange side down to rubber side down, and not vice versa, because the rubber side typically is much heavier than the flanged side. Accordingly, it is preferable that there is substantially less or even no resistance to rotation of the arm through the channel in the opposite direction (in the clockwise direction in the view shown in FIG. 6). Accordingly, the gap 83 between the edges of the U bolt and the side walls is of a width, i, (see FIG. 9) greater than the thickness, c, of the pad 72. Accordingly, there is very little frictional resistance to rotation of the arm through the channel in that direction since the strip 72 is not compressed in the gap 83.
The flexibility of the strip 72, i.e., its resistance to flexing in the direction of arrows 73 in FIG. 7 should be low enough so as not to offer any significant resistance to rotation in a clockwise direction. It should be noted that the length of the strip which is allowed to flex when the arm passes through the channel in the clockwise direction in FIG. 6, i.e., f-h, is much greater than the length of the strip which is allowed to flex when the arm passes through the channel in the counterclockwise direction, i.e., f-e. Thus, more force is required to flex the shorter exposed strip 72 upward in FIGS. 7-9 to fit through the channel 30 than to flex the longer exposed ends vertically downwardly to fit through the channel because a greater length of the strip is allowed to flex when flexed downwardly. Accordingly, the resistance to rotation in the clockwise direction is much less than in the counterclockwise direction, not only because of the substantial lack of frictional resistance to clockwise rotation, but also because there is substantially less force required to flex the ends of the strip to fit through the channel 30 when rotating the pad clockwise. Thus, the resistance to rotation in both directions is a function of the coefficient of friction of the strip material, the thickness of the strip material, and the stiffness of the strip material. Any one or more of these properties of the strip material can be used to set the desired force necessary for rotation beyond the contact point in either direction. For instance, if desired, a low friction material can be employed and the resistance to rotation can be primarily a function of flexibility, with friction playing almost no part.
It has been found that rubber strips cut from side wall segments of truck-tire carcasses provide acceptable material in terms of flexibility properties and surface friction properties to serve as rubber strips 72.
Of course, if in a particular stabilizer pad/arm combination, it is desirable to better prevent self-flipping in either direction, another steel plate 71 substantially of the same dimension as the top steel plate 70 can be placed between the top surface 14a of the arm 14 and the bottom surface of the rubber strip 72, as shown in FIG. 10, so as to offer the same resistance to rotation of the arm in the channel in both directions. Further, the steel plate 70 need not be coupled to the arm by a U bolt surrounding the arm but may simply be bolted to the arm itself, also as illustrated in FIG. 10. Alternately, the strip may be glued to the arm, eliminating the need for a steel plate. Even further, a stabilizer arm such as illustrated at 98 in FIG. 11 may be shaped with a stepped cross-section as shown in FIG. 11 with two rubber strips 95,97 glued or otherwise attached to the arm 98.
Even further, if resistance to rotation is to be provided in both directions, a compressible frictional pad 90 can be bolted, glued or otherwise fixed to the side surfaces 14d and 14e of the arm 14 which provide a high friction press fit between side walls 14d and 14e of the arm and side walls 24a and 26a of the stabilizer pad 18, as shown in FIG. 12.
Having thus described a few particular embodiments of the invention, various alterations, modifications and improvements will readily occur to those skilled in the art. Such alterations, modifications and improvements as are made obvious by this disclosure are intended to be part of this description though not expressly stated herein, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description is by way of example only, and not limiting. The invention is limited only as defined in the following claims and equivalents thereto. | A reversible stabilizer pad for use with earth moving equipment having a plate with first and second ground contact faces pivotally coupled to a stabilizer arm such that the plate can rotate about the arm to engage the ground surface with either ground contact face with the arm having to pass through a channel in the pad in order to change ground contact faces and a friction member fixed to the arm so that when the arm passes through the channel in at least a first direction, the friction member is trapped in the gap between the arm and the pad and provides a frictional resistance to further rotation in the first direction. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a division of U.S. application Ser. No. 098,638, filed Jul. 28, 1993, now U.S. Pat. No. 5,405,536, which, in turn, is a continuation-in-part of U.S. application Ser. No. 654,781, filed Feb. 13, 1991 and a continuation-in-part of U.S. application Ser. No. 654,789, filed Feb. 13, 1991, both now abandoned, both of which are continuations of U.S. application Ser. No. 505,938, filed Apr. 6, 1990, now U.S. Pat. No. 5,013,458, the complete disclosure of which is herein incorporated by reference.
This is also a continuation-in-part of U.S. application Ser. No. 954,657, filed Sep. 30, 1992, now abandoned, which, in turn, is a division of U.S. application Ser. No. 749,988, filed Aug. 26, 1991, now U.S. Pat. NO. 5,186,840, issued Feb. 16, 1993, the complete disclosure of which is herein incorporated by reference.
FIELD OF INVENTION
The present invention generally relates to a process for the treatment of waste prior to disposal. Additionally, the invention relates to an apparatus for the treatment of waste prior to disposal.
BACKGROUND OF THE INVENTION
The safe and sanitary disposal of waste is an ages old problem. Untreated waste, both in solid and liquid form, may contain any number of substances noxious to humans and the environment, including particulate solids, organic and inorganic compounds and pathogens.
It is desirable, therefore, to treat the waste before disposal. The treatment of the waste to destroy pathogens can be accomplished by a number of methods.
One method to treat waste to kill pathogens is to heat it to a high temperature for a period of time. Commonly known as pasteurization, this process neutralizes pathogens to a degree dependent upon the level of temperature and length of time that the waste is exposed to the elevated level.
Pasteurization, while effective to neutralize pathogens, may not reduce the odors emanating from the waste and may not reduce vector attractiveness. In the absence of reduction of vector attractiveness, vectors such as rats, mice and flies, will be attracted to the untreated waste. Vectors pose a health risk by themselves, as well as potentially spreading any pathogens present in the waste. Therefore, any treatment and subsequent disposal must reduce odors and attendant vector attractiveness factors.
One method to reduce vector attractiveness and also neutralize pathogens is by lime stabilization, which elevates the pH of the waste to a sufficient degree, for a sufficient period of time. This method is usually accomplished by the addition of an alkaline substance to the waste. Substances such as calcium oxide or calcium carbonate and compounds consisting of or containing them such as lime or quicklime, lime kiln dust, cement kiln dust, or dolomitic lime are commonly used for this process. The relatively low expense of sufficient quantities of these materials and their high alkalinity makes them well suited to the task.
In addition to the noxious components potentially present in and possible vector attraction to untreated waste, a further disposal problem is presented by the fact that untreated waste rarely is purely solid. Rather it usually has both solid and liquid components, with the solid component further potentially containing some degree of bound liquid, usually water. Thus the percent of liquid in the waste may be a sum of both the free liquid component as well as-the liquid bound to the solid component. Due to the presence of both these components, waste may vary from a liquid type consistency and appearance to a thick solid consistency and appearance. The need to deal with this variety of phases complicates treatment and disposal. For example, if the waste has mostly a liquid type consistency, the majority of the free liquid portion of waste is separated out and dealt with through techniques known in the art. The remaining solid portion, or sludge, includes the remaining free liquid water, any bound water and the solid. That sludge, which may have a solids content of from 1 to 4%, then undergoes a further dewatering step by any of a number of processes known in the art. If the waste is of a more solid consistency, then the dewatering is usually done is a single process.
After the waste has been dewatered sufficiently, it is referred to as dewatered sludge, which may have a solids content of anywhere from approximately 10% to 60% with the remainder water. This dewatered sludge is difficult to handle. The varying solids content and percentage of water as bound and free give the sludge physical characteristics ranging from a viscous, colloidal liquid to a dry cake or clay.
The Environmental Protective Agency (EPA) has promulgated regulations for proper treatment and disposal of waste or sludge. To ensure neutralization of pathogens to what it deems an environmentally safe level, the EPA has currently imposed two statutorily defined levels of processes for disposal of waste: Process to Significantly Reduce Pathogens (PSRP); and Process to Further Reduce Pathogens (PFRP). The use of either or both PSRP and PFRP depends upon the use to which the treated waste is to be put. Currently, PFRP result in a greater degree of pathogen reduction and waste treated by PFRP has less restriction surrounding its disposal. Although PSRP and PFRP as currently promulgated in Appendix II to 40 CFR 257 are limited to a few named processes, it is possible to qualify a process for either level by meeting, inter alia, the statutorily defined reduction in pathogens.
U.S. Pat. No. 4,781,842 discloses such an invention. Although the process set forth therein is not named as a PSRP or PFRP specifically in Appendix II 40 CFR 257, the process achieves pathogen reduction to current PFRP mandated levels. It does so by mixing the waste with lime or a lime mixture sufficient to raise the pH to 12 for at least a day, and then drying the lime waste mixture, by a natural or aeration process, for a period of time sufficient to reduce pathogens to the current PFRP regulations set forth in that patent.
The disclosure in the '842 patent is limited to current levels of pathogen reduction necessary to achieve PFRP, however. Changing regulations may lead to changing levels of pathogen reduction and the '842 patent does not seem to be easily adaptable to such a circumstance.
Accordingly, while there many different methods that are used to stabilize or reduce pathogens in sludge and to condition sludge for reuse, including digestion (aerobic and anaerobic), lime stabilization, chlorine stabilization and composting, and while there are other processes that are used to reduce the volume and to stabilize the sludge, such as heat drying or incineration, such techniques may lend themselves to other problems.
For example, incinerators heat and burn sludge resulting in an ash which has no significant beneficial reuse potential. Heat drying treats the sludge in order to drive off the water contained within the sludge while leaving much organic or inorganic solids intact, with the end product usually being pelletized and used for fertilizer.
The methods used to heat sludges are generally broken down into two categories, direct heating and indirect heating. For direct heating, heat transfer is accomplished by direct contact between the heating medium and the wet sludge, with the heating medium normally being hot air or hot gases.
Indirect heating is accomplished by contact of wet solids with hot surfaces, with the heating medium being normally kept away from the sludge and heating a surface which is in contact with the sludge. The heating medium in such instances is usually hot water, steam, or hot oil.
The amount of heat which can be transferred through indirect methods is a function of the heat transferability of the heat medium, heat transfer surface, and the material to be heated. The amount of heat transferred is formulated as follows:
.sup.q cond=.sup.h cond.sup.A (.sup.t m-.sup.t s)
where:
q cond=conductive heat transfer, Btu per hour (kJ/hr);
h cond=conductive heat transfer coefficient, Btu per hour per °F. (kJ/hr/°C.);
A=area of heat transfer surface, square feet (m 2 );
t m=temperature of heating medium--for example, steam, °F. (°C.)
t s - temperature of sludge at drying surface, °F. (°C.).
Various methods have been developed to try to optimize total heat transfer. Most of these prior efforts have attempted to increase the surface area in order to increase the total heat transfer.
Prior inventions have often attempted to increase heat transfer primarily by increasing the surface area. Such techniques may, for example, include a hollow rotating shaft in order to move the heating medium through a larger surface area, thereby providing an increase in total heat transfer. Variations and improvements on such have included the addition of hollow disks on the rotating shafts, in order to get the heating medium to the exterior of the shaft.
The use of hot water as a medium is restricted to 212° F. (100° C.). At 212° F., the temperature differential ( t m- t s) is very small. As a result, total heat transfer is extremely low. To overcome this restriction, steam may be used to allow for higher heat medium temperatures. Alternatively, oil can also be used. Above 250° F., steam develops pressures in excess of 15 psig. At this point, special constructions such as A.S.M.E. coding of all fabrication must be done for proper safety. In addition, once pressure is utilized, leaks can occur which allow the heating medium to escape into the sludge. Leaks cause not only loss of pressure and heat, but also contaminate the sludge or material being heated.
This invention teaches a method and apparatus which increases the temperature differential ( t m- t s) in order to increase the total heat transfer. The invention provides for an economical, high temperature method of heating the rotating mechanism to indirectly heat and to mix sludges with other material.
This invention thus provides a means to eliminate a fluid heat medium, avoiding elevated pressures and the possibility of leakage and contamination.
Accordingly, it is an object of the present invention to provide an apparatus and method to achieve currently mandated levels of PSRP and PFRP.
It is a further object of the present invention to provide an apparatus and method to achieve different levels than current regulations mandate of pathogen reduction in waste.
It is a further object of the present invention to provide a method and apparatus to achieve effective neutralization of pathogens in waste.
A further object is to provide an apparatus capable of both stabilizing and pasteurizing raw sludge in a low cost, time-efficient manner.
It is thus a further object of this invention to accomplish the above objects, wherein a method and apparatus is provided for adding supplemental heat to the sludge which indirectly heats the sludge by heat generated through electric elements.
Further objects and advantages, such as sensing the temperature of the sludge and controlling the amount of heat via a feedback control, by the placement of heat elements within either the mixing member, such as within a rotating cylindrical member, or by placing the heating elements outside or inside the walls of a chamber, are also provided.
SUMMARY OF THE INVENTION
According to the present invention, a sufficient quantity of lime is added to dewatered sludge, to raise the pH to a predetermined level and for a predetermined period of time in order to neutralize pathogens present in the sludge and reduce vector attractiveness. Furthermore, the heat of the lime-sludge reaction is retained and the measure of additional heat is added by indirectly heating the sludge by heat generated through electrical elements, so that the temperature of the lime-sludge mixture is raised to a predetermined level for a predetermined period of time for further neutralization of pathogens.
Apparatus for performing the method is also disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration, in side elevation, of a preferred apparatus embodying the invention.
FIG. 2 is a fragmentary section through FIG. 1, wherein the electric heating elements are shown, located outside the interior wall of the chamber, on an exterior surface thereof, with suitable wiring connections for delivery of electric current thereto.
FIG. 2A is a schematic illustration of a feedback circuit, by which sensors operate through a controller to control the voltage/amperage electrically provided to heat elements.
FIG. 3 is a sectional view similar to that of FIG. 2, but wherein heat elements are shown, located inside the shaft of the mixing member.
FIG. 4 is an enlarged longitudinal sectional view, taken generally along the line IV--IV of FIG. 3, wherein the electrical elements inside the shaft of the mixing member, and their connection to a stationary member outside the shaft, are shown at the left end thereof, with the shaft of the mixing member being only fragmentally illustrated.
FIG. 5 is a sectional view similar to that of FIGS. 2 and 3, but wherein the electric heating elements are shown inside the interior wall of the chamber, but outside the mixing member.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the preferred embodiment, dewatered sludge and an additive, usually lime, are deposited in a continuous stream to a chamber. They are thoroughly mixed when deposited, so the pH of the sludge begins to rise, stabilizing at or above the desired level which in the preferred embodiment is a pH of at least about 12. The process is then continued for the desired dwell time and is monitored to ensure it is maintained at about or above the desired level.
The mixing of the sludge and lime, at atmospheric conditions, leads to hydration reaction:
CaO+H.sub.2 O=Ca(OH).sub.2 +Heat
Using stoichiometric quantities in the reaction gives:
56 lbs. of CaO+18 lbs. H.sub.2 O=74 lbs. of Ca(OH).sub.2
as well as releasing 27,500 BTU's per pound mole.
Although lime (defined here as substantially pure calcium oxide) is utilized in this embodiment, other substances consisting of or containing calcium oxide or calcium carbonate, or calcium hydroxide, may be used, such as quicklime, dolomitic lime, or lime kiln dust cement kiln dust. Therefore, although lime is used herein, the additive is selected from the group comprising or consisting of calcium oxide, calcium carbonate and calcium hydroxide. The selection may be dependent on availability and pH level desired, because some members of the group may not be effective enough to raise the pH to the desired predetermined level. For example, if the desired predetermined pH level is twelve, dolomitic lime may not be volatile enough to raise the mixture to that level.
The dewatered sludge may contain anywhere from 10-60% of dry solids, although 15-50% is more usual. The lime-sludge ratio, by weight, can vary from 25% to 200%, so that for every pound of dry solids of sludge, from 0.25 to 2.0 pounds of lime may be added. As this equation shows, the hydration of the lime requires water. The free (and perhaps some or all of the bound) water in the dewatered sludge is utilized in the reaction.
The resultant hydroxide, which in this embodiment is Ca(OH) 2 , is the alkali utilized to elevate the pH of the sludge, and so cause lime stabilization. Elevation of the pH occurs quickly, and the sludge then remains at or above a predetermined level for a predetermined period of time. In the preferred embodiment the pH rises quickly to above 12. At about two hours the sludge is withdrawn and is tested to ensure it is at least about 12.
The predetermined period of time that the sludge dwells in the chamber is, in the preferred embodiment, at least two and a half hours during which, for the first about two hours, the sludge is at or above a pH of about 12. However, it should be noted that the dwell time is able to be shortened or lengthened. It can be as long as a number of days, or even weeks, depending on the degree of lime stabilization desired. The longer the dwell time, the greater the degree of stabilization. Additionally, the desired pH level may decrease over time, so that, for example, during a 24 hour dwell time, a pH of greater than or about 12 may be reached after 2 hours, and then, after 22 more hours, the pH may decline to at least about 11.5. The dwell time may also be shortened to be less than the two and one half hours. The lime may then be transferred another container or location. In an alternative preferred embodiment, the pasteurization is deemed to occur contemporaneously with the lime stabilization, and the dwell time is about thirty minutes. The pH is monitored at the end of two hours after initial mixing of the lime and sludge to ensure that it has remained at about or above 12. The temperature would be monitored for the initial at least about a half hour, to ensure it remains at about or above the desired 70° C. A further alternative is to monitor the temperature during the desired half hour pasteurization period at any time during the two hour time of lime stabilization.
In the first preferred embodiment having a two and one half hour dwell time, the sludge is exposed, after the two hour lime stabilization, for at least a half hour more to the elevated temperature of the chamber, caused by the heat released from the reaction and retained in the chamber. The chamber itself is substantially closed, which assists in retaining the sludge at least a substantial amount of the heat released during the hydration reaction.
Although the preferred embodiment utilizes a single chamber to retain the sludge during pasteurization and lime stabilization, it is possible to have the steps occur in separate chambers and have the sludge pass through to each. It is also possible for the process to oocur without any enclosure in a chamber, or partial enclosure during the process, as long as heat from the hydration reaction is retained within the sludge.
In the preferred embodiment enough heat is retained in the sludge during the course of the ongoing hydration reaction to maintain a temperature of at least about 70 degrees Celsius for at least 30 minutes and thereby pasteurize the sludge. It is also preferred to insulate the chamber to retain the heat in order to effect efficient pasteurization as well as increase the reaction rate. An increase in the temperature of 10° C. Celsius, for example, may double the reaction rate. A doubled reaction rate provides for increased heat and therefore temperature which in turn provides itself for a potentially further increase in temperature and as a result, further increase in reaction rate. This is a "snowball" or "avalanche" effect. If the heat is not released from the reaction in sufficient quantities to enable the sludge to reach the desired temperature, supplemental heat may be added.
The addition of supplemental heat may also be necessary because although a substantial amount of heat is released during the hydration reaction, excess water in the chamber may absorb the heat. It may be possible to bleed off or release some of the excess water, or use it in slaking the lime (which usually requires three parts water to one part lime), but the amount remaining may still absorb undesirable quantities of heat. For example, if 0.25 pound lime is added to every 1 pound sludge, and the sludge used as 15% solids content, then approximately 252 pounds of water will be released from the sludge during the reaction of stoichiometric quantities of lime and sludge. Insofar as 27,500 BTU's per pound mole are released during the reaction, the excess water will potentially absorb much of the heat released. Therefore, supplemental heat may be desirably added by controllable means. Note that, if the means are not controlled, due to the varying nature of the components, heat far in excess of that needed may be produced. For example, assuming that 2 pounds of lime are added to every 1 pound of sludge (in a 2:1 ratio) and the sludge utilized has 50% solids content, then only 18.5 pounds of water will be released by the sludge. This is barely enough for the hydration reaction to occur, and will lead to almost the entire 27,5000 BTU's released in the reaction being utilized to heat the mixture. In this instance, little, if any supplemental heat may be necessary to reach desired or pasteurization temperature.
Because in the preferred embodiment the reaction is an ongoing one, operating continuously, sludge is introduced into the chamber where mixing occurs in a continuous stream, on a first-in, first-out basis, so that the beginning of the continuous stream introduced into the chamber is also the first to leave the chamber, after it has spent the desired dwell time in the chamber. This continuous stream may contain varying degrees of dewatered sludge, within 10-60% solids content range. As the sludge dwells in the chamber, monitoring the pH and the temperature of the sludge is desirable to ensure that the predetermined levels of pH and temperature are achieved and maintained during the dwell time in the chamber. If the levels are not achieved or maintained, additional lime may be added to raise the heat and temperature through hydration. If necessary, additional water can also be added, if sufficient amounts are present in the sludge. Also, supplemental heat may of course be applied to the sludge.
In the preferred embodiment, the sludge is also preheated before being mixed with the lime. This preheating, which could potentially be of the lime as well, allows the reaction to occur more efficiently, because less released heat from the hydration reaction is then necessary to be utilized to achieve the desired temperatures. Additionally, the availability of additional heat provides the ongoing "snowball" type of reaction discussed earlier.
It is important to note that the heterogeneous character of sludge, as well as the variables in the lime utilized, for example the purity, may lead to some variation in the stoichiometric equation and therefore the reaction. Also, the rate at which the reaction occurs is dependent upon a number of factors. For example, preheating of the lime or sludge, before they are dumped in the chamber, will lessen the heat necessary to reach the preferred 70° C. temperature. Also, the particle size of the utilized lime will also affect the rate of hydration as well as the rate of pH change. A very fine (pulverized) lime will materially improve the hydration rate. Yet the storage and treating of a very fine lime is more difficult than a grosser composition.
At FIG. 1 is shown an apparatus embodying a preferred embodiment of the invention. Lime and dewatered sludge are dumped into the substantially closed chamber 10. The chamber 10 is a mixer, having an elongate generally helically shaped screw 20 driven by a motor. The screw 20 is retained within a generally cylindrical housing which serves as a chamber and as a mixer as well. It is also possible to use any other form of conveyor known in the art (and modified to reflect the present invention) as long as mixing occurs. For example, a flight screw conveyor, a hollow flight conveyor or a helical conveyor all may be used and the number of actual screws may vary. Two or more within the same chamber may be used.
As the lime and sludge travel from point "a" to point "b" they are mixed continuously. The hydration reaction occurs upon mixing and at least a substantial amount of the heat released during the reaction is retained within the sludge. Use of the screw conveyor also permits treatment of the sludge on the preferred first-in, first-out basis. Additionally, use of a screw conveyor also permits the desired dwell time, or the time required for the sludge to travel from point "a" to point "b" to be easily set, by merely adjusting the speed of the screw. Furthermore, supplemental heating of the sludge, if desired, is easily done as shown at FIG. 2. Heat elements, which provide supplemental heat to the sludge, are shown generally at 11 are placed around the conveyor shell 21. Insulation 12 is then wrapped around the heat elements 11. The heat elements 11, of a type known in the art, run the entire length of the conveyor 10 in a manner shown, and can be electrical resistance type elements, electric infrared elements, electric quartz elements or any other suitable electric elements that will provide the desired heat. This permits heating of the sludge during its travel through the conveyor. The insulation 12 also of a type known in the art, runs the entire length of the conveyor as well. The insulation 12 and heat elements 11 may be desirably combined in a unit or heat jacket for ease of assembly. The insulation 12 may also, in an embodiment not shown herein, be located on and run the entire length of the conveyor without any supplemental heat source.
Alternately, although this is not shown, the screws 20 of the conveyor on the shaft 22 on which they are carried can be hollow, and steam, hot air or hot water could be transported therethrough for a supplemental heat source.
Returning to FIG. 1, the monitors 13 serve to monitor the temperature to ,ensure that the desired, predetermined level of temperature is maintained. They may be placed wherever monitoring is desired. The monitors are any sort of thermometer, thermocouple, or other sensor known in the art including a tracking thermometer to view the temperature over time.
The pH may also be monitored during the dwell time of the sludge mixture. In the preferred embodiment, the monitoring is accomplished by withdrawal of a sample of sludge from the conveyor, from an access port (not shown), after about two hours. The sample is tested by a conventional type of pH sensor or meter known in the art to ensure it is at or above the desired level of about 12.
A spigot 15 is also shown, which permits the addition of additional water if desired for the reaction. Spigots may be located throughout the conveyor if desired, in a manner not shown here.
It will be apparent from the foregoing, that while the specific illustrations of chambers are chambers in which a single auger, only, is illustrated in the chamber, the present invention is equally adapted to placing electric heating elements in a multiple auger chamber, or inside the shafts of multiple augers in a chamber that holds two or more such augers, as is the case in U.S. Pat. No. 5,186,840, incorporated herein by reference, and that the claims of this invention cover either single-auger or multiple-auger chambers.
With specific reference to FIG. 2, it will be seen that the heating elements 11 are shown outside the cylindrical shell 21, but carried thereagainst, in order to provide heat to the sludge within the inner wall of the chamber shell 21, thus indirectly heating the sludge within the shell 21 via electric heating, with the electric supply for providing current to the heating elements 11, being provided via electric wires 16, from any suitable A.C. or D.C. source.
With reference to FIG. 2A, it will be seen that the thermocouples 13, or other suitable detection elements, are connected to a suitable feedback control member 17, via line 18, which in turn is connected via line 19, to a representative heating element 11, it being understood that a plurality of such connections 19 to heating elements 11 will be provided.
With reference now to FIG. 3, it will be seen that an alternative embodiment is provided to that of FIG. 2, in which the heating elements 23 are longitudinally disposed within the shaft 22', rather than outside the periphery of the shell 21 as is the case in FIG. 2. As is more specifically shown in FIG. 4, the elements 23 are disposed along the inside wall of the shaft 22' of the mixing member, and pass through an end plate 26 carried for rotational movement with the shaft 22' and its end flange 25, with such "passing through" of the wiring 32 for the heating elements 23 being shown in phantom, such that the wiring 32 passes through a suitable slip plate 28, or like conventional means, to in turn pass through a stationary, non-rotational end plate 27, and on to a source of power. The construction of the wiring passing through the plates 26, 27 and 28, may be in the form of a slip plate as indicated herein, or may be in the form of any conventional device for making electrical connections from the wiring of a fixed member, to electriconnections in a rotating member; such devices being conventionally available in the art. It will further be noted that the elements 23 are supported by suitable spacing disks 24, only one of which is shown along the length of the shaft 22', but it will be understood that a plurality of such spacing disks 24 will be disposed at various locations along the interior of the shaft 22'. In the embodiment of FIG. 4, it will be noted that the disks 24 support and hold the heat elements at the perimeter of the shaft, and that by attachment of the end flange 26 to the flange 25 at the end of the shaft, the elements 23 may expand longitudinally within the shaft 22', as may be necessary as they heat up. In this embodiment, the assembly as shown in FIG. 4 may readily be inserted into the central shaft 22' of the rotating auger, to allow for quick and easy maintenance and replacement of the entire assembly, if need be. In an alternative embodiment, it may be desired to fill the central cavity 29 of the shaft 22' with oil or another heat medium, preferably of the liquid type, which would be used to increase the heat transfer between the elements and the rotating auger.
With reference to the embodiment of FIG. 5, yet another alternative arrangement is provided, relative to that illustrated in FIG. 2, for having the heating elements 35 carried by a cylindrical shell 21', but in the arrangement of FIG. 5, the heating elements 35 are disposed on the inside wall of the inner housing or shell 21, for indirectly heating the sludge disposed inside the shell 21, as the sludge is mixed by a rotating mixer 38 disposed therein, and with the elements 35 being provided with electrical power via electric lines 36, as shown in FIG. 5.
The above description and the views depicted by the Figures are for purposes only and are not intended to be, and should not be construed as, limitations on the invention.
Moreover, certain modifications or alternatives may suggest themselves to those skilled in the art upon reading of this specification, all of which are intended to be within the spirit and scope of the present invention as defined in the appended claims. | Apparatus and process for pathogen reduction in waste where dewatered sludge having a solids content in the range of 10-60% is mixed with a selected alkaline additive selected from the group consisting of calcium oxide or calcium carbonate group. Hydration to calcium hydroxide occurs with an attendant release of heat. The pH of the sludge is then elevated and the heat of the hydration reaction is retained. Supplemental heat is added to the sludge, either to preheat the sludge prior to mixing it, or while mixing it, or both, such that effective neutralization of pathogens results. The supplemental heat is added by indirectly heating the sludge by heat generated by electric elements carried either in the mixing member, or by the chamber, or both, with electric power being supplied from outside the chamber. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a 371 U.S. National Stage of International Application No. PCT/EP2007/005453, filed Jun. 20, 2007. This application claims the benefit of German Patent Application No. DE 10 2006 034 153.8, filed Jul. 24, 2006. The disclosures of the above application are expressly incorporated herein by reference.
FIELD
The present invention relates to a transmission having a housing, a first output shaft, a second output shaft as well as a clutch system for the distribution of a torque between the output shafts, wherein at least two transmission components are operatively connected between the output shafts and generate lubrication oil pressure.
BACKGROUND
This section provides background information related to the present disclosure and which is not necessarily prior art.
Transfer cases are used in all-wheel drive vehicles for the distribution of the torque to a plurality of axles. The distribution takes place by a multi-disk clutch which is made such that the torque transmission between a first output shaft and a second output shaft can be controlled. On engagement by means of a controllable multi-disk clutch, one speaks of “torque on demand”.
The lubrication of transfer cases whose multi-disk clutch above all has a high cooling oil requirement in slip operation usually requires a separate oil supply. In addition, in particular on a blocking of the multi-disk clutch, the bearings which support the components of the multi-disk clutch are fully loaded, with the friction between the bearings and the components being at a maximum.
EP 0 268 904 B1 describes a transfer case having a transmission with a pump-less oil lubrication of a planetary gearset, wherein gears act as an oil pump to build up a specific pressure and wherein the lubrication oil is supplied to the planetary gearset through a passage and a gap between concentric shafts. The passage is integrated in the transmission housing. The transmission of EP 0 268 904 B1 thus does not have any direct oil lubrication of the multi-disk clutch and requires a complex and/or expensive housing design to form the passage.
SUMMARY
It is the object of the present invention to provide a transmission having improved efficiency, a simpler structure and improved oil lubrication properties.
Since the transmission of the invention delivers a pump-less oil lubrication, the transmission does not require any additional oil pump. In addition, the direct oil lubrication of the multi-disk clutch and of the supporting bearings improves the efficiency, in particular when the components are temperature loaded. The separate pipe additionally extends within the housing without the necessity of integrally forming a passage in the transmission housing. The transmission housing is simpler in this manner and requires less material and is thus lighter and cheaper.
In a first preferred embodiment of the invention, the pipe is coupled to the clutch system via a distributor element, with the distributor element conducting lubrication oil between the parts of the clutch system. The components of the clutch system are thus lubricated directly to improve the efficiency.
In a second preferred embodiment of the invention, one of the transmission components is a gear having cut-outs which are provided at at least one side surface of the gear. The lubrication oil is conducted through the cut-outs into the toothed arrangements of the gear to increase the lubrication oil pressure and thus to improve the lubrication oil supply.
In a third improved embodiment of the invention, a lubrication oil shield plate is provided which shields the transmission components with respect to the lubrication oil. The lubrication oil shield plate prevents the respective transmission components from permanently churning in the oil sump, whereby churning losses are reduced to a minimum. The temperature of the lubrication oil is reduced in this manner and the service life of the lubrication oil is extended. In addition, the viscosity of the lubrication oil is maintained for the better lubrication of the clutch system.
In a fourth preferred embodiment of the invention, a lubrication oil supply is provided with a pan, with the pan having a lubrication oil reservoir. The lubrication oil reservoir delivers additional lubrication oil to the transmission components.
Further areas of applicability will become apparent from the description provided herein. The description and specific example in this summary section are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
The invention will be described in the following only by way of example with reference to the drawings; in which are shown:
FIG. 1 shows a schematic representation of a motor vehicle powertrain equipped with a transfer case;
FIG. 2 illustrates a first sectional representation of a first embodiment of the transfer case;
FIG. 3 illustrates a second sectional representation of the first embodiment of the transfer case;
FIG. 4 shows a perspective representation of a housing a gear and a first embodiment of an oil shield plate of the transfer case;
FIG. 5 shows a perspective representation of the housing, the gear and a second embodiment of the oil shield plate of the transfer case;
FIG. 6 shows a perspective representation of a third embodiment of the oil shield plate;
FIG. 7 shows a perspective representation of a fourth embodiment of the oil shield plate;
FIG. 8 shows a perspective representation of a fifth embodiment of the oil shield plate;
FIG. 9 illustrates a sectional representation of a second embodiment of a transfer case;
FIG. 10 shows a perspective representation of a housing, a gear, an output shaft and a clutch lubrication arrangement of the second embodiment of the transfer case;
FIG. 11 shows a perspective representation of a lubrication oil supply of the clutch lubrication arrangement of FIG. 10 ;
FIG. 12 shows a sectional representation of a first embodiment for the clutch lubrication arrangement of FIG. 10 ; and
FIG. 13 shows a sectional representation of a second embodiment of the clutch lubrication arrangement of FIG. 10 .
DETAILED DESCRIPTION
A schematic representation of a vehicle powertrain 10 is shown in FIG. 1 which includes a drive 12 which includes a first power transmission path 14 , a second power transmission path 16 , an internal combustion engine 18 , a manual transmission 20 and a transfer case 22 . The internal combustion engine 18 generates a driving torque which drives the transfer case 22 via the manual transmission 20 . The transfer case 22 distributes the output torque of the manual transmission between the first and second power transmission paths 14 , 16 .
The first power transmission path 14 includes a Cardan shaft 24 which is driven by the transfer case 22 , a pair of half-shafts 26 connected to a pair of wheels 28 and a differential unit 30 which is operative to transmit a driving torque from the Cardan shaft 24 to one or both half-shafts 26 . In a similar manner, the second power transmission path 16 includes a Cardan shaft 32 which is driven by the transfer case 22 , a pair of half-shafts 34 connected to a pair of wheels 36 and a differential unit 38 which is operative to transmit a driving torque from the Cardan shaft 32 to one or both half-shafts 34 .
A control unit 40 controls the operation of the transfer case 22 on the basis of a plurality of vehicle parameters. The control unit 40 is electronically connected to at least one sensor and preferably to a plurality of further sensors. Exemplary sensors include a yaw rate sensor 42 and/or wheel speed sensors 44 . The sensors 42 , 44 detect a plurality of operating states, e.g. the yaw rate of the vehicle, the speed of each wheel and/or the speed of the vehicle. The control unit 40 processes the signal or signals and generates a control signal, with at least one actuator of the transfer case 22 being controlled on the basis of the control signal to distribute a torque between the power transmission paths 14 , 16 .
The components of a first embodiment of the transfer case 22 will now be described with reference to FIG. 2 and FIG. 3 . The transfer case 22 includes a transmission housing 50 , a first output shaft 52 , a second output shaft 54 , a multi-disk clutch 56 , an actuator 58 and torque transmission components 60 , 62 , 64 . The first output shaft 52 rotates around a first axis A and is driven directly by an output shaft, not shown, of the manual transmission 20 . The second output shaft 54 rotates around a second axis B. The multi-disk clutch 56 is controllable to control a torque transmission between the first output shaft 52 and the second output shaft 54 .
The transfer case 22 furthermore includes a clutch lubrication arrangement for the lubrication of the components of the multi-disk clutch 56 and of the supporting bearings. The clutch lubrication arrangement has a pressure chamber 66 integrally shaped in the transmission housing 50 , a pipe 68 and a distributor element 70 . The pipe 68 extends from the pressure chamber 66 to the multi-disk clutch 56 to supply lubrication oil from the pressure chamber 66 to the multi-disk clutch 56 . The distributor element 70 conducts the lubrication oil to the different components and to the supporting bearings of the multi-disk clutch 56 . The transfer element 70 in particular includes a plurality of openings 71 which distribute the supplied lubrication oil in different directions. The pipe 68 is preferably shaped of plastic and the distributor element 70 is preferably an injected molded part. As FIG. 3 shows, converging free spaces are formed with a spacing X and Y respectively in each case between the idler gear 62 and the second gear 64 as well as the transmission housing 50 . The spacings converge in the direction of rotation of the respective gear and serve to regulate the lubrication oil conveying amount. The converging free spaces in particular act as nozzles to increase the lubrication oil pressure.
The torque transmission takes place by the torque transmission components which include a first gear 60 , an idler gear 62 and a second gear 64 . The first gear 60 is rotationally fixedly connected to a component of the multi-disk clutch 56 and is rotationally journaled around the first output shaft 52 . The second gear 64 is rotationally fixedly connected to the second output shaft 54 . The idler gear 62 is rotationally journaled within the transmission housing 50 and meshes with each of the first and second gears 60 , 64 . The idler gear 62 and the second gear 64 dip partly into the lubrication oil which is located in the transmission housing and whose level is indicated by the line SN.
With respect to FIG. 2 , the multi-disk clutch 56 includes a clutch hub 73 which is rotationally fixedly connected to the first output shaft 52 . The clutch hub 73 can be coupled with friction locking via respective friction disks 72 to a clutch basket 74 which is rotationally journaled around the first axis A of the multi-disk clutch 56 or of the first output shaft 52 . The friction locking for the transmission of a torque between the clutch hub 73 and the clutch basket 74 is effected by means of a pressure plate 76 which is axially displaceable against the pre-stress of a plate spring arrangement 78 and hereby presses the respective friction disks 72 of the clutch hub 70 and the clutch basket 74 toward one another.
To selectively displace the pressure plate 76 against the pre-stress and to hereby actuate the multi-disk clutch 56 , the actuator 58 includes a support ring 80 and an adjustment ring 82 which are arranged coaxially to one another and with respect to the axis A. The support ring 80 is rotationally fixed and held fixedly axially. For this purpose, the support ring 80 is supported at the first output shaft 52 or a section 88 by means of a radial bearing 84 and of an axial bearing 86 and the support ring 80 is held rotationally fixedly by shape matched connection to a securing section of the transmission housing (not shown). The adjustment ring 82 is rotationally and axially displaceably journaled and it is supported at the pressure plate 76 by means of an axial bearing 90 .
The support ring 80 and the adjustment ring 82 each have a plurality of ball grooves 92 and 94 respectively at the mutually facing sides. Said ball grooves extend along the respective peripheral direction with respect to the axis A. A respective ball groove 92 of the support ring 80 and a ball groove 94 of the adjustment ring 82 stand opposite one another and hereby each surround an associated ball 96 . The ball grooves 92 , 94 are inclined with respect to the normal plane of the axis A, i.e. the ball grooves 92 , 94 have a varying depth along the named peripheral extent. It is hereby achieved that a rotational movement of the adjustment ring 82 relative to the rotationally fixedly held support ring 80 results in an axial displacement of the adjustment ring 82 so that the pressure plate 76 is axially offset by such a rotational movement of the adjustment ring 82 and the multi-disk clutch 56 can hereby be actuated. The pre-stress effected by the plate spring arrangement 78 in this respect ensures that the respective ball 96 remains captured in the associated ball grooves 92 , 94 in every rotational position of the adjustment ring 82 relative to the support ring 80 .
To be able to bring about the explained rotational movement of the adjustment ring 82 , it is coupled to an electric drive motor 100 via a gear drive 98 . A toothed segment 102 which is made as an angular segment is shaped radially outwardly along a angular range of approximately 90° at the adjustment ring 82 . This toothed segment 102 forms, together with a worm gear 104 of the drive motor 100 , the gear drive 98 . The teeth of the toothed segment 102 of the adjustment ring 82 can have a pitch angle with respect to the axis A of between 5° and 15°, for example. An axis C of the helical gear shaft 104 of the drive motor 100 , on the one hand, and the axis A or the axis of rotation of the adjustment ring 82 with the toothed segment 102 , on the other hand, intersect one another and form an axial angle of 90°.
The actuation of the shown multi-disk clutch 56 for the transmission of the torque between the first output shaft 52 and the second output shaft 54 takes place as follows:
By actuation of the drive motor 100 , a corresponding rotational movement of the worm gear 104 around the axis C is effected. This results due to the gear drive 98 in a rotational movement of the adjustment ring 82 around the axis A. The slanted position of the teeth of the toothed segment 102 of the adjustment ring 82 is in this connection aligned such that the axial forces of the helical gear pair caused by the slanting toothed arrangement on the adjustment rig 82 in the direction of the desired movement of the adjustment ring 82 act to bring about the pressing actuation of the multi-disk clutch 56 . The cooperation of the ball grooves 94 of the adjustment ring 82 via the respective ball 96 with the associated ball groove 92 of the support ring 80 has the effect during the rotational movement of the adjustment ring 82 that the adjustment ring 82 moves away axially from the support ring 80 and displaces the pressure plate 76 axially against the bias of the plate spring arrangement 78 . The respective friction disks 72 of the clutch hub 70 and the clutch basket 74 are hereby pressed toward one another such that an increasing torque can be transmitted from the clutch hub 70 to the clutch basket 74 . The release of the friction locking hereby effected takes place in the reverse order, i.e. the drive motor 100 causes the adjustment ring 82 to make a rotational movement in the reverse sense, with the corresponding axial movement of the adjustment ring 82 and the pressure plate 76 being supported in the direction of the support rig 80 by the plate spring arrangement 78 .
On the torque transmission by the multi-disk clutch 56 , the first gear 60 rotates around the axis A and drives the idler gear 62 . The idler gear 62 thus drives the second gear 64 around the axis B. Normally, the gears 62 , 64 have the direction of rotation reproduced by the arrows so that their portions dipping into the lubrication oil sump move with respect to one another. Pressure is generated in the toothed engagement by the conveying effect of the gears 62 , 64 to effect a conveying of the lubrication oil via the pressure chamber 66 , the pipe 68 and the distributor element 70 up to and into the actuator and the multi-disk clutch. In this connection, the components of the actuator 58 , in particular the supporting bearings 84 , 86 , 90 , and the components of the multi-disk clutch 56 are directly lubricated.
As FIG. 4 shows, radially extending cut-outs 122 are provided in an end face 120 of the idler gear 62 . Furthermore, a lubrication oil shield plate 124 is provided which approximately surrounds the lower half of the idler gear 62 . The pan-shaped lubrication oil shield plate 124 has side walls 126 and a peripheral section 128 between the side walls 126 and serves for the reduction of temperature development and for the regulation of the lubrication oil conveying amount. The lubrication oil shield plate 124 in particular prevents the idler gear 62 from constantly churning in the oil sump in the transfer case 22 . An unwanted foaming of the lubrication oil is hereby caused and the resulting churning losses result in an unwanted temperature increase specifically in the higher speed range and thus have to be reduced to a minimum.
In the embodiment of the lubrication oil shield plate 124 shown in FIG. 4 , openings are provided in the side walls 126 , with lubrication oil flowing in via a curved elongate hole 130 which is formed in the side wall 126 and being conducted into the toothed arrangement of the gears via the cut-outs 122 . In another embodiment shown in FIG. 5 , the elongate holes 130 a are formed at the edge between the side walls 126 a and the peripheral section 128 a . The lubrication oil shield plate 124 a includes additional openings 132 a in the side walls 126 a which serve for the holding tight of the lubrication oil shield plate 124 a within the transmission housing 50 , with the openings 132 a taking up projections, not shown, of the transmission housing 50 .
FIGS. 6 to 8 show additional embodiments of the lubrication oil shield plate. The lubrication oil shield plate 124 b of FIG. 6 is similar to the lubrication oil shield plate 124 a of FIG. 5 , but the elongate holes 130 b are formed at the bottom between the side walls 126 b and the peripheral portion 128 b , with the elongate holes 130 b lying completely within the lubrication oil sump. The lubrication oil shield plate 124 c of FIG. 7 is similar to the lubrication oil shield plate 124 of FIG. 4 , but made without openings in the side walls 126 c . Instead, an opening 134 c is provided in peripheral section 128 c . The lubrication oil shield plate 124 d of FIG. 8 is similar to the lubrication oil shield plate 124 b of FIG. 6 . Instead of openings in the side walls 126 d , however, an intermediate opening 130 d is provided in the peripheral section 128 d.
The components of a second embodiment of a transfer case 22 ′ will now be described with reference to FIG. 9 and FIG. 10 . The transfer case 22 ′ includes a transmission housing 50 ′, a first output shaft 52 ′, a second output shaft 54 ′, a multi-disk clutch 56 ′, an actuator 58 ′ and torque transmission components 60 ′, 62 ′, 64 ′. The first output shaft 52 ′ rotates around a first axis A′ and is driven directly by an output shaft, not shown, of the manual transmission 20 . The second output shaft 54 ′ rotates around a second axis B′. The multi-disk clutch 56 ′ is controllable to control a torque transmission between the first output shaft 52 ′ and the second output shaft 54 ′. In accordance with the second embodiment, the transfer case 22 ′ is made as a chain gear, with the torque transmission component including gears 60 ′, 64 ′ which are rotationally operatively connected by a chain 62 ′. The chain 62 ′ has a plurality of chain links 140 which form teeth 142 ( FIGS. 12 and 13 ). The teeth 142 mesh with the teeth of the gears 60 ′, 64 ′. The multi-disk clutch 56 ′ and the actuator 58 ′ each include components like the multi-disk clutch 56 and the actuator 58 ′ respectively.
With reference to FIGS. 10 to 13 , the transfer case 22 ′ furthermore includes a clutch lubrication arrangement 150 for the lubrication of the components of the multi-disk clutch 56 ′ and of the supporting bearings. The clutch lubrication arrangement 150 has a lubrication supply 152 and at least one pipe 154 a , 154 b . Although it is not shown, the clutch lubrication arrangement 150 can furthermore have a distributor element which distributes the supplied lubrication oil in different directions. The lubrication oil supply 152 is preferably an injection molded part and has a pan 156 having two arms 158 extending laterally. The pan 156 includes side walls 160 , end walls 162 , 162 ′ and a base 164 . The side walls 160 as well as the arms 158 form a chain path 165 through the chain 62 ′ runs. The arms 158 and an arcuate surface 166 of the end wall 162 ′ form a pocket which partly encloses the gear 60 ′.
The lubrication oil collects within the trough 156 , whereby an additional lubrication oil sump is formed. The base 164 includes passages, not shown, through which lubrication oil is supplied to the chain 62 ′. The pan 156 has the task of catching the lubrication oil drawn up from the lubrication oil sump by the chain 62 ′ and of immediately supplying it to the chain 62 ′ again. That lubrication oil is thus captured again which is not immediately conveyed into the multi-disk clutch 56 ′ through the pipe 154 , 154 b . The pan 156 thus serves for the improvement of the conveying power of the transfer case 22 ′.
In a first embodiment of the clutch lubrication arrangement 150 , a passage 170 is formed through the end wall 162 ′ and the surface 166 . The pipe 154 a is connected to a connection pipe 172 ( FIG. 12 ) to establish flow communication between the lubrication oil supply 152 and the multi-disk clutch 56 ′ and the actuator 58 ′. In a second embodiment of the clutch lubrication arrangement 150 , a passage 174 is formed by an arm 158 with the pipe 154 a being connected to a connection pipe 176 to establish flow communication between the lubrication oil supply 152 and the multi-disk clutch 56 ′ and the actuator 58 ′.
The chain 62 ′ carries lubrication oil upwardly out of the lubrication oil sump within the transfer case 22 ′. Normally, the gear 60 ′ and the chain 62 ′ have the direction of rotation reproduced by the arrows. Pressure is generated in the tooth engagement region ZB by the conveying effect of the gear 60 ′ and of the chain 62 ′ to effect a conveying of the lubrication oil via the pipe 154 a and/or the pipe 154 b up to and into the actuator 58 ′ and the multi-disk clutch 56 ′. In accordance with the first embodiment of the clutch lubrication arrangement 150 , the lubrication oil is conducted through the passage 170 and the connection pipe 172 up to the pipe 154 a . In accordance with the second embodiment of the clutch lubrication arrangement 150 , the lubrication oil is conducted through the passage 174 and the connection pipe 176 up to the pipe 154 b.
Since the transfer case 22 , 22 ′ of the invention provides a pump-less oil lubrication, the transfer case 22 , 22 ′ does not require any additional oil pump. In addition, the direct oil lubrication of the multi-disk clutch 56 , 56 ′ and of the supporting bearings improves the efficiency, in particular when the components are temperature loaded. Individual parts of the oil lubrication system, for example the pipe 68 , 154 a , 154 b , the distributor element 70 and the lubrication oil supply 152 , can be made of plastic. The parts are thus easy and cheap to make. In addition the pipe 68 , 154 a , 154 b extends within the housing 50 , 50 ′ without the need of forming a passage integrally in the transmission housing.
REFERENCE NUMERAL LIST
10 vehicle powertrain
12 drive
14 , 16 power transmission path
18 internal combustion engine
20 manual transmission
22 , 22 ′ transfer case
24 , 32 Cardan shaft
26 , 34 half-shafts
28 , 36 wheels
30 , 38 differential unit
40 control unit
42 , 44 sensors
50 , 50 ′ transmission housing
52 , 52 ′, 54 , 54 ′ output shaft
56 , 56 ′ multi-disk clutch
58 , 58 ′ actuator
60 , 60 ′, 64 , 64 ′ gear
62 idler gear
62 ′ chain
66 pressure chamber
68 , 154 a , 154 b pipe
70 distributor element
71 opening
72 friction disks
73 clutch hub
74 clutch basket
76 pressure plate
78 plate spring arrangement
80 support ring
82 adjustment ring
84 , 86 , 90 bearing
88 portion
92 , 94 ball groove
96 ball
98 gear drive
100 drive motor
102 toothed segment
104 worm gear
120 end face
122 cut-outs
124 , 124 a - d lubrication oil shield plate
126 , 126 a - d side walls
128 , 128 a - d peripheral section
130 , 130 a - d elongate hole/opening
132 a - d opening
140 chain links
142 teeth
150 clutch lubrication arrangement
152 lubrication oil supply
156 pan
158 arms
160 side walls
162 , 162 ′ end walls
164 base
165 chain path
166 surface
170 , 174 passage
172 , 176 connection pipe
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the invention, and all such modifications are intended to be included within the scope of the invention. | The present invention relates to a transmission having a housing, having a first drive output shaft, having a second drive output shaft and having a clutch system for distributing a torque between the drive output shafts. At least two transmission components are operatively connected between the drive output shafts and generate lubricating oil pressure. A separate tube extends within the housing from the at least two transmission components to the clutch system in order to supply lubricating oil to the clutch system. | 8 |
TECHNICAL FIELD
[0001] The invention relates to a support for the reed of a seam-weaving machine to make a plastic woven fabric continuous by means of a woven seam. To make the woven seam, a seam-weaving shed is formed from seam-warp threads and seam-weft threads are inserted into the seam-weaving shed and shifted against the fell. To shift the seam-weft threads against the fell, the reed has reed dents which are pivotably housed and, starting from the fabric end from which the respective seam-weft thread projects as a warp-thread fringe, press one after the other against the seam-weft thread to be shifted. According to a first mode of operation, the position of the reed dents can be staggered by means of a tilt bar and a pressure bar such that the points at which the reed dents touch the seam-weft thread to be shifted lie approximately on a straight or slightly curved line, the distance of which from the fell constantly changes across the reed.
STATE OF THE ART
[0002] Industrial-grade plastic woven fabric for uses where there is an absolutely even surface structure of the fabric, in particular in the case of flat woven plastic paper-forming screens, are made continuous by a woven seam, such as is known from EP-A-0 236 601. To produce a woven seam, warp threads are exposed to a length of e.g. 15 cm at the fabric ends which are to be joined to each other, by removing the weft threads in this area, cf. DE-A103 30 958 (=WO-2005/005718). The so-called woven seam, in which the original weave is exactly reproduced, is then formed from these warp-thread fringes and the weft threads removed from the fabric. To this end, a seam-weaving shed comprising the removed weft threads is stentered, wherein the removed weft threads serve as seam-warp threads. The warp-thread fringes are inserted alternately from the two fabric ends into this seam-weaving shed as seam-weft threads by means of draw-through grippers (cf. EP-A-0 597 494). The warp thread fringes, i.e. the seam-weft threads, and the removed weft threads, i.e. the seam-warp threads, are as a rule monofilaments from 0.1 to 0.5 mm in diameter, and the woven seam is produced after the thermosetting of the fabric, with the result that the threads already have the corrugation or knuckle corresponding to the respective weave. To obtain a woven seam which has a high tensile strength and does not differ from the rest of the fabric in the pattern of the surface which is decisive for the marking in the paper, the seam-warp threads and the knuckles of the seam-weft threads must interweave in the fabric so that a form locking results. The interweaving of the seam-warp threads and seam-weft threads according to their knuckle is achieved inter alia because the reed does not shift the seam-weft threads simultaneously over the whole length, but the seam-weft threads are progressively shifted through the seam-weaving shed, starting from their point of emergence from the fabric end (root position).
[0003] A reed which makes possible such a progressive shift of the seam-weft threads is described in DE-U-81 22 448. The reed can be pivoted into an operating position brought close to the fell. The reed dents housed pivotable on a shaft are held back from the fell by a rubber strip. A roll movable across the reed on a guide track presses the reed dents, against the elasticity of the rubber strip, one after the other against the seam-weft thread. Starting from the fabric end at which the seam-weft thread projects as a warp fringe, the roll is moved along the array of reed dents over the whole seam width for each shifting process.
[0004] The same object is achieved according to EP-A-0 043 441 by a rotatable needle cylinder which has a plurality of bending needles which are arranged in helical rows of needles. As a further possibility the shifting of seam-weft threads by means of Z-shaped needles, which are arranged in a guide bed alongside each other and individually axially displaceable, is described in this document. The needles engage in the shed with their front Z-end. The Z-shaped needles are pressed one after the other against the fell by means of a slide, with the result that the seam-weft thread is progressively shifted in a wave motion starting from its point of emergence from the fabric end.
[0005] A support for the reed of a seam-weaving machine of the type named at the outset is known from EP-A-0 586 959 in which the position of the reed dents can be staggered such that the points at which the reed dents touch the seam-weft thread to be shifted lie on a straight or slightly curved line, the distance of which from the fell increases starting from the point of emergence of the seam-weft thread from the fabric end. The weaving process can thereby be accelerated as, because of the staggering of the reed dents, the movement of the sley is already enough to progressively shift the seam-weft thread out of the fabric starting from its emerging end.
[0006] While the process known from DE-U-81 22 448, in which the reed dents are pressed one after the other against the seam-weft thread to be shifted by means of a roll running past them, can also be used with very complex fabrics, the quicker process, known from EP-A-0 586 959, in which the reed dents are arranged staggered on the sley, cannot be used with very complex fabrics, in particular with some structure-tied fabrics. By structure-tied fabrics are meant multi-layered fabrics in which the binding weft is tied into the fabric structure. If when making a woven seam firstly a sley with staggered reed dents is used according to EP-A-0 586 959 and then too many weaving faults and machine stoppages occur during the seam-weaving process, thus it is very troublesome and time-consuming to change to the process in which a sley with a running roll is used according to DE-U-81 22 448. To change over, the whole sley must actually be removed and replaced by a corresponding different sley. In cases of doubt the process with the running roll is therefore used, although there would be a time saving of 20 to 30% with the process with the staggered reed dents.
DESCRIPTION OF THE INVENTION
Technical Object
[0007] The object of the invention is to simplify in a seam-weaving process the change from the seam-weaving process using staggered reed dents to the process using a running roll.
Technical Achievement
[0008] According to the invention this object is achieved in that, with a support of the type named at the outset, a roll is provided which can be moved on a guide path across the width of the reed in order to pivot the reed dents one after the other to the fell for operation in a second mode of operation and the tilt strip or the pressure strip can be removed from the reed dents for operation in the second mode of operation.
ADVANTAGEOUS EFFECTS
[0009] The tilt strip and the pressure strip impact on the reed dents with opposite torque, with the result that together they determine the position of the reed dents. The reed dents are acted on by the torque created by the tilt strip such that their top ends are pressed towards the fell at one end of the reed and away from the fell at the other, while the pressure strip presses the upper ends of the reed dents towards the fell. Expediently both strips are arranged on the rear of the reed dents, the side facing away from the fell, wherein the tilt strip acts on the reed dents underneath the shaft and the pressure strip acts on the reed dents above this shaft. The tilt strip and the pressure strip are both housed at the support such that they can be pivoted in an approximately horizontal plane. Expediently both are rotatably housed in the centre about a vertical shaft and are acted on at the two side ends by adjustment devices, e.g. pneumatic tilt cylinders and, respectively, bearing pressure cylinders. The tilt cylinders can be controlled such that they take up a specific extended position while the bearing pressure cylinders are controlled such that they apply a specific pressing force.
[0010] Preferably the bearing pressure cylinders are controlled such that the bearing pressure cylinder on the side of the root position applies approximately 50% more force than the bearing pressure cylinder on the opposite side, wherein it is assumed that the pressure strip is housed at the centre.
[0011] As the sley advances the reed dents push the seam-weft thread to be inserted against the fell. Once the seam-weft thread is attached to the fell it presses the reed dents slightly rearward against the force of the pressure strip. In order to permit this rearward pivot movement of the reed dents, the pressure strip is housed such that it can give rearward. To this end, the normally present pivot bearing in the centre of the pressure strip is housed on a sliding block which allows a movement in the direction of the sley movement. Simultaneously the rearward end-position of the reed dents reached by the sliding block when beating up the reed dents is sensed in order to control the progressive rearward movement of the seam-weaving machine along the fabric ends.
[0012] The first mode of operation, in which the reed dents are set tilted, has been previously described. The support according to the invention can be modified with few handles such that the seam-weaving machine can also operate in a second mode of operation, in which the seam-weft threads are shifted by means of a running roll, such as is known from DE-U81 22 448 and has been described above. The roll is moved across the width of the reed on a guide track in order to pivot the reed dents one after the other towards the fell. The guide track of the roll is preferably arranged on the front of the support with the result that the roll acts on the reed dents below the shaft. The reed dents are held approximately vertical by a U-shaped bar which extends over the width of the sley. The U-shaped bar is arranged approximately at the level of the shaft with the result that the upper arm of the U-shaped bar abuts the reed dents above the shaft and the lower arm of the U-shaped bar below the shaft. The upper arm of the U-shaped bar is provided with a microcellular rubber strip and the reed dents are pivoted forwards one after the other by the roll and pressed into the microcellular rubber strip in the process. Depending on the arrangement of the tilt strip and the pressure strip, these interfere when operating in the first mode of operation and must be removed or at least pulled back from the reed dents.
[0013] For the change from the first mode of operation into the second mode of operation, the tilt strip and/or the pressure strip, if they interfere, are removed from the reed dents or dismantled, the bearing pressure and tilt cylinders or the other adjustment devices are connected without pressure or drive and the U-shaped bar is attached.
[0014] For the change from second mode of operation into the first mode of operation, the U-shaped bar is removed and the roll is moved into a parking position on the edge of the support. Also, the tilt strip and the pressure strip are brought into their operating position and the tilt and bearing pressure cylinders or the other adjustment devices subjected to pressure.
[0015] Preferably the support is structured such that the tilt strip and the pressure strip act on the reed dents on the rear, the tilt strip below the shaft and the pressure strip above the shaft, and the roll acts on the reed dents on the front below the shaft and the U-shaped bar abuts the front of the reed dents, wherein the arm of the U-shaped bar abutting the shaft has a microcellular rubber strip. For the change from the first mode of operation into the second mode of operation, the tilt strip then merely needs to be removed and the U-shaped bar screwed on. For the change from second mode of operation into first mode of operation, the U-shaped bar is unscrewed, the roll moved into a lateral parking position and the tilt strip fitted. The pressure strip is present in both modes of operation in this version of the invention as already mentioned, in the first mode of operation its task is to press the reed dents against the seam-weft thread to be shifted and thus this against the fell, and it also has the task of controlling the progressive rearward movement of the seam-weaving machine. In the second mode of operation it has no role and is thus moved back until it no longer abuts the reed dents.
[0016] The sley customarily consists of an arm hinged to the bottom end on which a crossarm or sley head is arranged which in turn carries the reed. The sley head is preferably attached to the upper end of the arm by means of a joint, wherein the joint shaft runs parallel to the pivot shaft of the sley.
[0017] In the first mode of operation this joint is blocked, with the result that the sley head is rigidly connected to the arm of the sley.
[0018] In the second mode of operation, on the other hand, the sley head can be pivoted. By means of adjustment devices, e.g. pneumatic cylinders, the sley head is pressed with an adjustable force against a stop with the result that the reed is in its basic position. In the basic position the reed is aligned approximately parallel to the arm of the sley. In the second mode of operation the angle piece is sensed or scanned in order that the sley head, when beating up the seam-weft thread, pivots rearward, and corresponding to this angle piece the progressive rearward movement of the seam-weaving machine along the fabric ends is controlled according to the advance of the seam.
[0019] The forces applied by the draw-through gripper and the bearing pressure cylinders are as small as possible in order to achieve the form locking between the seam-weft thread and the seam-warp threads. A particularly preferred procedure in the first mode of operation is that the stress which the draw-through gripper exerts on the seam-weft thread to be shifted and the force with which the bearing pressure cylinder acts on the pressure bar are not constant during the rolling-in or shifting of the seam-weft thread. These forces are preferably greater at the start, while the seam-weft thread is e.g. being pressed into the first three seam-warp threads, and are then reduced. These increased forces make sense, as the shifting of the seam-weft thread at the so-called root position, i.e. the position from which it emerges from the fabric end as a warp-thread fringe, is particularly difficult and according to experience requires greater forces. If the seam-weft thread is made to engage with say the first three warp threads it makes sense to lower the stress applied by the draw-through gripper in order to prevent the corrugation or knuckle of the seam-weft thread from being partly pulled flat. Generally the tension applied by the draw-through gripper is reduced by approximately half and the force applied by the bearing pressure cylinders is likewise approximately halved. As already mentioned, the bearing pressure cylinder on the root side applies in each case approximately 50% more force on the pressure strip than the bearing pressure cylinder on the other side. Reducing the applied forces requires a short period of time, and the sley therefore preferably remains stationary during this period of time once the seam-weft thread has been made to engage with the first seam-warp threads.
[0020] This reduction in force when shifting a seam-weft thread in a seam-weaving machine in which the seam-weft thread is progressively introduced by means of a tilted reed is particularly useful when operating the seam-weaving machine with the support according to the invention. However, this process for operating a seam-weaving machine is also suitable and advantageous for operating a seam-weaving machine which can be operated only in the first mode of operation (EP-0 586 959).
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] An embodiment example of the invention is explained below with reference to the drawing. There are shown in:
[0022] FIG. 1 in a side view, the whole sley including the drive;
[0023] FIG. 2 the support of the reed dents in a spatial representation from above and the rear;
[0024] FIG. 3 the support of the reed dents in a spatial representation from above and the front;
[0025] FIG. 4 the support in a side view, set up for the first mode of operation and
[0026] FIG. 5 the support in a side view, set up for the second mode of operation.
WAY(S) OF CARRYING OUT THE INVENTION
[0027] In FIG. 1 a sley 10 is shown which is pivoted in customary manner by a linear motor 12 as a sley drive. The sley 10 consists of an arm 14 which can be pivoted at the bottom end in a bearing and at the top end carries a sley head 16 , wherein the drive rod of the linear motor 12 is articulated to the arm 14 just below the sley head 16 . Bearing supports 18 in which a shaft 20 , removable by means of a shaft bar 21 ( FIG. 4 ), is fixed, project upwards at the lateral ends of the sley head 16 . Reed dents 22 which in their totality form the reed are ranged on the shaft 20 . For reasons of clarity, however, only one of the reed dents is represented. In their lower region the reed dents 22 have a bore with which they are strung onto the shaft 20 . Spacing rings lying between keep them at the distance which is predetermined by the thread count of the fabric.
[0028] As can be seen from FIG. 2 , on the rear of the sley head 16 which faces the linear motor 12 , a tilt strip 24 which extends over almost the whole width of the sley head 16 is housed pivotable about a vertical axis, wherein the pivot point is located in the middle of the tilt strip 24 . Tilt cylinders 26 which act on the lateral ends of the tilt strip 24 are attached to the two lateral bearing supports 18 ( FIGS. 2 and 4 ). The degree of extension of the tilt cylinders 26 can be set. The tilt strip 24 is arranged below the shaft 20 with the result that it engages with the reed dents 22 below the shaft 20 .
[0029] A pressure strip 30 is housed similar to the tilt strip 24 above the tilt strip 24 and above the shaft 20 rotatable about a vertical axis. The pressure strip 30 also extends over the whole width of the sley head 16 . Bearing pressure cylinders 32 which act on the pressure strip 30 at their lateral ends are also attached to the bearing supports 18 . The pressure strip 30 is housed in the middle at a sliding block 34 which can be displaced in a guide in longitudinal direction, i.e. in the direction of the sley movement. The front of the pressure strip 30 which acts on the reed dents 22 is provided with a rubber bearing support 36 .
[0030] The seam-weaving machine is operated in a first mode of operation by means of the tilt strip 24 and the pressure strip 30 . By way of explanation it is assumed that first of all a seam-weft thread which projects from the right-hand fabric end as a warp-thread fringe and has been inserted into the seam-weaving shed by means of a draw-through gripper is now to be rolled in and shifted against the fell by means of the sley. The points at which the reed dents 22 beat up the fell lie approximately in the centre of the length of each of the reed dents 22 . These points always lie on a straight or slightly curved line, the so-called beat-up line. When the sley 10 is located at its rear reversal point, the left-hand tilt cylinder 26 is extended and the right-hand tilt cylinder 26 withdrawn. The tilt strip 24 thus rotates in a roughly clockwise direction viewed from above. As the tilt strip 24 engages below the shaft 20 onto which the reed dents 22 are strung, the part of the reed which is located above the shaft 20 , and thus the beat-up line, moves in the opposite direction, and the reed is deformed such that the reed dents 22 on the right-hand side are pivoted slightly forwards and the reed dents on the left-hand side slightly rearward. The outermost right-hand reed dent 22 is thus the first to meet the seam-weft thread and presses it against the fell. At the rear reversal point of the sley 10 the pressure in the right-hand bearing pressure cylinder 32 is increased with the result that the seam-weft thread is pressed into the shed with particularly great force immediately after emerging from the fabric end. The draw-through gripper still applies to the seam-weft thread the relatively high draw-through stress with which it has drawn the seam-weft thread through the seam-weaving shed. Because of the high bearing pressure which is applied by the bearing pressure cylinder 32 to the seam-weft thread, and because of the draw-through stress which is applied by the draw-through gripper, it is ensured that the knuckles of the seam-weft thread grip in form locking manner and precisely with the knuckles of the first, i.e. the outermost right-hand, seam-warp threads. As mentioned at the outset, fabric-weft threads are used as seam-warp threads and fabric-warp threads as seam-weft threads, after the thermofixing of the fabric, with the result that the threads have a residual knuckle or corrugation. In order that the woven seam in the woven pattern does not differ from the fabric, the seam-warp threads and the seam-weft threads must interlock with their knuckles again corresponding to the weave. The creation of this engagement between seam-weft thread and seam-warp threads is particularly critical in the first three seam-warp threads. In order to bring the seam-weft thread into engagement with the first three seam-warp threads, the pressure in the bearing pressure cylinders 32 is approximately doubled. When the engagement with the first three seam-warp threads is created, the pressure is reduced to the normal value, thus approximately halved. The sley 10 remains stationary during the period of time necessary for the pressure reduction. This period of time is e.g. approximately 50 ms. Simultaneously the stress applied by the draw-through gripper is also reduced from the draw-through stress to the hold or roll-in stress.
[0031] While the outermost right-hand reed dents 22 press the seam-weft thread into the seam-warp threads, the sley 10 moves on. The chosen pressure in the bearing pressure cylinders 32 is such that the pressure strip 30 is pressed rearward by the reed dents 22 which have reached the fell, i.e. pivoted clockwise in the chosen example. The reed dents 22 act progressively from right to left on the seam-weft thread to be shifted with the result that finally this is completely pressed against the fell and engages with the seam-warp threads. Generally, the next seam-weft thread to be shifted is a warp-thread fringe which projects from the left-hand fabric end. The tilt cylinders 26 and the bearing pressure cylinders 32 are therefore controlled in mirror-image fashion, i.e. the right-hand tilt cylinder 26 is now extended and the pressure in the left-hand bearing pressure cylinder 32 raised to the pressure necessary to press the seam-weft thread into the first left-hand seam-warp threads.
[0032] Depending on the horizontal distance of the bearing of the sley 10 from the fell, the sliding block 34 at which the pressure strip 30 is housed is shifted rearward to a greater or lesser degree after the shifting of a seam-weft thread. The rearward end-position reached by the sliding block 34 when beating up the reed dents 22 is sensed by a first sensor 35 . If the displacement of the end-position exceeds a predetermined extent, the seam-weaving machine is moved rearward from the fell by a predetermined step. The progression of the fell is thereby taken into account. As both fabric ends fest are clamped fast, it is the seam-weaving machine which must be moved on according to the progress of the seam.
[0033] The seam-weaving process according to this first mode of operation is very quick, but cannot be used with all fabrics. With very complex fabrics, in particular with structure-tied fabrics, it has thus far not been possible to use it. If too many faults occur when making a continuous fabric and therefore the seam-weaving machine too often remains stationary, then it is possible to change the invention over to a second mode of operation with which almost all fabric can be made continuous. This requires a modification of the sley 10 . In FIGS. 1 to 3 both the components necessary for the first mode of operation and those necessary for the second mode of operation are fitted to the sley 10 . FIG. 4 shows, on the other hand, the sley 10 with the components which are necessary for the first mode of operation, and FIG. 5 shows the sley 10 with the components which are necessary for the second mode of operation, wherein in each case the interfering components of the other mode of operation are removed or have been moved out of the operating position.
[0034] To modify the sley 10 from the first into the second mode of operation, the reed dents 22 can remain on the shaft 20 , but the tilt strip 24 is removed and a bar 40 with a U-profile is attached in front of the reed dents 22 , added to which the bearing pressure cylinders 32 are connected without pressure, with the result that the pressure strip 30 no longer abuts the rear of the reed dents 22 . As will be explained later in more detail, the fixing of a joint 64 between the sley head 16 and the arm 14 is also released for the second mode of operation. The U-shaped bar 40 is screwed on at approximately the level of the shaft 20 to the shaft bar 21 to which the shaft 20 with the reed dents 22 is attached. The lower arm 42 of the U-profile of the bar 40 abuts the reed dents 22 below the shaft 20 , and the upper arm 44 of the U-profile abuts the reed dents 22 above the shaft 20 . The upper arm 44 carries a microcellular rubber strip, not shown, which is inserted into a groove 46 on the rear of the upper arm 44 .
[0035] Below the lower arm 42 on the sley head 16 there is a guide track 50 which extends over the whole width of the sley head 16 and in which a roll 52 is guided. In the second mode of operation the roll 52 acts on the bottom ends of the reed dents 22 below the lower arm 42 , with the result that the upper, substantially longer part of the reed dents 22 is pivoted forwards and in the process is pressed into the microcellular rubber strip on the rear of the upper arm 44 of the bar 40 . When the roll 52 is moved into the guide track 50 over the front side of the sley head 16 , it presses the reed dents 22 forward one after the other. The roll 52 is carried by a sliding block, sliding in the guide track 50 , which is fixed to a toothed belt 54 which is guided over two cogged-belt pulleys 56 which are arranged laterally at the bearing supports 18 . The left-hand cogged-belt pulley 56 is driven by a step motor 58 ( FIG. 3 ). In the first mode of operation the roll 52 is not needed and is therefore moved into a lateral parking position.
[0036] To shift the seam-weft threads in the second mode of operation, the sley 10 is pivoted into its front end-position in which the reed dents 22 , the beat-up line of which is aligned parallel to the fell in the second mode of operation, stand immediately in front of the fell or can already touch the seam-weft thread to be shifted. The sley 10 stops briefly in its front end-position, while the roll 52 is pulled along the guide track 50 and in the process briefly pivots out the individual reed dents 22 one after the other, with the result that these can then roll the seam-weft thread into the shed. After the roll 52 has passed, the individual reed dents 22 are pivoted back into their starting situation by the microcellular rubber strip in the groove 46 . The roll 52 thus creates a continuous wave in the reed dents 22 .
[0037] A sheet-metal strip 60 which extends over the whole width of the sley head 16 and is attached to the lower arm 42 is arranged before the bottom ends of the reed dents 22 . The roll 52 thereby does not directly act on the bottom ends of the reed dents 22 , but firstly displaces only the sheet-metal strip 60 which transmits this displacement onto the reed dents 22 . The shape of the continuous wave can be influenced by the elasticity of the sheet-metal strip 60 . The more elastic the sheet-metal strip 60 , the steeper the edges of the wave. If a flatter wave is desired, a thicker sheet-metal strip 60 of lower elasticity can be used, or two sheet-metal strips 60 can be inserted.
[0038] As is seen in FIG. 1 , the arm 14 of the sley 10 has a joint 62 approximately in the middle of its length. The angle which the sley head 16 and thus the reed dents 22 adopt vis-à-vis the fell can be set by means of this joint 62 .
[0039] The sley head 16 is articulated to the top end of the arm 14 by means of the joint 64 already mentioned above ( FIG. 3 ). The joint 64 is operative only in the second mode of operation. The sley head 16 can be tilted by two pneumatic pressure cylinders 66 , 68 . The left-hand pressure cylinder 66 is smaller in size and is used in the second mode of operation to control the force with which the reed is pressed against the fell. A second sensor 69 is fitted to the arm 14 of the sley 10 and senses the angle of tilt of the sley head 16 around the joint 64 . The second sensor 69 ascertains the end-position reached under the force of the left-hand pressure cylinder 66 and thereby controls the progressive rearward movement of the seam-weaving machine.
[0040] The larger right-hand pressure cylinder 68 serves likewise in the second mode of operation to support the sley head 16 at the rear reversal point of the sley movement in order that this and the reed dents 22 do not strike the harness. When the sley 10 moves rearward the right-hand pressure cylinder 68 is therefore subjected to pressure.
[0041] Attached to the bottom of the sley head 16 is an angle piece 70 , the vertical arm of which rests against the front of the arm 14 when the reed is aligned parallel to the arm 14 , and which thereby prevents the sley head 16 from tilting forwards. In the first mode of operation the joint 64 is fixed by solidly connecting the angle piece 70 to the arm 14 by means of a threaded bolt 72 ( FIGS. 3 and 4 ). The pressure cylinders 66 , 68 are thereby without effect in the first mode of operation. For the second mode of operation, on the other hand, the threaded bolt 72 is removed ( FIG. 5 ), with the result that the joint 64 becomes operative.
[0042] In a recess of the U-shaped bar 40 a thrust block 74 is arranged which in the first mode of operation serves to bend the shaft 20 , as shown in FIGS. 5 and 6 of EP-0 586 959, in order to match the shape of the reed to the curvature of the fell.
LIST OF REFERENCE NUMBERS
[0000]
10 sley
12 linear motor
14 arm
16 sley head
18 bearing supports
20 shaft
21 shaft bar
22 reed dents
24 tilt strip
26 tilt cylinder
30 pressure strip
32 bearing pressure cylinder
34 sliding block
35 first sensor
36 rubber bearing support
40 U-shaped bar
42 bottom arm
44 top arm
46 groove
50 guide track
52 roll
54 toothed belt
56 cogged-belt pulley
58 step motor
60 sheet-metal strip
62 joint
64 joint
66 left-hand pressure cylinder
68 right-hand pressure cylinder
69 second sensor
70 angle piece
72 threaded bolt
74 thrust block | The support is provided for the reed of a seam weaving machine used for joining two opposite ends of a synthetic fabric by means of a woven seam. The reed is provided with pivotally mounted reed dents ( 22 ) for sliding seam weft threads to the fell. The support comprises a tilt strip ( 24 ) and a pressure strip ( 30 ) which are disposed at a distance from the bearing mechanism ( 20 ) and apply opposite torques to the reed dents ( 22 ), as well as devices ( 26, 32 ) for positioning the tilt strip ( 24 ) and the pressure strip ( 30 ) at angles relative to the bearing mechanism ( 20 ) in order to stagger the reed dents ( 22 ) in the position thereof by means of the tilt strip ( 24 ) and the pressure strip ( 30 ) so as to operate the machine in a first mode of operation. A roll is also provided which can be moved along a track across the width of the reed in order to successively swivel the reed dents ( 22 ) towards the fell so as to operate the machine in a second mode of operation. The tilt strip ( 24 ) or the pressure strip ( 30 ) can be removed from the reed dents ( 22 ) to operate the machine in the second mode of operation. A U-shaped bar ( 40 ) can be placed on the front side of the reed dents ( 22 ) in the second mode of operation, the bottom arm ( 42 ) of said U-shaped bar ( 40 ) impinging the reed dents ( 22 ) below the shaft ( 20 ) and the top arm ( 44 ) thereof impinging the reed dents ( 22 ) above the shaft ( 20 ). | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Japanese Patent Application No. 2015-130293 filed on Jun. 29, 2015, the entire contents of which are incorporated by reference herein.
TECHNICAL FIELD
[0002] The present invention relates to a wireless aircraft flying in the air and a method for outputting location information.
BACKGROUND ART
[0003] A wireless aircraft flying in the air with a propeller that rotates by the motor has been put to practical use in recent years. Such a wireless aircraft is used to take an image such as moving and still images.
[0004] A wireless aircraft takes an image from height and performs image analysis on the taken image.
[0005] Moreover, apart from the wireless aircraft, it is generally performed that when a user wearing an image capturing device encounters a danger, the image of the place is transmitted to a center along with the location information, and when another user wearing an information display device approaches this place, information such as an image of a dangerous place is delivered to the user. (Refer to Patent Document 1)
CITATION LIST
Patent Literature
[0006] Patent Document 1: JP 2015-41969A
SUMMARY OF INVENTION
[0007] Patent Document 1 describes that the center acquires the location information of each user's information display device and if judging that the acquired location information on a user's information display device is matched with location information on a dangerous place which has been transmitted from an image capturing device, the information such as an image of the dangerous place is transmitted to the user's information display device.
[0008] However, in the method described in Patent Document 1, the cost of the entire system increases as the image capturing device needs to transmit the location information to the center, and the process might become complicated as whether or not it is dangerous is judged based on the biological information.
[0009] Therefore, in the present invention, the inventor has paid attention that a cost can be reduced, a process is simplified, and the necessary information can be output by a wireless aircraft which takes an image, performs image recognition on the taken image, and transmits the location information of the taken image to the terminal.
[0010] Accordingly, an objective of the present invention is to provide a wireless aircraft and a method for outputting location information to reduce a cost, simplify the process, and output the necessary information.
[0011] The first aspect of the present invention provides a wireless aircraft flying in the air, including:
[0012] a camera unit that takes a live image;
[0013] a location information detecting unit that detects the location information on which the wireless aircraft is located;
[0014] a specific image storage unit that stores a specific image of an extracted object;
[0015] an object recognition unit that compares the live image taken by the camera unit with the specific image to recognize an object to be extracted from the live image; and
[0016] a location information output unit that outputs the location information detected by the location information detecting unit when the object is recognized.
[0017] According to the first aspect of the present invention, the wireless aircraft flying in the air takes a live image, detects the location information on which the wireless aircraft is located, stores a specific image of an extracted object, compares the live image taken by the camera unit with the specific image to recognize an object to be extracted from the live image, and outputs the location information detected by the location information detecting unit when the object is recognized.
[0018] The first aspect of the invention belongs to the category of a wireless aircraft but has the same working effects under different categories such as a method for outputting location information.
[0019] The second aspect of the present invention provides the wireless aircraft according to the first aspect of the present invention, including a device activating unit that activates a predetermined device according to the type of the specific image when the wireless aircraft moves to the position in which the location information was output.
[0020] According to the second aspect of the present invention, the wireless aircraft according to the first aspect of the present invention activates a predetermined device according to the type of the specific image when the wireless aircraft moves to the position in which the location information was output.
[0021] The third aspect of the present invention provides a method for outputting the location information performed by the wireless aircraft flying in the air includes the steps of;
[0022] taking a live image;
[0023] detecting the location information on which the wireless aircraft is located;
[0024] storing a specific image of an extracted object;
[0025] comparing the live image taken by the camera unit with the specific image to recognize an object to be extracted from the live image; and
[0026] outputting the detected location information when the object is recognized.
[0027] The present invention can provide a wireless aircraft and a method for outputting location information to reduce a cost, simplify the process, and output the necessary information.
BRIEF DESCRIPTION OF DRAWINGS
[0028] FIG. 1 shows an overview of the location information output system 1 .
[0029] FIG. 2 shows an overall schematic diagram of the location information output system 1 .
[0030] FIG. 3 is a functional block diagram of the wireless aircraft 10 and the portable terminal 100 .
[0031] FIG. 4 is a flow chart of the location information output process executed by the wireless aircraft 10 and the portable terminal 100 .
[0032] FIG. 5 is a flow chart of the countermeasure process executed by the wireless aircraft 10 .
[0033] FIG. 6 shows the image data table that the wireless aircraft 10 stores.
[0034] FIG. 7 shows the imaging target area 3 on which the wireless aircraft 10 takes an image.
[0035] FIG. 8 shows the location information table that wireless aircraft 10 stores.
[0036] FIG. 9 shows the countermeasure information table that wireless aircraft 10 stores.
[0037] FIG. 10 shows the farm products map that the portable terminal 100 displays.
DESCRIPTION OF EMBODIMENTS
[0038] Preferred embodiments of the present invention are described below with reference to the attached drawings. However, this is illustrative only, and the scope of the present invention is not limited thereto.
Overview of Location Information Output System 1
[0039] FIG. 1 shows an overview of the location information output system 1 according to a preferred embodiment of the present invention. The location information output system 1 includes an imaging target area 3 , a GPS system 5 , a wireless aircraft 10 , and a portable terminal 100 .
[0040] The wireless aircraft 10 flies in the air with the propeller, etc., of its own. Moreover, the wireless aircraft 10 is a wireless aircraft which is capable of remote control from an external terminal such as the portable terminal 100 or other operational terminals and automatic control based on the predetermined action which is programmed in it. Moreover, the wireless aircraft 10 includes the data communication functions for transmitting the taken image data, its own location information, and other data, etc., to the portable terminal 100 , and receiving the data, etc., transmitted from the portable terminal 100 .
[0041] The wireless aircraft 10 includes a camera, etc., that takes the moving and still images of the current status of the imaging target area 3 as a live image. Moreover, the wireless aircraft 10 detects and acquires its own location information from the GPS system 5 . Moreover, the wireless aircraft 10 includes a memory unit that stores a specific image of the extracted object. Examples of the extracted objects are a farm product and a person. Examples of the specific image of the extracted objects are size, shape, color, and irregularity in case of a farm product, and age, sex, and costume in case of a person. Moreover, the wireless aircraft 10 compares a live image with a specific image to recognize an object to be extracted from the live image. The objects to be extracted are size, shape, color, and irregularity of the farm products, or age, sex, and costume of the person included in the live image. The wireless aircraft 10 includes the data communication functions that transmit the location information of its own acquired from the GPS system 5 to the portable terminal 100 when it has recognized the object. Moreover, the wireless aircraft 10 includes a device activating unit that activates a predetermined device according to the type of the specific image when moved back to the previous position in which the location information was output. Examples of the activation of the predetermined device is a chemical spraying for the harvest of the crops or for exterminating the pests and diseases in case of the farm products or a distribution of handbills depending on the sex or assistance including route guidance in case of a person.
[0042] The user terminal 100 is a home or an office appliance with a data communication function and performing a data communication with the wireless aircraft 10 . Examples of the mobile terminal 100 includes information appliances such as a mobile phone, a mobile terminal, a personal computer, a net book terminal, a slate terminal, an electronic book terminal, and a portable music player.
[0043] In this embodiment, the imaging target area 3 is a place such as a field where farm products are grown, and the grown farm products are a-p. Moreover, the extracted object is a farm product. The specific image is an image of the farm products for determining the appropriate harvest time. Moreover, the information recognized as extracted objects are size, shape, color, and irregularity of the farm products. Moreover, the activation of the predetermined device is a chemical spraying for the harvest of the crops or for exterminating the pests and diseases.
[0044] Moreover, the imaging target area 3 , the extracted object, the specific image, the information recognized as extracted object, and the activation of the predetermined device may be changed as appropriate. Furthermore, the imaging target area 3 , the extracted object, the specific image, the information recognized as extracted object, and the activation of the predetermined device may be other than the farm products. For example, when the imaging target area 3 is crowded place, the extracted object is a person, the specific image is a person who is appropriate for the predetermined conditions, the information recognized as extracted objects are age, sex, and costume of a person, and the activation of the predetermined device may be an activation of a device that distributes handbills or performs the assistance including route guidance. Examples of the predetermined conditions are age, sex, and costume. Moreover, the activation of a predetermined device may be other actions.
[0045] First, for the farm products grown in the imaging target area 3 , the portable terminal 100 transmits a plurality of the image data of the farm products for determining the appropriate harvest time to the wireless aircraft 10 (step S 01 ). The wireless aircraft 10 stores the image data transmitted from the portable terminal 100 . In step S 01 , the portable terminal 100 acquires the image data of the farm products for determining the appropriate harvest time and transmits it through the public line network such as the Internet. Moreover, in step S 01 , the portable terminal 100 may take an image of the farm products for determining the appropriate harvest time using the imaging device such as a camera installed in the portable terminal 100 , and transmit the taken image data to the wireless aircraft 10 . Moreover, the image data acquired by other methods may be transmitted to the wireless aircraft 10 . Furthermore, the number of the image data transmitted from the mobile terminal 100 may be one.
[0046] The portable terminal 100 transmits the imaging instruction to the imaging target area 3 to the wireless aircraft 10 (step S 02 ). In step S 02 , the location information of the imaging target area 3 is included in the imaging instruction. In step S 02 , the portable terminal 100 may directly instruct the location information of the imaging target area 3 , or instruct through other applications, etc., such as map application, or otherwise instruct the location information acquired through the public line network.
[0047] The wireless aircraft 10 may move to the imaging target area 3 based on the location information of the imaging target area 3 included in the imaging instruction and take the live image of the farm products (step S 03 ). In step S 03 , the wireless aircraft 10 may move to the imaging target area 3 based on the location information of imaging target area 3 that was previously programming into it and take the live image of the farm products. In step S 03 , the wireless aircraft 10 takes the live image of the farm products.
[0048] The wireless aircraft 10 takes an image of the farm product a, and simultaneously detects and acquires its own location information from the GPS system 5 (step S 04 ). More specifically, the wireless aircraft 10 takes the live image of the farm product a, and simultaneously detects and acquires its own location information from the GPS system 5 .
[0049] The wireless aircraft 10 compares the live image of the farm products with the stored image data of the farm products for determining the appropriate harvest time (step S 05 ). In step S 05 , the wireless aircraft 10 performs image analysis on the stored image data and identifies the size, shape, color, and irregularity, etc., of the farm products for determining the appropriate harvest time. The wireless aircraft 10 also performs image analysis on the taken live image data and identifies the size, shape, color, and irregularity, etc., of the farm products in the live image data. The wireless aircraft 10 judges whether or not the size, shape, color, and irregularity, etc., of the farm products identified in the stored image data are similar to the same identified in the live image data. In step S 05 , to determine whether or not the size, shape, color, and irregularity, etc. are similar, each of the size, shape, color, and irregularity, etc., is extracted as the feature amount from the stored image data and the taken live image data, compared separately, and judged if each of them is near or equal, respectively.
[0050] In step S 05 , if judging that the taken live image data is similar to the stored image data, the wireless aircraft 10 associates and stores the harvest information showing that the farm products in the taken live image can be harvested with the location information of the taken live image (step S 06 ).
[0051] On the other hand, in step S 05 , if judging that the taken live image data is not similar to the stored image data, the wireless aircraft 10 judges whether or not pests or diseases exist (step S 07 ). In step S 07 , the wireless aircraft 10 performs image analysis on the stored image data and identifies the shape, color, and irregularity, etc., of the farm products for determining the appropriate harvest time. The wireless aircraft 10 also performs image analysis on the image data of the taken live image and identifies the shape, color, and irregularity, etc., of the farm products in the live image. The wireless aircraft 10 judges whether or not the shape, color, and irregularity, etc., of the farm products identified in the stored image data is different from the same identified in the live image data. To determine whether or not the shape, color, and irregularity, etc., is different, each of the shape, color, and irregularity, etc., is extracted as the feature amounts from the stored image data and the taken live image data respectively, compared separately, and judged if each of them is different, respectively.
[0052] In step S 07 , if judging that the taken live image data is matched with the stored image data, the wireless aircraft 10 judges that no pests and diseases exist, and associates and stores the countermeasure unnecessary information showing that it is not necessary to take countermeasure with the location information of the taken live image (step S 08 ).
[0053] On the other hand, in step S 07 , if judging that the taken live image data is not matched with the stored image data, the wireless aircraft 10 judges that pests or diseases exist and associates and stores the countermeasure information showing that it is necessary to take countermeasure with the location information of the taken live image (step S 09 ). The wireless aircraft 10 executes the imaging instruction processes on and after step S 03 for other farm products.
[0054] After executing processes in steps S 03 to S 09 for all the farm products a-p, the wireless aircraft 10 transmits the harvest information, countermeasure information, countermeasure unnecessary information, and location information on the farm products to the portable terminal 100 (step S 10 ).
[0055] Based on the received harvest information, countermeasure information, countermeasure unnecessary information, and location information on the farm products, the portable terminal 100 generates and displays the farm products map showing that the farm products can be harvested, or it is necessary to perform the predetermined countermeasure against the pests and diseases (step S 11 ).
Configuration of the Location Information Output System 1
[0056] FIG. 2 shows a configuration diagram of the location information output system 1 according to a preferable embodiment of the present invention. The location information output system 1 includes an imaging target area 3 , a GPS system 5 , a wireless aircraft 10 , and a portable terminal 100 .
[0057] Wireless aircraft 10 has functions to be described later and a capability of data communication, which flies in the air with propeller of its own. Moreover, the wireless aircraft 10 is a wireless aircraft which is capable of remote control from an external terminal such as the portable terminal 100 or other operational terminals, and automatic control based on the predetermined action which is programmed in it.
[0058] The wireless aircraft 10 includes a camera, etc., that takes moving and still images of the imaging target area 3 as a live image. Moreover, the wireless aircraft 10 detects and acquires its own location information of the current location from the GPS system 5 . Moreover, the wireless aircraft 10 includes a memory unit that stores a specific image of the extracted object. Examples of the extracted objects are farm products and a person. Examples of the specific image of the extracted objects are size, shape, color, and irregularity in case of a farm product, and age, sex, and costume in case of a person. Moreover, the wireless aircraft 10 compares a live image with a specific image to recognize an object to be extracted from the live image. The objects to be extracted are size, shape, color, and irregularity of the farm products, or age, sex, and costume of the person included in the live image. The wireless aircraft 10 includes the data communication functions that transmit the location information of its own acquired from the GPS system 5 to the portable terminal 100 when it has recognized the object. Moreover, the wireless aircraft 10 includes a device activating unit that activates a predetermined device according to the type of the specific image when moved back to the previous location in which the location information was output. The activation of the predetermined device is a chemical spraying for exterminating the pests and diseases in case of the farm products and is a distribution of handbills depending on the sex or assistance including route guidance in case of a person.
[0059] The user terminal 100 is a home or an office appliance with a data communication function and performing a data communication with the wireless aircraft 10 . Examples of the mobile terminal 100 include information appliances such as a mobile phone, a mobile terminal, a personal computer, a net book terminal, a slate terminal, an electronic book terminal, and a portable music player.
[0060] The GPS system 5 is a general GPS system that transmits the location information of the wireless aircraft 10 to the wireless aircraft 10 based on the request by the wireless aircraft 10 .
[0061] The imaging target area 3 is a place such as a field where farm products are grown. In the imaging target area 3 , two or more of the farm products a-p are grown. The number of the farm products grown in the imaging target area 3 is not limit to the number of this embodiment and may be more or less than the number of this embodiment. The imaging target area 3 may be a place such as a road or a facility where a person or a vehicle, etc., exists or may be other places.
Functions
[0062] The structure of each device will be described below with reference to FIG. 3 .
[0063] The wireless aircraft 10 includes a control unit 11 such as a central processing unit (hereinafter referred to as “CPU”), random access memory (hereinafter referred to as “RAM”), and read only memory (hereinafter referred to as “ROM”) and a communication unit 12 such as a device capable of communicating with other devices, for example a Wireless Fidelity or Wi-Fi® enabled device complying with IEEE 802.11. Moreover, the communication unit 12 is provided with a device for Near Field Communication such an IR communication, a device to send and receive radio wave of predetermined bandwidth, and a device to acquire its own location information from the GPS system 5 .
[0064] The wireless aircraft 10 also includes an imaging unit 13 that takes an image, for example, a camera.
[0065] The wireless aircraft 10 also includes a memory unit 14 such as a hard disk, a semiconductor memory, a record medium, or a memory card to store data. The memory unit 14 includes the function that stores the image data of the moving and still images, etc., taken by the imaging unit 13 of the wireless aircraft 10 described later. The memory unit 14 also includes the function that stores the image data of the farm products received from the portable terminal 100 . Moreover, the memory unit 14 includes the function that stores the program for activating the predetermined device. Furthermore, the memory unit 14 includes the image data table, location information table, and countermeasure information table described later.
[0066] Moreover, the wireless aircraft 10 is provided with a device activation unit 15 to maintain and spray agricultural chemicals and to harvest and store the farm products.
[0067] In the wireless aircraft 10 , the control unit 11 reads a predetermined program to run a data transceiver module 20 , an instruction receiver module 21 , a location information acquisition module 22 , and an instruction judging module 23 in cooperation with the communication unit 12 . Moreover, in the wireless aircraft 10 , the control unit 11 reads a predetermined program to run an imaging module 40 in cooperation with the imaging unit 13 . Furthermore, in the wireless aircraft 10 , the control unit 11 reads a predetermined program to run a data storing module 50 , an image data judging module 51 , an imaging completion judging module 52 , a countermeasure information acquisition module 53 , and a countermeasure completion judging module 54 in cooperation with the memory unit 14 . Yet still furthermore, in the wireless aircraft 10 , the control unit 11 reads a predetermined program to run a countermeasure execution module 60 in cooperation with the device activation unit 15 .
[0068] The mobile terminal 100 includes a control unit 110 including a CPU, a RAM, and a ROM; and a communication unit 120 including a Wireless Fidelity or Wi-Fi® enabled device complying with, for example, IEEE 802.11, or a Near Field Communication such as IR communication enabled device, and a device for transmitting the radio wave of a predetermined bandwidth enabling the communication with other devices in the same way as the wireless aircraft 10 .
[0069] The portable terminal 100 also includes an input-output unit 130 including a display unit outputting and displaying data and images that have been processed by the control unit 110 ; and an input unit such as a touch panel, a keyboard, or a mouse that receive an input from a user. The mobile terminal 100 also includes a device capable of acquiring location information, such as a GPS system 5 , a device such as a camera capable of taking an image and a device displaying the farm products map described later.
[0070] In the portable terminal 100 , the control unit 110 reads a predetermined program to run a data transceiver module 150 and an imaging instruction module 151 in cooperation with the communication unit 120 . Still furthermore, in the portable terminal 100 , the control unit 110 reads a predetermined program to run a display module 160 in cooperation with the input-output unit 130 .
Location Information Output Process
[0071] FIG. 4 is a flow chart of the location information output process executed by the wireless aircraft 10 and the portable terminal 100 . The tasks executed by the modules of each of the above-mentioned units will be explained below together with this process.
[0072] First, the data transceiver module 150 of the portable terminal 100 transmits the image data of the farm products for determining the appropriate harvest time and the name of the farm products which are grown in the imaging target area 3 to the wireless aircraft 10 (step S 20 ). In step S 20 , the data transceiver module 150 acquires the image data of the farm products for determining the appropriate harvest time for the farm products through the public line network such as the Internet, and transmits the acquired image data and the name of the farm products to the wireless aircraft 10 . In step S 20 , the data transceiver module 150 may take an image of the farm products for determining the appropriate harvest time using the imaging device such as a camera installed in the portable terminal 100 , and transmit the taken image data and the name of the farm products to the wireless aircraft 10 . Moreover, the data transceiver module 150 may obtain an image data of the farm products for determining the appropriate harvest time of the farm products which is acquired by the other methods and the name of the farm products, and transmit the acquired image data to the wireless aircraft 10 . Moreover, the number of the image data that the data transceiver module 150 transmits may be one, or more than one.
[0073] The data transceiver module 20 of the wireless aircraft 10 receives the image data transmitted from the portable terminal 100 . The data storing module 50 of the wireless aircraft 10 stores the received image data in the image data table shown in FIG. 6 (step S 21 ).
Image Data Table
[0074] FIG. 6 shows the image data table that the data storing module 50 of the wireless aircraft 10 stores. The data storing module 50 associates and stores the received image data with the name of the farm products. In this embodiment, the name of the farm products that the data storing module 50 stores is “Farm product A”. Moreover, the image data that the data storing module 50 stores is the image data of the farm products for determining the appropriate harvest time of the Farm product A. The data storing module 50 associates and stores two or more image data with a Farm product A.
[0075] The image data that the data storing module 50 of the wireless aircraft 10 stores may be not limited to more than one and may be one. Moreover, the number of the image data that the data storing module 50 stores is not limited to 3 but may be 2, 4 or more. Moreover, one or two or more image data for each different kind of farm products may be stored. Moreover, the image data stored in the data storing module 50 is not limited to an image but it only has to be data for judging an image such as size, color, shape, or irregularity, and may be other type of data such as character or symbolic data.
[0076] Next, the imaging instruction module 151 of the portable terminal 100 transmits the imaging instruction of the imaging target area 3 to the wireless aircraft 10 (step S 22 ). In step S 22 , location information of the imaging target area 3 and the place of the farm products are included in the imaging instruction transmitted from the imaging instruction module 151 . In step S 22 , the location information of the imaging target area 3 and the location information of each farm products which is included in the imaging instruction transmitted from the imaging instruction module 151 may be input directly by a user, or input through other applications, etc., such as map application, or otherwise input through the public line network.
[0077] The instruction receiver module 21 of the wireless aircraft 10 receives the imaging instruction transmitted from the portable terminal 100 . The imaging module 40 of the wireless aircraft 10 moves to the imaging target area 3 shown in FIG. 7 based on the information on the imaging target area 3 and the place of the farm products that are included in the imaging instruction and takes the live image of the farm products a-p (step S 23 ). In step S 23 , the wireless aircraft 10 may move to the imaging target area 3 based on the information on the imaging target area 3 and the place of the farm products which is previously programmed in it and take the live image of the farm products. Whenever taking an image of the live image of one of the farm products, the wireless aircraft 10 executes the following process.
[0078] FIG. 7 shows an imaging target area 3 . As mentioned above, two or more of the farm products a-p are grown in the imaging target area 3 .
[0079] The imaging module 40 takes the live image of the farm products a, and simultaneously the location information acquisition module 22 of the wireless aircraft 10 detects and acquires its own location information from the GPS system 5 (step S 24 ). More specifically, in step S 24 , the location information acquisition module 22 acquires its own location information on which the live image is taken from the GPS system 5 .
[0080] The data storing module 50 of the wireless aircraft 10 associates and stores the live image taken by the imaging module 40 with the location information of the taken live image acquired by the location information acquisition module 22 in the location information table shown in FIG. 8 (step S 25 ).
Location Information Table
[0081] FIG. 8 shows a location information table that the data storing module 50 of the wireless aircraft 10 stores. The data storing module 50 associates and stores the live image taken by the imaging module 40 with the location information acquired by the location information acquisition module 22 . The data storing module 50 associates and stores each image data of the farm products a-p taken by the imaging module 40 with each location information of the farm products a-p.
[0082] The number of the image data that the data storing module 50 of the wireless aircraft 10 stores is not limit to the number of this embodiment and may be more or less than the number of this embodiment. Moreover, the image data stored in the data storing module 50 is not limited to an image but it only has to be data such as size, color, shape, or irregularity for judging an image, and may be other type of data such as character or symbolic data. Moreover, the location information that the data storing module 50 stores is not limited to the embodiment of the present invention but may be stored by north latitude and east longitude, or by latitude and longitude, or otherwise by other methods.
[0083] The image data judging module 51 of the wireless aircraft 10 compares the live image data of the farm products that the data storing module 50 stored with the stored image data of the farm products for determining the appropriate harvest time that the data storing module 50 stores and judges whether or not the farm products of the live image can be harvested (step S 26 ). In step S 26 , the image data judging module 51 performs image analysis on the image data of the farm products for determining the appropriate harvest time, and identifies the shape, color, and irregularity, etc., as the feature amounts that are appropriate for harvest. Additionally, the image data judging module 51 performs image analysis on the stored live image of the farm products, and identifies the size, shape, color, and irregularity, etc., as the feature amounts. The image data judging module 51 judges whether or not the size, shape, color, and irregularity, etc., extracted from the stored image data of the farm products for determining the appropriate harvest time is similar to the same extracted from the live image of the farm products, and determine whether or not the farm products of the live image can be harvested. In step S 26 , to determine whether or not the size, shape, color, and irregularity, etc., are similar, the image data judging module 51 compares the size, shape, color, irregularity of the stored and live image data separately and judges if they are near or equal, respectively.
[0084] The image data judging module 51 may judge whether or not the stored image data and the taken live image data are similar based on whether or not any one of the size, shape, color, or irregularity, etc., is near or equal, or two or more than two of such feature amounts are near or equal. Moreover, the image data judging module 51 may extract other feature amounts other than the size, shape, color, and irregularity, to judge whether or not the stored image data and the taken live image data are similar.
[0085] In step S 26 , the image data judging module 51 of the wireless aircraft 10 judges that the taken live image data is similar to the stored image data of the farm products for determining the appropriate harvest time (YES), the data storing module 50 associates and stores the location information of the taken live image with the harvest information showing that the farm products can be harvested in the countermeasure information table shown in FIG. 9 described later (step S 27 ).
[0086] In step S 27 , the data storing module 50 of the wireless aircraft 10 may previously acquire and store the information on the growth of the farm products. The information on the growth of the farm products is, for example, the information on the amount of growth of the size and shape for each day or the period from the germination to the harvest becomes possible. The image data judging module 51 may calculate the period until the harvest of the farm products becomes possible from the state of the taken live image data based on the stored information on the growth, and the data storing module 50 may store the calculated period as the harvest information.
[0087] On the other hand, in step S 26 , if judging that the taken live image data is not similar to the stored image data of the farm products for determining the appropriate harvest time (NO), the image data judging module 51 of the wireless aircraft 10 compares the live image data of the farm products that the data storing module 50 stores with the stored image data of the farm products for determining the appropriate harvest time that the data storing module 50 stores to judge whether or not a countermeasure against the pests or diseases, etc., is necessary for the farm products of the live image data (step S 28 ). In step S 28 , the image data judging module 51 perform the image analysis on the image data of the farm products for determining the appropriate harvest time and identifies the shape, color, and irregularity, etc., as the feature amounts. Additionally, the image data judging module 51 performs image analysis on the stored live image of the farm products and identifies the shape, color, and irregularity, etc., as the feature amounts. The image data judging module 51 judges whether or not the feature amounts such as shape, color, and irregularity extracted from the stored image data of the farm products for determining the appropriate harvest time are different from the same extracted from the live image data of the farm products and determines whether or not a countermeasure against the pests or diseases, etc., is necessary for the farm products of the live image data. In step S 27 , to determine whether or not the shape, color, and irregularity, etc., are different, the image data judging module 51 compares the color or irregularity and judges if the stored image data and the taken live image data are different.
[0088] In step S 28 , the image data judging module 51 may acquire the image data of the pests or diseases from the portable terminal 100 , a database, etc., perform the image analysis on the acquired image data, identify the shape, color, and irregularity, etc., as the feature amounts, and judge whether or not pests or diseases exist by comparing with the shape, color, and irregularity, etc., extracted from the live image data. Moreover, the image data judging module 51 may judge that a countermeasure against the pests or diseases, etc., is necessary in case that all of the feature amounts or any of the 2 feature amounts among from the shape, color, and irregularity, etc., are different. Furthermore, the image data judging module 51 may extract other feature amounts other than the shape, color, and irregularity to judge the similarity. In this case, the image data judging module 51 may judge whether or not a countermeasure is necessary based on whether or not all, a plural of, or any of the extracted feature amounts are different for the stored image data and the live image data.
[0089] In step S 28 , if the image data judging module 51 of the wireless aircraft 10 judges that the live image data and the stored image data of the farm products for determining the appropriate harvest time is different (YES), the data storing module 50 associates and stores the location information of the taken live image with the countermeasure information showing that a countermeasure is necessary for the farm products in the countermeasure information table shown in FIG. 9 described later (step S 29 ).
[0090] On the other hand, in step S 28 , the image data judging module 51 of the wireless aircraft 10 judges that the live image data and the stored image data of the farm products for determining the appropriate harvest time is not different (NO), the data storing module 50 associates and stores the location information of the taken live image with the countermeasure unnecessary information showing that no countermeasure is necessary for the farm products in the countermeasure information table shown in FIG. 9 described later (step S 30 ).
Countermeasure Information Table
[0091] FIG. 9 shows a countermeasure information table that the data storing module of the wireless aircraft 10 stores. The data storing module 50 associates and stores the location information of the image taken by the imaging module 40 with the harvest information showing whether or not the farm products grown in this location can be harvested and the countermeasure information showing whether or not a countermeasure is necessary for the farm products grown at this location. In FIG. 9 , the location information “(X01,Y01)” of the farm product a, is associated and stored with the harvest information “0” and the countermeasure information “-”. For other farm products b-p, the location information is also associated and stored with the harvest information and the countermeasure information. In this embodiment, the “O” mark in item “Harvest information” shows that the farm products grown in the location information associated with this harvest information is appropriate for harvest. The “-” mark in item “Harvest information” shows that the farm products grown in the location information associated with this harvest information is not appropriate for harvest. The “O” mark in item “Countermeasure information” shows that a countermeasure against the pests or diseases, etc., is necessary for the farm products grown in the location information associated with this countermeasure information. The “-” mark in item “Countermeasure information” shows that a countermeasure against the pests or disease, etc., is not necessary for the farm products grown in the location information associated with this countermeasure information.
[0092] The number of the items of the countermeasure information table stored by the data storing module 50 of the wireless aircraft 10 is not limited to the embodiment of the present invention, and other items may be added or any of the items may be deleted. Moreover, the harvest information stored by the data storing module 50 may be any information other than “O” or “-”. Furthermore, the countermeasure information stored by the data storing module 50 may be any information other than “O” and “-”. For example, as described above, the data storing module 50 may store the remaining number of the days until the harvest becomes possible as the harvest information or the necessary chemical as the countermeasure information.
[0093] The imaging completion judging module 52 of the wireless aircraft 10 judges whether or not taking images of all the farm products a-p in the imaging target area 3 is completed (step S 31 ). In step S 31 , the imaging completion judging module 52 judges whether or not the location information, the harvest information, and the countermeasure information on all the farm products a-p is stored in the countermeasure information table.
[0094] If judging that any of the location information, harvest information, or countermeasure information for all the farm products a-p is not stored, the imaging completion judging module 52 of the wireless aircraft 10 judges that taking images of all the farm products a-p in the imaging target area 3 is not completed (step S 31 NO) and repeats the processes in steps S 23 to S 30 mentioned above until the imaging module 40 completes taking the live image data of all the farm products a-p.
[0095] On the other hand, if judging that the location information, harvest information, and countermeasure information on all the farm products a-p is stored, the imaging completion judging module 52 of the wireless aircraft 10 judges that taking images of all the farm products a-p in the imaging target area 3 is completed (step S 31 YES), and the data transceiver module 20 transmits the location information, harvest information, and countermeasure information on each farm product stored in the countermeasure information table to the portable terminal 100 (step S 32 ).
[0096] The data transceiver module 150 of the portable terminal 100 receives the location information, harvest information, and countermeasure information on each farm product that the wireless aircraft 10 transmits. The display module 160 of the portable terminal 100 displays the farm products map shown in FIG. 10 based on the received information (step S 33 ).
Farm Products Map
[0097] FIG. 10 shows a farm products map that the display module 160 of the portable terminal 100 displays. The display module 160 displays the place of each farm products a-p in the imaging target area 3 based on the received location information of the farm products a-p. Moreover, the display module 160 displays each farm products a-p using display mode to show that the farm products a-p can be harvested, a countermeasure is necessary, or the harvest is not possible and no countermeasure is necessary, respectively. In FIG. 10 , the display module 160 displays by hatching as display mode to show that targeted farm products can be harvested. Moreover, in FIG. 10 , the display module 160 displays by any hatching other than the hatching used for the farm products that can be harvested as display mode to show that a countermeasure is necessary for the targeted farm products. Furthermore, in FIG. 10 , the display module 160 displays by void as display mode to show that the targeted farm products cannot be harvested and no countermeasure is necessary. In the embodiment of the present invention, the farm products a, d, g, o, and p are shown that they can be harvested, the farm products c, i, j, and n are shown that a countermeasure is necessary, and the farm products b, e, f, h, k, l, and m are shown that they don't fall into any category.
[0098] The display module 160 displays that the harvest is possible or the countermeasure is necessary by hatching, but may display using display mode such as coloring, shape modifying, and blinking, or by executing the notification by voice, or otherwise by combining with two or more of such display modes.
[0099] Next, the countermeasure execution module 60 of the wireless aircraft 10 executes the countermeasure process described later to the farm products for which countermeasure is necessary (step S 34 ).
[0100] After executing the countermeasure process, the wireless aircraft 10 terminates the location information output process.
Countermeasure Process
[0101] FIG. 5 is a flow chart of the countermeasure process executed by the wireless aircraft 10 . The tasks executed by the modules of each of the above-mentioned units will be explained below together with this process.
[0102] The instruction judging module 23 of the wireless aircraft 10 judges whether or not the execution instruction of the countermeasure process is received (step S 40 ). In step S 40 , the instruction judging module 23 judges whether or not the countermeasure instruction is received directly from the portable terminal 100 or from other external terminals or whether or not the countermeasure instruction to the farm products for which countermeasure is necessary is previously included in the predetermined action that is programmed in it.
[0103] In step S 40 , if judging that the execution instruction of the countermeasure process is not received (NO), the instruction judging module 23 of the wireless aircraft 10 ends the process.
[0104] On the other hand, in step S 40 , if the instruction judging module 23 of the wireless aircraft 10 judges that the execution instruction of the countermeasure process is received (YES), the countermeasure information acquisition module 53 of the wireless aircraft 10 acquires the location information, harvest information, and countermeasure information on each farm product that the data storing module 50 stored in the countermeasure information table (step S 41 ).
[0105] The wireless aircraft 10 moves to the place of the targeted farm products based on the acquired location information (step S 42 ).
[0106] The countermeasure execution module 60 of the wireless aircraft 10 executes countermeasures to the farm products (step S 43 ). In step S 43 , if the farm products are appropriate for harvest, the countermeasure execution module 60 harvests, retains, and moves the farm products to a predetermined place. Moreover, if pests or diseases exist, the countermeasure execution module 60 sprays a chemical. In step S 43 , the countermeasure execution module 60 drives the device necessary for the countermeasure and executes necessary countermeasure.
[0107] The countermeasure completion judging module 54 of the wireless aircraft 10 judges whether or not countermeasures to all the farm products are completed (step S 44 ). In step S 44 , the countermeasure completion judging module 54 judges whether or not the movements to all the location information stored in the countermeasure information table are completed.
[0108] In step S 44 , if the countermeasure completion judging module 54 of the wireless aircraft 10 judges that the countermeasure to all the farm products is not completed (NO), the countermeasure execution module 60 repeats the processes on and after step S 41 until all the countermeasures to the farm products completes.
[0109] On the other hand, in step S 44 , if judging that the countermeasures to all the farm products are completed (YES), the countermeasure completion judging module 54 of the wireless aircraft 10 ends the countermeasure process.
Variations
[0110] A variation of the invention is described below. The present invention can be applied to, for example, a person other than a farm product. Hereinafter, the following variation is explained as the case applied to a person.
[0111] In this variation, the imaging target area is a road or a facility. Moreover, the specific image of the extracted object is an image to identify age, sex, or costume.
[0112] The wireless aircraft receives the image data of a specific image through a portable terminal, other external terminals, or public line networks, and stores it. The wireless aircraft receives an imaging instruction of a person based on the predetermined action which is programmed in a portable terminal, in other external terminals, etc., or in it.
[0113] The wireless aircraft takes an image of the person who exists in the imaging target area as a live image. Simultaneously, the wireless aircraft acquires the location information of the taken image from the GPS system. The wireless aircraft associates and stores the taken image of the person with the location information of the same.
[0114] The wireless aircraft compares the stored specific image data with the live image data to identify person's age, sex, and costume, etc. The wireless aircraft associates and stores the personal data such as age, sex, and costume of the identified person with the location information of the taken image data.
[0115] The wireless aircraft transmits the stored location information and the personal data to the portable terminal. The portable terminal generates and displays the congestion map based on the received location information and the personal data. The congestion map displayed by the portable terminal includes, for example, the position of each person that exists in the imaging target area which is shown with an icon or a figure, etc., and the personal data overlapping with the icon or the figure. The congestion map may use other display mode. Moreover, the personal data may be displayed using display mode, in the same way as the embodiment mentioned above, by displaying an icon or figure, etc., with hatching, coloring, shape modifying, and blinking, etc., or by executing the notification by voice, or otherwise by combining with two or more of such display modes. Moreover, the displaying position of the personal data can be changed as appropriate.
[0116] When receives the execution instruction of the countermeasure process, the wireless aircraft executes the previously set countermeasure action based on the location information and the personal data of each person. The countermeasure action that a wireless aircraft executes is, for example, a voice guidance for a person of a specific age or distribution of a handbill to a person of a specific sex. A wireless aircraft may execute other countermeasure actions.
[0117] Additionally, it should be understood that the variation in the present embodiment is not limited to the example described above and may be other examples.
[0118] To achieve the means and the functions that are described above, a computer (including a CPU, an information processor, and various terminals) reads and executes a predetermined program. For example, the program is provided in the form recorded in a computer-readable medium such as a flexible disk, CD (e.g., CD-ROM), or DVD (e.g., DVD-ROM, DVD-RAM). In this case, a computer reads a program from the recording medium, forwards and stores the program to and in an internal or an external storage, and executes it. The program may be previously recorded in, for example, a storage (record medium) such as a magnetic disk, an optical disk, or a magnetic optical disk and provided from the storage to a computer through a communication line.
[0119] The embodiments of the present invention are described above. However, the present invention is not limited to these embodiments. The effect described in the embodiments of the present invention is only the most preferable effect produced from the present invention. The effects of the present invention are not limited to that described in the embodiments of the present invention.
REFERENCE SIGNS LIST
[0000]
3 Imaging target area
5 GPS system
10 Wireless aircraft
100 Portable terminal | The present invention is to provide a wireless aircraft and a method for outputting location information to reduce a cost, simplify the process, and output the necessary information. The wireless aircraft 10 flying in the air takes an live image, detects the location information on which the wireless aircraft is located, stores a specific image of an extracted object, compares the taken live image with the specific image to recognize an object to be extracted from the live image, and outputs the detected location information when the object is recognized. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
Reference is made to commonly assigned U.S. pat. application Ser. No. 08/868,426, filed Jun. 3,1997 entitled "Continuous Tone Microfluidic Printing", by DeBoer, Fassler, and Wen. The disclosure of this related application is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a personal writting instrument and, more particularly, to a microfluidic pen.
BACKGROUND OF THE INVENTION
Microfluidic pumping and dispensing of liquid chemical reagents is the subject of three U.S. Pat. Nos. 5,585,069, 5,593,838, and 5,603,351, all assigned to the David Sarnoff Research Center, Inc. The system uses an array of micron sized reservoirs, with connecting micro channels and reaction cells etched into a substrate. Electrokinetic pumps comprising electrically activated electrodes within the capillary micro channels provide the propulsive forces to move the liquid reagents within the system. The electrokinetic pump, which is also known as an electroosmotic pump, has been disclosed by Dasgupta et al., see Electroosmosis: A Reliable Fluid Propulsion System for Flow Injection Analysis, Anal. Chem. 66, pp 1792-1798 (1994). The chemical reagent solutions are pumped from a reservoir, mixed in controlled amounts, and then pumped into a bottom array of reaction cells. The array may be decoupled from the assembly and removed for incubation or analysis.
Writing devices have their own sets of problems. One problem is to provide a writing pen which can selectively provide different colors. It is difficult with such writing instruments to provide continuous tone colors with a wide range of hue variations.
SUMMARY OF THE INVENTION
It is an object of this invention is to provide a pen to write all different color hues on a suitable receiver.
It is a further object of the invention to provide a compact, low powered pen which could rapidly write a high quality line on paper at any pre-set color.
Another object of this invention is to provide a compact, low power, portable pen to write lines which can have various thicknesses.
These objects are achieved by a microfluidic pen for selectively writing lines of different colors, comprising:
a) means defining an ink mixing chamber and a writing tip in communication with the ink mixing chamber;
b) a plurality of colorant reservoirs disposed in the pen and which contain different colorants;
c) pumping means selectively effective to deliver colorant in selected amounts from the colorant reservoirs to the ink mixing chamber wherein the colorants are mixed to provide a colorant of the desired color;
d) color selector means responsive to a user selecting the desired line colors and for actuating the pumping means so as to cause the desired amount of colorants to be delivered to the ink mixing chamber where the writing tip can write a line of the desired line colors.
ADVANTAGES
The present invention provides high quality lines of desired line width, density, and color hue on a writing surface.
Another feature of the invention is that the pen is low power, compact refillable and portable.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective showing a writing pen with a color hue adjustment knob;
FIG. 2 is a view showing another embodiment of a writing pen which can adjust color, line thickness, and select the desired colorant; and
FIG. 3 is a sectional view showing internal parts of the microfludic pen of FIGS. 1 and 2;
FIG. 4 shows another embodiment of the invention with a smaller mixing chamber than in FIG. 3;
FIG. 5 is a detail of the tip of the pen of FIG. 4; and
FIG. 6 is a block diagram of the electrial circuitry embodied in the pens of FIGS. 1 and 4.
DETAILED DESCRIPTION OF THE INVENTION
Colorants in accordance with the present invention can be dispersions of cyan, magenta, and yellow colorants. Preferably as will be described a single mixing chamber is used to mix the colorants to obtain the hue as selected by the user of the pen. When contacted with paper, the capillary force of the paper fibers pulls the colorant from the cells and holds it in the paper, thus producing a line on. The present invention provides accurate control of the colorant density and ensures that the capillary force of the paper fibers is strong enough to pull the colorant from the pen at a permitable capillary flow and a microfluidic pump controls the mixture and impacts the capillary flow rate.
The colorants used in this invention can be those commonly used in ink jet printers. Examples of water soluable dyes are CI direct Yellow 132, C1 Acid Yellow 23, C1 acid red 52, C1 acid red 249, CL direct blue 9, C1 food black 2, and C1 direct black 168. Inks made up with dispersion of colorants in water or other common solvents can also be used in this invention. Examples of such inks may be found in U.S. Pat. No. 5,611,847 by Gustina, Santilli, and Burgner; U.S. patent application Ser. No. 08/699,955 and U.S. patent application Ser. No. 08/699,963, both filed Aug. 20, 1996 by McInerney, Olfield,Bugner, Bermel, and Santilli; U.S. patent application Ser. No. 08/790,131 filed Jan. 29, 1997 by Bishop, Simons and Brick; and in U.S. patent application Ser. No. 08/764,379 filed Dec. 13, 1996 by Martin.
Referring now to FIGS. 1-3, the pen 10 includes three supply reservoirs 100, 101, and 102 (FIGS. 3 and 4) for the colorants and micro-channels 200 to conduct the colorants from the supply reservoirs 100, 101, 102 into a mixing chamber 201 and onto a receiver surface 300. The mixing chamber 201 mixes the colorants before delivery to the receiver surface 300. FIG. 1 shows the pen 10 and a line 11 being written by the pen 10 on the receiver surface 300. The casing of the pen 10 in FIG. 1 includes a rotatable color selection knob 20 and a color selection chart 21. The selected color is indicated by a pointer 22 fixed to the rotatable knob 20. The casing of FIG. 2 includes the same structure as that of FIG. 1 and it also has a rotating line width adjusting knob 25 which includes pointer 26. The line width chart 27 is also provided.
FIG. 3 shows the mixing chamber 201 and three microkinetic electrodes 202 each associated with a different color supply reservoir 100, 101 and 102 respectively. Each pump is disposed in one micro-channels 200 and includes an electrode and one common electrode located in the mixing chamber 201. As will be discussed, these microkinetic electrodes 202 cause the delivery of colorants to the mixing chamber 201 wherein the colorants are mixed so that a line of any color can be written.
Each pair of electrodes associated with each color supply reservoir 100, 101, 102 constitutes the microkinetic electrode 202 of this invention. As will be described more fully with reference to FIG. 6, application of a potential between the electrodes of each microkinetic electrode 202 causes the flow of colorant into the corresponding micro-channels 200 and into the colorant mixing chamber 201. When the colorant mixing chamber 201 has received the correct amount of each colorant to reproduce the selected color of the line to be written, the correct color is mixed in the mixing chamber 201 before the line is written on a receiver 300. If a single line with a preferred or special colorant is written, another color supply reservoir (not shown), with a microkinetic pump can be provided for writing a single color. That colorant can, of course, be black or blue.
The pen tip writes by contacting a suitable reciever surface and this contact pressure is sensed so that circuitry activates the microkinetic pumps to supply the colorant in the selected measure. The pressure sensor can be a simple switch or a pressure drop in the mixing chamber can be sensed to register the mode of writing in the microcomputer 500.
Turning now to FIGS. 4 and 5, where there is shown a shorter mixing chamber 201 than the pen 10 of FIG. 3. Further, a tip 310 is in the form of a rotating ball. When a user presses the tip 310 against the receiver 300 it causes the ball to open a channel 311 which couples the mixing chamber 201 to the receiver surface. The tip moves up a distance m. A microswitch 315 is actuated by the tip 310 moving upwardly which causes a signal to be sent to a micro-computer 500 shown in FIG. 6. When the tip 310 is removed from the receiver 300, it closes off the channel 311 to prevent the flow of mixed colorant from the mixing chamber 201 to the receiver 300 surface. It should be noted that the arrows in FIGS. 3 and 4 show the flow of colorant from the color supply reservoirs 100, 101, 102 to the receiver 300 surface.
Turning now to FIG. 6 which shows the electrical circuitry which can be used to operate the different embodiments of the pen 10 shown in FIGS. 1 and 2. When the tip 310 activates or closes the microswitch 315, the microswitch 315 couples the circuitry to a battery 316. The battery 316 is coupled to a potentiometer 317 which is controlled by the color selection knob 20. When the pen 10 of FIG. 2 is used, the battery 316 is also connected to a potentiometer 318 which is controlled by the line width adjusting knob 25. Signals from the potentiometers 317 and 318 are applied to the micro-computer 500. The micro-computer 500 will be understood to include analog to digital circuits which convert the analog signals from the potentiometers 317 and 318 respectively into digital signals. The micro-computer 500 provides signals to power amplifiers 320a, 320b, and 320c. These power amplifiers 320a, 320b and 320c apply the appropriate signal levels to the microkinetic electrodes 202. A DC to DC power amplifier 319 also connected to the battery 316 provides the appropriate voltage levels for controlling the power amplifiers 320a, 320b, and 320c.
In operation, when the FIG. 1 pen 10 arrangement is used, the knob 20 selects the appropriate colors. After the tip 310 closes the microswitch 315, the microcomputer 500 produces digital signals which are converted to analog signals by the power amplifiers 320a, 320b, and 320c. The appropriate amount of colorant from the color supply reservoirs 100, 101, and 102 are now delivered to the mixing chamber 201 and onto the receiver 300 through the channel 311. When the line is completed the user lifts the pen 10 and the channel 311 and the microswtich 315 is opened under the control of the tip 310. The operation of the pen 10 shown in FIG. 2 is the same as with FIG. 1 except that the line width is also computed. The line width is controlled by the micro-computer 500 by adjusting the amount of colorant that will be delivered through the channel 311 to the tip 310.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
______________________________________PARTS LIST______________________________________pen 10rotating color selection knob 20color selection chart 21pointer color select 22line width adjusting knob 25pointer line width 26line width chart 27color supply reservoir 100color supply reservoir 101color supply reservoir 102micro-channels 200mixing chamber 201receiver surface 300rotating ball tip 310outflow channel 311micro computer 500battery 316color potentiometer 317line width potentiometer 318power amplifiers 320a, b, and cmicro computer 500______________________________________ | A microfluidic pen for selectivly writing lines of different colors, includes a colorant mixing chamber and a writing tip in communication with the colorant mixing chamber; a plurality of colorant reservoirs disposed in the pen and which contain different colorants; microkinetic pump selectively effective to deliver colorant in selected amounts from the colorant reservoirs to the colorant mixing chamber wherein the colorants are mixed to provide a colorant of the desired color. The color is selected by a user and actuates the microkinetic pump to cause the desired amount of colorants to be delivered to the colorant mixing chamber where the writing tip can write a line of the desired line colors. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of and claims priority to co-pending U.S. application Ser. No. 12/787,199, filed May 25, 2010, which is a divisional of U.S. application Ser. No. 11/785,174, filed Apr. 16, 2007, which is a continuation of U.S. application Ser. No. 11/343,199, filed Jan. 31, 2006, which is a continuation-in-part of U.S. application Ser. No. 11/066,099, filed Feb. 28, 2005, each of which is incorporated by reference herein in its entirety. U.S. application Ser. No. 10/347,489 (now U.S. Pat. No. 6,860,074) filed on Jan. 21, 2003, U.S. application Ser. No. 09/986,414, filed on Nov. 8, 2001, and U.S. application Ser. No. 10/748,852 filed on Dec. 31, 2003, are also incorporated by reference herein in their entireties.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The invention is a joint cover assembly that includes a molding, similar to a transition molding between two separate parts, such as a T-Molding, for covering a gap that may be formed between adjacent panels in a generally planar surface, such as between two adjacent flooring or wall or ceiling materials; or between a floor and a hard surface or carpet, or even a riser and a runner in a step (or a series of steps).
[0004] 2. Background of-the Invention
[0005] Hard surface floors, such as wood or laminate flooring have become increasingly popular. As such, many different types of this flooring have been developed. Generally, this type of flooring is assembled by providing a plurality of similar panels. The differing types of panels that have developed, of course, may have differing depths and thicknesses. The same is true when a laminate floor (often referred to as a “floating floor”) abuts another hard surface, such as a resilient surface (such as vinyl), tile or another laminate surface, a ceramic surface, or other surface, e.g., natural wood flooring. Thus, when laminate panels having different thicknesses or different floor covering materials are placed adjacent to a laminate floor, transition moldings are often used to create a transition between the same.
[0006] Additionally, one may desire to install floor panels adjacent to an area with different types of material. For example, one may desire to have one type of flooring in a kitchen (e.g., solid wood, resilient flooring, laminate flooring or ceramic tile), and a different appearance in an adjacent living room (e.g., linoleum or carpeting), and an entirely different look in an adjacent bath. Therefore, it has become necessary to develop a type of molding or floorstrip that could be used as a transition from one type of flooring to another.
[0007] A problem is encountered, however, when ‘flooring materials that are dissimilar in shape or texture are used. For example, when a hard floor is placed adjacent a carpet, problems are encountered with conventional edge moldings placed therebetween. Such problems include difficulty in covering the gap that may be formed between the floorings having different height, thickness or texture.
[0008] Moreover, for purposes of reducing cost, it is important to be able to have a molding that is versatile, having, the ability to cover gaps between relatively coplanar surfaces, as well as surfaces of differing thicknesses.
[0009] It would also be of benefit to reduce the number of molding profiles that need to be kept in inventory by a seller or installer of laminate flooring. Thus, the invention also provides a method by which the number of moldings can be reduced while still providing all the functions necessary of different styles transition moldings.
SUMMARY OF THE INVENTION
[0010] The invention is a joint cover assembly for covering a gap between edges of adjacent floor elements, such as floor panels of laminate or wood, although it may also be used as a transition between a laminate panel and another type of flooring, e.g., carpet, linoleum, ceramic, wood, etc. The assembly typically includes a body having a foot positioned along a longitudinal axis, and a first arm extending generally perpendicularly from the foot. The assembly may include a second arm also extending generally perpendicular from the foot. Securing elements are provided to secure attachments to the at least one of the first and second arms. These securing elements may take the form of adhesive. The securing elements may also be in the form of a tab, which may be provided on at least one of the first or second arms, displaced from, or adjacent, the foot, extending generally perpendicularly from the arm.
[0011] The outward-facing surface of the assembly may be formed as a single, unitary, monolithic surface that covers both the first and second arms. This outward-facing surface may be treated, for example, with a laminate or a paper, such as a décor, impregnated with a resin, in order to increase its aesthetic value, or blend, to match or contrast with the panels. Preferably, the outward fading surface has incorporated therein a material to increase its abrasion resistance, such as hard particles of silica, alumina, diamond, silicon nitride, aluminum oxide, silicon carbide and similar hard particles, preferably having a Moh's hardness of at least approximately 6. This outward-facing surface may also be covered with other types of coverings, such as foils (such as paper or thermoplastic foils), paints or a variety of other decorative elements.
[0012] The assembly is preferably provided with a securing means to prevent the assembly from moving once assembled. In one embodiment, the securing means is a clamp, designed to grab the foot. Preferably, the clamp includes a groove into which the foot is inserted. In a preferred embodiment, the clamp or rail may joined directly to a subsurface below the floor element, such as a subfloor, by any conventional means, such as a nail, screw or adhesive.
[0013] A shim may also be placed between the foot and the subfloor. In one embodiment, the shim may be positioned on the underside of the clamp; however, if a clamp is not used, the shim may be positioned between the foot and the subfloor. The shim may be adhered to either the foot or subfloor using an adhesive or a conventional fastener, e.g., nail or screw.
[0014] The assembly may also include a leveling block or reducer positioned between at least one of the first and second arms and the adjacent floor. The leveling block generally has an upper surface that engages the arm, and a bottom surface that abuts against the adjacent floor. In a preferred embodiment, the leveling block has a channel or groove formed in an upper surface, configured to receive the tab on the arm. The particular size of leveling block is often chosen to conform essentially to the difference in thicknesses between the first and second panels. The exposed surfaces of the leveling block are typically formed from a variety of materials, such as a carpet, laminate flooring, ceramic or wood tile, linoleum, turf, paper, natural wood or veneer, vinyl, wood, ceramic or composite finish, or any type of covering, while the interior of the leveling block is generally formed from wood, fiberboard, such as high density fiberboard (HDF) or medium density fiberboard (MDF), plastics, or other structural material, such as metals or composites, at least over a portion of the surface thereof may be covered with a foil, a plastic, a paper, a decor or a laminate to match or contrast with the first and second arms. The leveling block additionally facilitates the use of floor coverings having varying thicknesses when covering a subfloor. The leveling block helps the molding not only cover the gap, but provide a smoother transition from one surface to another.
[0015] Alternatively, the tab may be positioned to slidingly engage the edge of a panel when no leveling block is used. A lip may additionally be provided and positioned on the tab in order to slidingly engage a protuberance, adjacent an upper edge of the clamp, in order to retain the assembly in its installed position.
[0016] The tab is preferably shaped as to provide forces to maintain the assembly in the installed position. Thus, typically the, tab may be frustum-shaped, (e.g., dove-tailed) with its narrow edge proximate the arm and the wider edge furthest from the arm. Additionally, the tab may be lobe shaped, having a bulbous end distal from the arm. In another embodiment, only one side of the tab need be tapered (e.g., half dove-tailed). Of course, any suitable shape is sufficient, as long as the engagement of the tab and groove can provide enough resistive forces to hinder removal of the installed assembly. By forming a suitable groove in the leveling block, the tab can help to secure the assembly in place. Typically, a corresponding groove, having a similar shape as the tab is included in the leveling block or reducer, e.g., having its wider base distal the arm and its narrower opening proximate the arm. It is to be understood by those skilled in the art that although the description throughout this specification is that the position of the tab is on the at least one of the first and second arms, and the groove is on the attachment, e.g., leveling block, the relative position of the tab and groove can be reversed.
[0017] The assembly may additionally be used to cover gaps between tongue-and-groove type panels, such as glueless laminate floor panels. In addition to the uses mentioned above, the tab may also be designed to mate with a corresponding channel in the panel, the edge of one of the flooring elements, or may actually fit within a grooved edge. In order to better accommodate this type of gap, a second tab may be positioned to depend from the second panel engaging surface.
[0018] An adhesive, such as a glue, a microballoon adhesive, contact adhesive, or chemically activated adhesive including a water-activated adhesive, may be also positioned on the tab, in the groove, on the foot, and on at least one of the arms. Of course, such an adhesive is not necessary, but may enhance or supplement the fit of the assembly over the gap between the floor elements. Additionally, the adhesive may assist in creating a more air-tight or moisture-tight joint.
[0019] The assembly may be used in other non-coplanar areas, such as the edge between a wall and a floor, or even on stairs. For example, the assembly may include the first and second arms, and foot as described above, but instead of transitioning between two floor elements placed in the same plane, may form the joint between the horizontal and vertical surfaces of a single stair element.
[0020] The inventive assembly may be used for positioning between adjacent tongue-and-groove panels; in this regard, the assembly functions as a transition molding, which provides a cover for edges of dissimilar surfaces. For example, when installing floors in a home, the assembly could be used to provide an edge between a hallway and a bedroom, between a kitchen and living or bathroom, or any areas where distinct flooring is desired. Additionally, the assembly may be incorporated into differing types of flooring, such as wood, tile, linoleum, carpet, or turf.
[0021] The invention also is drawn to an inventive method for covering a gap between adjacent panels of a generally planar surface. The method includes multiple steps, including, inter alia, placing the foot in the gap, pressing the respective arms in contact with the respective floor elements, and configuring at least one of the tab and the foot to cooperate to retain the assembly in the gap after the assembly has been installed.
[0022] Other objects, features and advantages of the present invention will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is an exploded view of an embodiment of the joint cover assembly in accordance with the invention;
[0024] FIGS. 1A and 1B are alternate embodiments for the molding of the invention;
[0025] FIG. 2 is a perspective view of a second embodiment of the joint cover assembly in accordance with the invention;
[0026] FIGS. 3 and 3A are comparative perspective views of embodiments of the leveling block;
[0027] FIG. 4 is perspective view of an additional embodiment of the joint cover assembly in accordance with the invention;
[0028] FIGS. 5 and 5A are comparative perspective views of embodiments of the leveling block;
[0029] FIGS. 6-16 show comparative cross-sectional views of various embodiments of the melding portion of the joint cover assembly;
[0030] FIG. 17 depicts an embodiment of the assembly of the invention for use with stairs;
[0031] FIG. 18 shows a second embodiment of the assembly for use with stairs;
[0032] FIG. 19 is a side view of a generic element, which may be broken into the components of the invention; and
[0033] FIGS. 20-81 are various modifications of molding of the invention.
[0034] FIGS. 82-111 depict additional modifications of the molding the invention.
[0035] FIGS. 112-119 show even further modifications of the molding of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] FIG. 1 shows an exploded view of the various parts of the inventive joint cover assembly 10 . The assembly 10 includes a T-shaped molding 11 , having a foot 16 formed so that it can fit in a gap 20 between adjacent floor elements 24 , 25 . FIG. 1 demonstrates a typical use, in which the gap 20 is formed adjacent an edge 27 of a floor element 24 . Although FIG. 1 depicts all of the floor elements 24 to be conventional tongue-and-groove type floor panels (having a groove 27 positioned adjacent to the gap 20 ), this is merely one of any number of embodiments. For example, floor elements 24 , 25 need not be the same type of floor element. Specifically, the floor elements 24 can be any type of flooring designed to be used as a floor or placed over a subfloor 22 , e.g., tile, linoleum, laminate flooring, concrete slab, parquet, vinyl, turf, composite or hardwood. As is known, laminate floors are not attached to the subfloor 22 , but are considered “floating floors.” Although the figures illustrate particular locations for features such as the tab 18 and channel 42 , it is within the scope of the invention to reverse the relative locations of such features.
[0037] The molding 11 is provided with a first arm 12 and a second arm 14 extending in a single plane generally perpendicular to the foot 16 . Preferably, the foot 16 , first arm 12 , and the second arm 14 form a general T-shape, with the arms 12 and 14 forming the upper structure and the foot 16 forming the lower structure. Although the foot 16 is shown as being positioned at a central, axis of the molding 11 , such is only a preferred embodiment. In other words, it is within the scope of the invention to vary the position of the foot 16 “off center” with respect to the first and second arms 12 , 14 . For example, the foot 16 may be placed at the midpoint, or anywhere in between, as is depicted, for example, in FIGS. 82-99 .
[0038] As shown in FIGS. 82-111 , a molding 1110 need not form a true right angle with its foot 1116 . For example, the transition from a respective outstretched arm 1112 or 1114 to a foot 1116 may be achieved by one or more rounded sections, or a plurality of straight sections. While the figures only illustrate an angle of other than 90° between arm 1114 and foot 1116 , it is within the scope of this invention to provide the transition between arm 1112 and foot 1116 , or both transitions with such an angle. Typically, these transitions are formed by undercutting the desired angle, as will be described in greater detail, below.
[0039] The molding 11 , as well as any of the other components used in the invention, may be formed of any suitable, sturdy material, such as wood, polymer, fiberboard, plywood, or even a wood/polymer composite, such as stranboard. Due to the growing popularity of wood and laminate flooring and wood wall paneling, however, a natural or simulated wood-grain appearance may be provided as the outward facing surface 34 of the molding 11 . The outward facing surface 34 may be a conventional laminate, such as a high pressure laminate (HPL), direct laminate (DL) or a post-formed laminate (as described in U.S. application Ser. No. 08/817,391, herein incorporated by reference in its entirety); a foil; a print, such as a photograph or a digitally generated image; or a liquid coating including, for example, aluminum oxide. Thus, in the event natural wood or wood veneer is not selected as the material, the appearance of wood may be simulated by coating the outer surface 34 with a laminate having a décor sheet that simulates wood. Alternatively, the décor can simulate marble, ceramic, terrazzo, stone, brick, inlays, or even fantasy patterns. Preferably, the outward facing surface 34 extends completely across the upper face of the molding, and optionally under surface 36 and 38 of arms 12 and 14 , respectively.
[0040] The core structure of components of the invention, including the center of the molding 11 , that is in contact with the outward facing surface 34 is formed from a core material. Typical core materials include wood based products, such as high density fiberboard (HDF), medium density fiberboard (MDF), particleboard, strandboard, plywood, and solid wood; polymer-based products, such as polyvinyl chloride (PVC), thermoplastics or thermosetting plastics or mixtures of plastic and other products, including reinforcements; and metals, such as aluminum, stainless steel, brass, aluminum or copper. The various components of the invention are preferably constructed in accordance with the methods disclosed by U.S. application Ser. No. 08/817,391, as well as U.S. application Ser. No. 10/319,820, filed Dec. 16, 2002, each of which is herein incorporated by reference in its entirety.
[0041] The resulting products typically have durability rating. As defined by the European Producers of Laminate Flooring; such products can have a durability rating of anywhere from AC 1 to AC 5 . Preferably, the products of this invention have a rating of either AC 3 or AC 5 .
[0042] A securing element, such as a metal clamp, track or rail 26 , may be coupled to the subfloor 22 within the gap 20 formed between the two floor elements 24 . The clamp may be coupled to the subfloor 22 by fasteners, such as screws or any conventional coupling method, such as nails or glue. The clamp 26 and the foot 16 are preferably cooperatively formed so that the foot 16 can slide within the clamp 26 without being removed. For example, the clamp 26 may be provided with in-turned ends 30 designed to grab the outer surface of the foot 16 to resist separation in a vertical direction. Typically, the foot 16 has a dove-tail shape, having the shorter parallel edge joined to the arms 12 and 14 ; and the clamp 26 is a channeled element having a corresponding shape as to mate with the foot 16 and hold it in place. Additionally, the securing element may take the form of an inverted T-element 50 ( FIG. 1A ), configured to mate with a corresponding groove 52 in an end of foot 16 , such that friction between the T-element 50 and the groove 52 secures the molding 11 in place, or, in the alternative, the end of the foot 16 may be provided with a narrowed section, designed to mate with a groove in the securing element. Finally, each of the T-element 50 , mating section of the foot 16 and/or various grooves, may be provided with notched or barbed edges 55 to simultaneously assist in mating and resist disassembly ( FIG. 1B ). However, in an alternative embodiment, the securing element can be eliminated because the molding 11 can be affixed to one of the floor elements 24 , 25 , by, for example, an adhesive. Preferably, however, the molding 11 is not secured to both floor elements 24 , 25 , as to permit a degree of relative movement, or floating, between the floor elements 24 , 25 .
[0043] The clamp 26 may additionally be formed of a sturdy, yet pliable material that will outwardly deform as the foot 16 is inserted, but will retain the foot 16 therein. Such materials include, but are not limited to, plastic, wood/polymer composites, wood, and polymers. The clamp 26 may additionally engage recesses in, for example, sides of the foot 16 .
[0044] A tab 18 is shown as extending downwardly from the first arm 12 . As shown in FIG. 1 , the tab 18 extends downward, or away from an outward facing surface 34 of the molding, and runs generally parallel to the foot 16 . As shown in FIG. 1 , the tab 18 may also be in the shape of a dove-tail with a shorter edge adjacent to the first arm 12 ; however, other suitable shapes are possible. The shape of the outwardly facing surface 34 of the molding 11 is shown as being convex in some of the Figures (e.g., FIGS. 1A , 1 B and 7 ), and substantially planar in others (e.g., FIGS. 1 , 2 , 4 , and 6 ). When the outwardly facing surface 34 is substantially planar, the edges of the molding 11 may either be upright or at an angle, typically angling away from the foot 16 . However, the relative positions of the tongue/groove may also be reversed.
[0045] The assembly may further include a leveling block 40 otherwise known in the art as reducers. When flooring elements 24 and 25 are of differing heights, the leveling block 40 is positioned between either the first arm 12 or the second arm 14 and the subfloor 22 . Preferably, the size of the leveling block 40 is selected to correspond essentially to the difference in heights of the two flooring elements 24 and 25 . However, if an adjustable pad 1120 (as described below) is used, the particular height of the reducer is not particularly important. For example, if one flooring element 24 is a ceramic tile, having a thickness of 2″ and the second flooring element 25 is vinyl, having a thickness of ¼″, the leveling block 40 would typically have a thickness of 1¾″ to bridge the difference and be placed between arm 12 and the other flooring element 25 . Without the leveling block 40 , a significant space would exist between the second flooring element 25 and the molding 11 , allowing for moisture and dirt to accumulate. While the difference in heights of the flooring elements 24 , 25 is generally caused by a difference in thickness between the two flooring elements 24 , 25 , the present invention may also be used to “flatten out” an uneven subfloor 22 . In addition, a shim may be placed under the track to adjust for differences in floor thickness. In a preferred embodiment, the leveling block is provided with a channel 42 designed to receive the tab 18 .
[0046] The width of the foot 16 , 1116 may be different, depending upon the particular application. For example, when a reversible molding element 1250 is used, it is preferred that the width of the foot 16 , 1116 be narrower to accommodate the proximal portions of the molding element. Typically, the clamp 26 , 1126 is also adjusted to accommodate the appropriate foot 16 , 1116 .
[0047] Even though the assembly 10 may function without any type of glue or adhesive, an alternate embodiment includes the placement of adhesive 31 on the molding 11 . The adhesive may be placed on molding 11 at the factory (for example, pre-glued). Alternatively, the glue may be applied while the floor elements 24 , 25 are being assembled. As shown in FIG. 6 , the adhesive 31 may be provided as a strip-type adhesive, but any type of adhesive, such as glue, chemical or chemically-activated adhesive, water-activated adhesive, contact cements, microballoon or macroballoon encapsulated adhesive may be used. Additionally, while the embodiment in FIG. 6 shows a single adhesive strip 31 attached to the arm 12 , the adhesive 31 may be attached to the tab 18 , foot 16 , and/or any location where two pieces of the assembly are joined. In some embodiments, the adhesive may be used as an alternative to tab 18 and groove 42 . Preferably, adhesive 31 is only applied to one of the arms 12 , 14 in order to allow or accommodate some slight relative movement that may occur during changes of temperature, for example. This relative movement is known in the flooring art as “float”. Allowing float may also eliminate unneeded material stresses as well, thereby reducing warping or deterioration of the material surface. Typical adhesives used in the invention include a fresh adhesive, such as PERGO GLUE (available from Perstorp AB of Perstorp, Sweden), water activated dry glue, dry glue (needing no activation) or an adhesive strip with a peel off protector of paper.
[0048] FIG. 2 shows a typical embodiment of the assembly 10 in an installed condition, wherein the floor elements 24 and 25 are of differing thicknesses (H and H′ respectively). Of course, the element 24 may be of any type of covering, such as carpet, turf, tile, linoleum or the like. As shown in FIG. 3 , the leveling block 40 typically includes a substantially flat bottom 46 , and a top 45 having a groove 42 , and an inner surface 44 . The top 45 of the leveling block 40 is designed to firmly abut the under surface 36 of the first arm 12 , while the bottom 46 abuts floor element 25 . Typically, the groove 42 is shaped as to firmly hold the tab 18 . By having a corresponding shape, for example, the groove 42 can have a dove-tail shape, where both lateral sides diverge from the upper surfaces or a “half-dove tail,” where only one of the two sides is so configured. The inner surface 44 of the leveling block 40 need not abut the foot, as generally, a small amount of clearance is provided between the clamp 26 or foot 16 and the inner surface 44 of the leveling block. However, the inner surface 44 may be configured to contact either of the clamp 26 or foot 16 . The tab 18 may also be of a shape different than groove 42 , e.g., a wedged-shaped tab fitting within a straight-walled groove. In other embodiments, friction will be sufficient to maintain the position of the tab and groove elements.
[0049] The leveling block 40 may be made of a composite, pliable material that is also resilient. For example, the tab 18 may be formed to be slightly larger than the opening of the channel 42 , thereby forcing the channel 42 to outwardly deform in order to accommodate the tab 18 , and therefore snap-fit together.
[0050] As shown in FIG. 3 , the outer surface 47 of the leveling block 40 is generally treated to match or blend with the outer surface 34 of the molding or the floor element 24 , 25 in order to improve aesthetics.
[0051] FIG. 3A shows an alternate embodiment of a leveling block 40 ′. An outer surface 47 ′ of this embodiment is configured generally perpendicular to an upper surface 44 ′ and a lower surface 46 ′ of the leveling block 40 ′. This alternate configuration of the outer surface 47 ′ not only provides a different appearance, it also has been shown to be preferred when softer surfaces, such as carpet or turf, are positioned beneath the lower surface 46 ′ of the leveling block 40 ′.
[0052] FIG. 4 shows yet another alternate embodiment of the leveling block 140 . The leveling block 140 includes a bottom 146 , and a top 145 and an inner surface 144 . The top 145 of the leveling block 140 is designed to firmly abut the under surface 36 of the first arm 12 , while the bottom 146 abuts floor element 25 . This leveling block 140 is positioned between a first arm 112 of the molding 111 and the flooring element 125 . In this embodiment of the assembly 110 , the tab 118 engages the inner surface 144 of the leveling block 140 .
[0053] FIG. 5 shows an embodiment of a leveling block 140 that may be used in the assembly shown in FIG. 4 . Specifically, the leveling block 140 in FIG. 5 has a solid, uninterrupted upper surface 145 , without the need for a channel because the tab ( 118 , as in FIG. 4 ) will engage the inner surface 144 of the leveling block instead of the top surface 145 . In such an embodiment, the tab 118 may also be adjacent the foot. In some embodiments, the use of adhesive will reinforce the positioning of the leveling block 140 relative to tab 118 .
[0054] FIG. 5A shows an additional shape of a leveling block 140 ′ that can be incorporated into the assembly shown in FIG. 4 . Leveling block 140 ′ has a front surface 146 ′ that will be generally perpendicular to a floor 122 (as shown in FIG. 4 ) when the leveling block 140 ′ is installed. This perpendicular configuration of the front surface 147 ′ not only provides a different appearance, it has also been found to be preferred with softer surfaces, such as carpet or turf. FIG. 6 shows an underside view of the molding 11 . In particular, the first under surface 36 of the first arm 12 , and the second under surface 38 of the second arm 14 are shown. In one embodiment, under surface 36 is provided with the adhesive 31 positioned to adhere to a surface of a floor element 24 , 25 or leveling block 40 , 40 ′, 140 , 140 ′.
[0055] FIGS. 7-15 show various cross-sectional views of the molding 11 . These figures show comparative configurations for the arms 12 , 14 , the tab 18 , and the shape of molding 11 .
[0056] In FIG. 7 , the tab 18 is selected to be an outward-facing hook having a barb facing away from the foot 16 , while the upper surface of the molding has a convex curvature. This particular selection for the tab 18 may be used to engage an edge or groove of an adjacent floor element 24 , 25 , or, in the alternative, an adjacent leveling block 40 . Additionally, a shim 48 may be positioned between the foot 16 and the subfloor 22 . The shim 48 is generally formed of a pliable and flexible, yet durable, material, such as a polymer, preferably a polymer exhibiting electrometric properties. The shim 48 may be used in place of, or in combination with, clamp 26 . Preferably, the shim 48 is sized in accordance with the size of the clamp 26 , 1126 .
[0057] FIGS. 8-15 show cross-sections of other shapes for the molding 11 . The configurations of the moldings are very similar, except for the shape of the tab 18 . The differing tabs have been assigned decimal numbers beginning with 18 , for clarity purposes. A tab 18 . 1 ( FIG. 8 ) is a bulbous shape, having its rounded end furthest from the arm 12 . tab 18 . 2 ( FIG. 9 ) is provided with a hook-shape with a point facing the foot 16 . In the embodiment shown in FIG. 10 , a tab 18 . 3 is in the shape of a dove-tail, similar to the shape of the tab 18 shown in FIG. 2 . The tab 18 may additionally be configured to have a substantially rectangular cross section with two opposite rounded off corners, as shown in FIGS. 82-111 or any of the other shapes described herein, with one or more of the corners/ends being rounded.
[0058] The purpose of the various-shaped tabs ( 18 - 18 . 8 ) is multi-fold. Primarily, the tab 18 serves to engage the channel 42 of the leveling block 40 , which is used when covering of differing thickness is used. Alternatively, the respective tab ( 18 - 18 . 8 ) may engage an edge of a panel, carpet, turf, or other type of floor covering. As shown herein, the respective tab ( 18 - 18 . 8 ) may even be configured to engage a leveling block.
[0059] It is additionally considered within the scope of the invention to eliminate the tab. In such an embodiment, preferably, the molding 11 includes an adhesive on the under surface 36 , 38 of one of the arms 12 , 14 .
[0060] With respect to FIG. 16 , the invention may also be used when the floor elements are not co-planar. For example, one embodiment includes a stair nose attachment 210 that can be attached to the same molding 11 , as described above. As used herein, a stair nose attachment is a component capable of mating with the molding 11 so as to conceal, protect or otherwise cover a joint forming a single stair. Typically, the molding 11 is provided atop the first floor element 24 on the horizontal, or run 220 of the stair, such that the stair nose attachment 210 bridges the joint between the first floor element 24 and the second floor element 25 , forming the vertical section of the stair, or rise 230 . As a result, the invention can be used to cover and protect joints between flooring elements on stairs. While in a preferred embodiment, the floor elements covering the rise 220 and run 230 are the same type of flooring material, the flooring elements need not be of the same construction or type of materials.
[0061] The stair nose attachment 210 may include a tab receiving groove 212 , permitting connection of the stair nose attachment 210 to the molding 11 . Because the tab receiving groove 212 in the stair nose attachment 210 is preferably shaped according to the shape of the tab 18 of the molding 11 , the stair nose attachment 210 may be attached to the molding 11 by, for example, snapping or sliding.
[0062] However, in other embodiments, the tab on the under surface 36 is eliminated. While the tabs and corresponding grooves may be eliminated, it is nevertheless considered within the scope of the invention to utilize an adhesive, as described herein. Alternatively, the stair nose attachment 210 may include a tab 218 to mate with a corresponding groove 219 on the foot 16 of the molding 11 ( FIG. 17 ), or vice-versa.
[0063] By allowing an end user to purchase the generic element 300 instead of separate components, the retailers and/or distributors may accordingly reduce their inventory requirements. For example, typically over one-hundred different design patterns for the outwardly facing surface 34 of the molding 11 (as well as for the leveling block 40 and stair nose attachment 210 ) are produced. By allowing for the inventory to include only the generic elements of the invention, the total number of components retained can be reduced from three per design to one per design. Similarly, the installer only need purchase the generic elements 300 , rather than three individual components. Thus, both retailers and installers may profit from having less storage and/or retail bays to service the same types of accessories as prior to the invention.
[0064] FIGS. 20-53 depict alternate embodiments, for the leveling block (or other pieces) and the molding 11 .
[0065] FIG. 20 shows a general representation of the molding with a track 101 and shim 102 , below the molding 11 . Preferably, the track 101 is metal and the shim 102 is plastic. However, it is within the scope of the invention to form either of these pieces out of either material. Additionally, other materials may be used, such as materials which flex, but return to their original configuration when pressure is applied and then released. In one embodiment, a track 101 , formed of metal, is fastened to a subfloor with screws. For thicker laminate flooring, the shim 102 may be snapped to the underside of the track before it is fastened to the subfloor. Use of the shim 102 offers a height adjustment for multiple thicknesses of laminate, or other flooring. Thus, where the height of a surface below the molding 11 requires the molding to be raised, the shim 102 can be used to provide the necessary spacing. However, it must be noted that, although FIG. 20 shows the shim 102 being used, such is an optional element, as the shim 102 may be used with each of the shapes and designs of moldings 11 disclosed herein, or similarly, eliminated from each embodiment, as required by the particular circumstances.
[0066] As shown in FIGS. 90-99 and 102 - 111 , the shim 102 may be in the form of a pad 1102 , which may be provided with one or more upturned ends 1102 a and 1102 b . Preferably, the upturned ends 1102 a and 1102 b of the pad 1102 are sized and shaped to receive foot 1116 if desired. Thus, in a number of embodiments, shown for example in FIGS. 102-111 , the foot 1116 is positioned in the pad 1102 , such that the upturned ends 1102 a and 1102 b grip or grasp the clamp 1126 . If the upturned ends 1102 a and 1102 b , or even the entire pad, 1102 are formed from a resilient material, such as a plastic or elastomer or certain types of metal, the gripping force provided can be greater. However, the pad 1102 and the parts thereof can be constructed of any material. The pad 1102 may additionally be affixed to a clamp 1126 with a fastener, such as a screw or nail, and/or an adhesive, such as a glue or adhesive tape. In the embodiment shown in FIGS. 98 , 99 , 110 and 111 , the pad 1102 is inverted, such that upturned ends 1102 a and 1102 b are directed toward the subfloor and away from the clamp 1126 in order to provide the clamp 1126 with additional height. This allows a single pad 1102 to accommodate a variety of height requirements. Moreover, if needed, it is possible to cut off a terminal section of the upturned ends 1102 a and 1102 b to accommodate an unlimited number of additional heights. The size and depth of the pad 1102 is not limited by the present invention and is typically any height from 1 mm up to 4 mm, with additional height being provided when the pad 1102 is inverted. Typically, the pad 1120 , just like the shim 102 , is sized in accordance with the clamp 26 , 1126 .
[0067] The size of the clamp 1126 is not particularly limited by the present invention. Typical clamp 1126 heights can be any dimension, preferably from 6-10 mm, most preferably 6.55 or 6.8 mm.
[0068] The embodiment of FIG. 21 has a leg of the molding 11 extended. Herein, there is a choice of height adjusting shims, which, in addition to the snap-on shim 102 , may additionally include a second shim 103 , formed of any material, such as wood, plastic, fiberboard, stone, metal, etc., that can be attached via any method to either the molding or the subsurface, such as with an adhesive, or screw. Typically, the extended leg of the T-molding is fastened to a subfloor with a silicone sealant, acting as an adhesive. Such a construction permits easy and quick installation, especially avoiding the need to drill holes and insert plugs for screws when installing over a concrete subfloor. The shim 102 can be attached to the underside of the extended leg of the T-molding to provide the appropriate height adjustment.
[0069] FIGS. 20 and 21 additionally represent the double and reversed tongue-and-groove configuration that functions to fasten a foot, hard surface reducer or carpet/end molding to the T-molding. In this configuration the tongue that extends from the underside of the T-molding is placed so that it falls within the expansion space of the installed flooring transition. This configuration does not require the removal of this tongue in order to install the T-molding part as a T-molding only. Should the laminate floor expand, the pressure will be sufficient to shear off this tongue on the underside of the molding, and the floor can move freely as if there were no extended tongue present in the expansion space.
[0070] Preferably, the shim 102 is a metal or plastic structure, having a pair of grabbing flanges 102 a for the purpose of clamping onto, for example, the track 101 . The grabbing flanges 102 a typically form an acute angle with respect to the remainder of the shim 102 , such that when the molding 11 is inserted into the shim 102 , the grabbing flanges 102 a are forced outward, and the grabbing flanges 102 a function to hold the molding 11 in place.
[0071] In a preferred embodiment, the molding 11 and a second member, such as a reducer; leveling block, stair nose, or any other molding attachment. Are joined by one or more tongue-and-groove joints. For example, the second, member can be provided with a tongue and the molding 11 is provided with a matching groove. As shown in FIGS. 25 and 26 , the tongue, which may be located on the second member, may be shaped as a dove-tail or a “half dovetail,” wherein only one of the two sides defines an angle other than ninety degrees. Such a tongue may extend over any potion of the mating surface, such as small amount ( FIG. 25 ), approximately half ( FIG. 26 ), or even substantially the entire mating surface.
[0072] Typically, the tongue-and-groove are not simply rectangular” in shape, but are provided with elements which tend to hold the pieces together. For example, as shown in FIGS. 20 , 21 , 25 , 28 and 29 , the tongue may have, on at least one side a tapered surface, resembling a dovetail, such that the pieces cannot simply dissociate without manipulation.
[0073] In the embodiments of FIGS. 20 and 21 , the reducer has on its mating surface, one tongue and one groove, while the molding 11 has the matching groove and tongue. In FIG. 21 a , the extended leg of the T-molding allows the T to be adhered to the sub-floor with construction adhesive or tapes or other adhesives. A shim can be placed on the bottom of the extended leg of the T-molding to raise the height, either a snap-on type of shim or a simple rectangular piece of material which can be adhered onto the bottom of the foot and then the assembly is adhered to the floor.
[0074] FIGS. 22 through 27 can represent either installation method, with a track or with an extended leg on the T-molding for, T-molding, bard surface reducer, carpet/end molding and stair nosing.
[0075] In the embodiments of FIGS. 22 and 23 , the pieces are provided with a horizontal flange 111 and the molding 11 has a similarly shaped groove. In FIG. 22 , the groove is not provided with any locking elements, while in FIG. 23 , the groove is provided with a locking flange 121 , which joins with a locking groove 112 on the second member to hold the pieces together. Although not specifically shown, it is within the scope of the invention to swap the location of the tongue/groove, such that the tongue is on the molding 11 , and the groove is positioned on the second member. Similarly, there may be any number of matching tongues/grooves, and each piece may have any combination of tongues and grooves. Similarly, as shown in FIG. 27 , the tongue and groove need not be positioned adjacent to the underside of one of the arms of the molding 11 , and a gap 114 may be provided in the second member to allow for greater movement between the second member and the first member without permitting dissociation. This gap may be a break-away feature.
[0076] In FIG. 22 , a recess lateral slot is present on the underside of the T-molding, as well as a groove in the leg of the T-molding. The recessed slot and raised platform of the top of each foot hinders lateral movement of the foot and the tongue and groove stabilize the foot against the top of the T-molding.
[0077] In FIG. 23 , there is a tongue and groove with a snap-fit ridge or tab at the end of the groove or in the, tongue of the leg′ of the T-molding. There is also shown a corresponding groove in the underside of the tongue of each foot that snaps into the tab.
[0078] In the embodiment of FIG. 24 , the locking element 110 is a downwardly facing flange, sized and shaped to mate with the locking groove 112 on the second member. When the pieces are connected, the locking element 110 and locking groove 112 function to resist separation of the pieces in a horizontal direction. Although not shown, the locking element 110 and locking groove 112 , as shown in FIG. 24 , may be combined with any of the structures as shown in any of the other embodiments disclosed herein in order to assist in maintaining a secure connection between the elements.
[0079] In one embodiment, the extension 114 is affixed to the subfloor, by a means for securing. The securing means may be, for example, a mechanical fastener or a chemical fastener through, for example, boss 134 . As used herein, a mechanical fastener is any device which joins the elements with, e.g., pressure, and includes, but is not limited to, a nail, screw, staple, claw, clamp, barb, cant hook, clapper, crook, fang, grapnel, grappler, hook, manus, nipper, paw, pincer, retractile, spur, talon, tentacle, unguis, ungula, brad, point, push pin, and tack. Additionally, a chemical fastener is a component, such as a sealant or adhesive, and includes tapes, glues and epoxies. This extension 114 may also attach to the track.
[0080] The embodiments shown in FIGS. 28-35 each have an extension 120 of the second member which extends below the foot of the molding. In such embodiments, typically, the second member is a stair molding and is secured to the subfloor. The T-molding is then attached to the second member, as the T-molding does not contact the subfloor. However, it is considered within the scope of the invention to additionally provide an extension bracket, (not shown) for securing the T-molding to the subfloor. As shown in FIGS. 28 , 29 and 35 , the second member may include a recess 124 into which the foot of the T-molding is inserted, or in the alternative, a depression 126 ( FIGS. 30 , 33 and 34 ).
[0081] Additionally, the second member may have a wedge 128 ( FIGS. 31 and 32 ) to secure the T-molding in place. The foot of the T-molding may either be angled into position to bypass the uppermost section of the wedge 128 , or the wedge may be formed such that it deflects under pressure and snaps back after the foot of the T-molding is properly positioned. Again, the embodiments' of FIGS. 28-35 may be combined with one or more of the tongue and groove-configurations' as shown or described in connection with FIGS. 20-27 .
[0082] The second member, shown as a stair nosing, in FIGS. 28-35 may be installed using construction adhesives, specialized tapes (such as simple double-sided tapes), silicone or other sealants (such as epoxies or glues) or mechanical fasteners (such as screws or nails).
[0083] The embodiments of FIGS. 36-42 can be installed using a track 101 , similar to the embodiments shown in FIGS. 20-27 . In particular, either one or both of the T-molding and second member (shown as a stair nose) may be secured with the track 101 . The members can also be fastened to the track 101 after a construction adhesive or sealant/adhesive has been applied into the track and/or additional mechanical fasteners may be used to assist in fixing the second member to the subfloor (or tread, as necessary).
[0084] FIG. 43 demonstrates an extended face for a stair nose. Therein, the extended face is sufficient in breadth to cover the edge of common stair treads, thus eliminating the need to place a separate piece of flooring on the edge of stair treads or to cover the edge of a subfloor when stepping down from a floating floor installation to a lower level floor. However, stair noses may also be installed using the method described in connection with FIG. 21 , above, without the need of a track 101 , when the T-molding has an extended leg.
[0085] The embodiments of FIGS. 44-53 allow installation of the multipurpose flooring transition using only adhesives, tapes or sealants, as no track 101 is required. The additional surface area beneath the transition is increased adding additional adhesion area for strength in bonding the transition to the subfloor. This installation method also avoids the need for a track, screws and/or plugs (although they are certainly not prohibited), and additionally allows for faster installation over subfloors formed from, for example, wood based products or concrete.
[0086] FIGS. 44 and 45 show two assembled members held together with glue before fastening to the subfloor. Such members may also be installed by other methods described herein.
[0087] FIGS. 46-49 depict two members joined together with a snap-fit, such that no glue is necessary. Such members may also be installed by another method described herein. Although FIGS. 46-49 show a particular location for various snap-fitting elements, i.e., tongue and groove, it is certainly within the scope of this invention to increase the size, shape, location and number of the tongues and grooves as necessary. For example, FIG. 30 depicts one groove on either side of the foot of the T-molding and corresponding tongues on the second member. However, additional tongues/grooves may be located on the bottom of the foot or even on the underside of the arm. Additionally, the second member may include both tongues and grooves, combining the features illustrated in FIGS. 46 and 47 with FIGS. 48 and 49 .
[0088] FIG. 50 represents a shim, which can be made, from waste cuttings of the core material during the manufacture of the transition. This shim may be used to elevate the foot of the assembly to accommodate a thicker flooring material.
[0089] FIG. 51 shows an additional embodiment wherein the second member is a stair molding. ‘The pieces, i.e., the T-molding and the stair molding, can be held together with glue before fastening to the subfloor, or by any other installation method described herein.
[0090] In FIG. 52 , an additional T-molding is shown that can snap-fit, i.e., without the need for glue, and FIG. 53 shows a corresponding track or structure to be incorporated into a second member. Specifically, the second member piece of FIG. 53 includes a plurality of alternating tongues and grooves, such that the foot of the T-molding, also having alternating tongues and grooves, form a snap action that functions to hold the T-molding firmly. Additionally, this design permits the elimination of the shim 102 , as the foot of the T-molding need not be completely seated in the second member. In other words, because the T-molding can be secured to the second member with a gap or space remaining between the bottom of the foot 130 and the inner-most part of the second member 130 , height variations can be accounted for without the need for an additional part.
[0091] FIGS. 54-66 show an alternate embodiment of the invention. Specifically, as shown in FIG. 64 , a single reversible molding element 1001 has an outer face 1005 , which extends over a front face 1007 and a rear face 1009 . This outer surface 1005 is the same on both the front face 1007 and the rear face 1009 , and preferably includes a laminate, but may also be of a foil. While the outer surface 1005 may be limited to only the front face 1007 and the rear face 1009 , the outer surface 1005 may extend across any additional surfaces as well. Due to the novel construction of the reversible molding element 1001 , the versatility of the invention can be greatly increased.
[0092] An example of the versatility of the reversible molding element 1001 is specifically shown in FIGS. 55 and 56 , wherein the significant distinction between FIGS. 55 and 56 is the orientation of the reversible molding element 1001 . In FIG. 55 , the reversible molding element 1001 has its front face 1007 facing outward, while in FIG. 56 , the opposite, or rear face 1009 facing outward. As a result, when the front face 1007 is oriented outward, reversible molding element 1001 functions as a hard surface reducer. In contrast, when reversible molding element 1001 is reversed, and the rear face 1009 is oriented outward, the reversible molding element 1001 functions as an end molding. Thus, when the T-molding is put together in a single package with the reversible molding element 1001 , the combination can be used as either a hard surface reducer or an end molding, in contrast to other systems which require three independent pieces to accomplish the same result.
[0093] When using two parts instead of three, maximum use of materials is accomplished, making the invention more economical to produce and, as a result, more environmentally friendly sound. This new configuration of two pieces allows a third piece to be introduced, also reversible, that broadens the use of the pieces to include a increased range of flooring thicknesses found in such products as hardwood and other finished flooring that could not be previously accommodated. An additional option that increases the range of use of the invention is to permit it to transition to a broader range of flooring thicknesses by adding a second reversible part that is higher (thicker) than the first reversible part.
[0094] In FIG. 54 , there is a tongue/groove connection in the attachable parts, for example, on the underside of the T-molding. However, it is within the scope of the invention to reverse the position of each of the tongue and groove from that illustrated. This figure shows the reversible molding element 1001 in a configuration with the track and shim, as optionally used in the other embodiments discussed herein.
[0095] In FIG. 57 the underside of the T-molding does not have a tongue or groove. It does, however, have a notch or shoulder, which holds the other molding piece, such as the reversible molding element 1001 , from moving laterally toward the track. The reversible molding element 1001 , preferably, is smooth, without a groove or tab on the surface which comes into contact with the underside of the T-molding. The underside of the reversible molding element 1001 preferably has a groove to accommodate an extension from the track that stabilizes the lateral movement of the reversible molding element, preventing movement away from the track. In order to hold the element 1001 in place, the track can be provided with a gripping flange 1010 , which may be formed as a break-away section on the remainder of the track, such that when the gripping flange 1010 is not to be used, it can be easily removed to have the track in a different configuration.
[0096] FIG. 58 shows both a groove and stabilizing notch on the underside of the T-molding, with a tab on the reversible molding element 1001 .
[0097] FIG. 59 shows an extendable track extension 1012 , which may be one, piece or with break-away elements, and may also act as a shim to raise the track. When used as one piece, the, raised tab, on the extension that affixes to the underside of the reversible molding element 1001 , can slide beneath the finished flooring when the track is used to hold a T-molding or the height of the tab can be the equivalent to the height of underlayments used in the floating floor application, and will not interfere with the floating floor, because the extension is no higher than the foam underlayment commonly used in such installations, the apparatus does not interfere with the floating floor. When used with the break-away feature, the extension can be removed and the remaining part can be used as a shim to raise the track to accommodate a thicker floor. The track may be joinable-with a tongue/groove connection system to prevent relative movement. FIGS. 60 and 62 show a similar attachable extension using thinner material and a different attachment configuration.
[0098] In FIG. 61 , the underside of the T-molding does not have either a tongue or groove. It does, however, have a notch or shoulder that holds the reversible molding element from moving laterally toward the track. The reversible molding element may also be smooth, i.e., no tongue or groove 6 n the surface that comes into, contact with the underside of the T-molding. These parts can be assembled With any type of glue or adhesive, such as fresh glue, pre-applied glue, encapsulated glue, reactive adhesives, contact adhesives, or adhesive tapes., 7 .
[0099] In FIG. 63 , the T-molding has a milled groove 1012 . The top of for example, the reversible molding element also has a groove 1014 . To complete assembly, a loose double-sided tongue 1016 can be pressed into the groove 1012 as the reversible molding element 1001 is attached to the tongue 1016 . The tongue 1016 can be pressure fit or glued into one or both of the grooves 1012 , 1014 .
[0100] The two different sizes of elements 1001 of FIGS. 65 and 66 allow for accommodation of a wide range of thicknesses.
[0101] In FIG. 67 a , there is a groove and stabilizing notch on the underside of the T-molding, and a tab on the reversible molding element 1001 (not shown); Here, the T-molding can accommodate either reversible parts (such as those shown in FIGS. 65 and 66 ), and a shim can be used with an extension (which can be broken away or folded under the shim) to increase its thickness to raise the track and accommodate thicker flooring. FIG. 67 b shows the break-away shim extension with tabs that can snap to the underside of the shim.
[0102] FIGS. 68-80 utilize the reversible concept with aluminum or other metals or composites. Generally all of the same features of the previously described materials can be used with these elements. These structures may additionally be covered, at least in part, by a decor layer (which may be, optionally directly, digitally printed and coated or a decor sheet which can be subsequently coated), such as a foil or other laminate structure.
[0103] FIG. 69 shows two grooves in the T-molding and two matching tongues on the second or reversible molding element. Again, the location of the tongue/groove of any embodiment described herein can be swapped without departing from the invention.
[0104] FIG. 70 shows a T-molding with one single foot and a track to accommodate this foot, similar to FIGS. 1A and 1B .
[0105] FIG. 71 shows a T-molding and, a reversible, molding element with grooves that can accommodate a clip′ 1 020 that joins the two parts together. The clip has a similar function as the double-tongue of FIG. 63 .
[0106] FIG. 72 shows a reversible molding element with a tab on the top and groove on the underside to accommodate a track extension and aid the prevention of lateral movement, similar to that which is shown in FIG. 57 .
[0107] In FIG. 73 , the T-molding is provided with serrated grooves 1022 which match similar grooves 1024 on the reversible molding element. These grooves may be serrated “inwards” to hinder pulling-out of the reversible molding element, or inwards to hinder the reversible molding element from being pushed inward, i.e., toward the foot of the T-molding. Alternate embodiments which differ from the traditional tongue/groove connection are shown in FIGS. 75 and 76 . The T-molding can have a notch or shoulder and the reversible molding element can have a corresponding tongue to prevent lateral movement away from the track. The pieces may also be smooth and held together with an adhesive, as described elsewhere herein, or may be held together using only the track extension.
[0108] In FIG. 74 , the track is shown with an extension as a break-away section, similar to that which is shown in FIGS. 60 and 62 .
[0109] FIGS. 77-80 show a metal or composite stair nose attachment in accordance with the invention.
[0110] In FIG. 77 , the stair nose is attached to a T-molding, which need not be formed from an aluminum. This structure may be from HDF, MDF, plastic, or other metal or composite materials. Such composites can include combinations of wood based and plastic resin composites. Hidden fasteners, which are not visible from the surface of either element can be used to secure the elements to the subfloor. There can also be a track to hold the elements in place.
[0111] In FIG. 78 , the stair nose is a separate piece apart from the T and the track. It can be fastened to the subfloor or stair tread with screws through apertures 1030 integrated into the structure of the stair nose. The separate track can be secured to the subfloor also with separate screws. Additionally, the same screws may be used to affix the track and the stair nose. The T-molding can be attached to the stair nose by the tongue and groove arid can be held to the subfloor or stair tread by the track.
[0112] FIGS. 79 and 80 show the stair nose and track as one piece. While the track and stair nose can be separately formed, and joined, for example, by a tongue/groove system, they can also be formed and sold as a single unit.
[0113] FIG. 81 shows a modification of the T-molding of the invention. Specifically, it is possible to remove one of the arms or members from the T-molding to create an end molding or carpet reducer. This T-molding 1801 can be in accordance with any of the embodiments described herein. For example, the T-molding 18801 may be formed from HDF, MDF, metal or composite, and optionally provided with a decor layer, which may be printed or otherwise provided directly on the surface. Additionally, the removable section may be pre-fabricated as a frangible section, as is shown and described in accordance with FIG. 19 . A kit, such as a single package, may also be provided which includes at least two, but preferably all, of the individual parts described herein.
[0114] As shown in FIG. 19 , it is also possible to form the molding 11 , leveling block 40 . and stair nose attachment 210 from the same element. Specifically, a generic element, indicated at 300 can be milled, sawed or otherwise constructed with a variety of “break away,” or readily separable, sections 300 A, 300 B, and 300 C. When one or more sections 300 A, 300 B, 300 C are removed by for example, scoring and snapping, cutting, sawing or simply bending, the individual pieces can result. Preferably, the generic element 300 is initially formed as a unitary structure which is then scored as to provide stress-points to allow the removal of the sections. While not required by the present invention, typically, the removal of the break-away sections 300 A, 300 B, 300 C requires a significant amount of physical force or labor, as the remaining structure must maintain its structural integrity. Alternatively, removal of the sections 300 A, 300 B, 300 C may require the use of a specialized tool.
[0115] By designing the generic element 300 in accordance with the invention. An installer can manipulate the generic element 300 to produce any needed component. For example, removing sections 300 B and 300 C would produce a typical stair nose attachment 210 , while removing sections 300 A and 300 C would produce a typical molding 11 . Due to this construction, it is, possible to manufacture the generic elements to be purchased with appropriate selection being left to the, installer. Similarly, when removing sections 300 A and 300 C to form the molding 11 , section 300 A can be used as a leveling block as described herein.
[0116] By allowing an end user to purchase the various pieces as an assembled generic element 300 instead of separate components, the retailers and/or distributors may accordingly reduce their inventory requirements. For example, typically over one-hundred different design patterns for the outwardly facing surface 34 of the molding 11 (as well as for the leveling block 40 and stair nose attachment 210 ) are produced. By allowing for the inventory to include only the generic elements of the invention, the total number of components retained can be reduced from three per design to one per design. Similarly the installer only need purchase the generic elements 300 , rather than three individual, components. This results in savings both to the retailer and installer by reducing the space needed for retailing bays and storage, respectively.
[0117] The molding 1110 may also be provided with a shoulder 1115 , located preferably on the underside of one of the arms 1114 , 1112 . This shoulder can be similar to the stabilizing notch shown in FIGS. 56-61 . The position of the shoulder is typically selected to provide a stop surface to the attachment 1140 to help prevent lateral movement of the attachment 1140 with respect to the molding 1110 . This shoulder 1115 is preferably formed by a beveled cut into the surface, such that when the attachment 40 is seated in shoulder 1115 , movement of the attachment 40 is hindered. The presence of this shoulder 1115 can eliminate any gap or space at the distal or exposed edge of the molding element 1140 , 1250 as it meets the surface of the subfloor or floor element.
[0118] The attachment 1140 can also be provided with. one or more spacing gaps 1200 on an undersurface thereof ( FIGS. 86-99 , 100 , 102 , 104 , 106 , 108 and 110 ). When used with an appropriately sized spacer 1210 , the molding 1110 and attachment 1140 can be used with a wide variety of flooring thicknesses, from as small as 6 mm or smaller to as large as 15 mm or larger. The spacer 1210 are typically formed from a rigid or flexible plastic material, preferably, a solid thermosetting plastic. However, it is within the scope of the invention to construct the spacers 1210 of a thermoplastic, such as polyvinyl chloride (PVC) or a resilient foam material. Additionally, the spacer 1210 preferably includes at least one extension 1212 , sized and shaped to fit within a spacing gap 1200 .
[0119] In one embodiment, at least the extension 1212 is formed from a resilient compressible material such as a structural foam, and is slightly larger in width than the width of the spacing gap 1200 . When the extension 1212 is inserted into the spacing gap 1200 , it is necessary to compress the extension 1212 . Because the extension 1212 in this embodiment must be compressed to be inserted into the spacing gap 1200 , the internal forces of the material of the extension 1212 should maintain the spacer 1210 in the correct position.
[0120] As a substitute for the compressible embodiment or in addition thereto, the spacer 1210 may be joined to the spacing gap 1200 with an adhesive. Typical adhesives include any of the other adhesives discussed elsewhere. However, it is within the scope of the invention to eliminate any means for securing the spacer 1210 in the spacing gap 1200 .
[0121] In a preferred embodiment, a different reversable molding element 1250 can be used, having an end molding surface 1252 and a hard surface reducer surface 1254 and two spacing gaps 1212 a , 1212 b in the lower surface thereof. The presence of one spacing gap associated with each of the molding surfaces allows one spacer 1210 to be used closest to the exposed surface of the reversible molding element 1250 , as shown in FIGS. 94 , 96 and 98 . Although these figures show the reversible molding elements 1250 having two spacing gaps 1200 positioned in an underside thereof, it is within the scope of the invention to utilize a single spacing gap 1200 positioned, for example, centrally or not centrally, i.e., off center, in the underside of the reversible molding element 1250 .
[0122] Typically, the height of the reversible molding element 1250 or 1140 permits the molding 1110 to rest parallel to the higher surface element 1111 when used with an appropriately sized spacer 1210 . In order to provide such appropriately sized spacers 1210 for a variety of different applications, the spacer 1210 may include a second extension 1212 . As shown, for example in FIG. 98 , the extensions 1212 are preferably located on opposite sides of the spacer 1210 , such that inverting the spacer 1210 allows insertion of the correct extension 1212 into the spacing gap 1200 . It is also considered within the scope of the invention to provide the spacer 1210 with up four or more extensions 1212 of different lengths to permit use in a large number of different installations.
[0123] It should be understood that the spacer 1210 is not necessary. The shape of the molding element 1140 and/or reversible molding 1250 allows an installation wherein the molding element 1140 , 1250 rests directly on the subfloor. In certain installations, depending in part o˜the height of the adjacent flooring elements, this can cause the molding 1110 to form an angle with the flooring elements. However, such an angle is not problematic, as clamps 1126 used in accordance with the invention are preferably versatile enough to sufficiently grip the foot 1116 of the molding 1110 despite the presence of such an angle.
[0124] By utilizing the embodiments shown in FIGS. 100-111 it is possible to eliminate a gap 1300 between the subfloor and the molding by providing the molding 1140 , 1250 with an angled cut 1305 . The moldings 1140 , 1250 depicted in these figures are similar to that which are shown in FIGS. 112-119 with the same undercut. However, the foot 1116 that fits into the clamp 1126 is longer than the foot 1116 of FIGS. 112-119 .
[0125] The embodiment of FIGS. 112-119 differs from prior designs in a variety of ways. The molding 1110 can be made thicker to provide additional strength, as well as to allow for easier placement of an undercut 1150 . This undercut 1150 is preferably located on the portion of the molding 1110 that rests on a surface of the finished flooring. In some embodiments, the undercut 1150 provides close contact, i.e., no gap, between the surface of the floor and the outer edge of the molding 1110 as the flooring increases in thickness and raises the molding 1110 from a horizontal position to a more angular position, as described above.
[0126] Additionally, the clamp 1126 and pad 1120 configuration may be replaced by a reconfigured track 1126 ′ as shown, for example, in FIG. 114 . In this embodiment, the clamp 1126 and pad 1120 are combined into a single structure, which structure is secured to the subfloor and grips the foot 1116 of the molding 1110 . Preferably, the track 1126 ′ has a general H-shape, with two upstanding sections 1128 and a middle horizontal section 1130 . As the pad 1120 may also be used in an inverted orientation to achieve multiple configurations, the track 1126 ′ may also be inverted for-the same purpose. Accordingly, in a preferred embodiment, the middle horizontal section 1130 is not placed exactly at the middle of the heights of the upstanding sections. Thus, when the molding 11 , 1110 is inserted into the track 1126 ′, the lowest point of the foot 16 , 1116 can be supported by the middle horizontal section 1130 . The entire structure of the track 1126 ′ can be formed from a resilient, but structural material, just as the clamp 26 , 1126 may be.
[0127] The track 1126 ′ may be secured to the subfloor though a variety of methods. In one embodiment, as shown, for example, in FIG. 116 , one or both of the upstanding sections 1128 may have a base 1132 which can be secured to the subfloor with a screw or nail or adhesive. A fastener may also be positioned through the middle horizontal section 1130 to secure the lowermost portions of the upstanding sections to the subfloor.
[0128] The invention additionally includes packaging to be used by, for example, wholesalers or retailers. In one embodiment, multiple individual pieces, e.g., a reversible molding 1250 , a molding 11 , 1110 , a pad 1120 and a damp 1126 may be bundled in a single package or kit. In another embodiment, the package or kit includes two, or three, or even up to twenty or more, of each piece packaged therein. For example, a single package may include three approximately one-meter (or three foot) sections of each item contained therein, for a total length of about three meters (about nine feet). It is additionally within the scope of the invention to include different sets of items in a single package, for example, one set being about one meter (about three feet) long and an additional set being about two meters (about six feet) long.
[0129] It should be apparent that embodiments other than those specifically described above may come within the spirit and scope of the present invention. Hence, the present invention is not limited by the above description. | The invention is a joint cover assembly and related method for covering a gap adjacent an edge of a panel that covers a sub-surface. The assembly includes a molding having a foot, a first arm, and a second arm. The foot is positioned along a longitudinal axis of the molding, wherein the first arm, and optionally the second arm, extend generally perpendicularly to the foot. A tab depends from at least one of the first and second arms. At least one of the tab and the foot engage a track in order to position the assembly over the gap. The method includes placing the foot in the gap, pressing the respective panel engaging surfaces into contact with respective panels, and configuring at least one of the tab and the foot to cooperate to retain the molding in the gap when the assembly is installed. | 4 |
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0001] N/A
RELATED APPLICATIONS
[0002] This application claims foreign priority and the benefit of the filing date of the application entitled “Mejoras al Bloque de Concreto del Sistema Constructivo Prefabricado y su Utilizacion en la Construccion de Viviendas” filed with the Department of Patents of Invention of the Registry of Industrial Property of Costa Rica on May 9, 2002, which is incorporated by reference herein as if fully set forth in its entirety, and which constitutes an improvement to the Utility Model registered under number 150, denominated “Sistema Constructivo Prefabricado y su Utilizacion en la Construccion de Viviendas” whose application number was 5654.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates generally to prefabricated construction systems for housing construction and, more specifically, to a concrete block used in said systems and its use in the construction of housing offering the user the ability to build a structure in-site at a low cost and with minimal equipment.
[0005] 2. Discussion of the Background
[0006] Present day masonry practices may be separated into three major groups as follows:
[0007] a. Confined masonry structures (concrete blocks placed in stack or interlocked and confined by reinforced concrete frames, said frames constructed in-situ or prefabricated; the frames also may be constructed with other types of materials different from concrete).
[0008] b. Reinforced masonry structures (concrete blocks placed in stack or interlocked, forming a structural element by means of the placement of reinforcing steel in their cells and filling the same with concrete).
[0009] c. A hybrid of groups a and b.
[0010] Lightened concrete blocks of great length, produced by vibrocompression, are used only in the confined masonry practices group, where utility model 150 (“MU 150”) of Costa Rica, titled “Prefabricated Construction System and its use in the Construction of Housing” has its preferred field of application.
[0011] The aforesaid device and method in the prior art, however, needs to be improved in accordance with the construction requirements of our day and age. There is a need for an improved block such as the one used in the aforesaid MU-150 by implementing special geometric cavities at the ends of said block, which represents a significant innovation in the use of reinforced masonry. There is a need for a Concrete Block and System for its Use in the Construction of Housing Units which overcomes these and other deficiencies in the prior art.
[0012] The block of the invention belongs to the technology sector of the production of construction materials and its application in the sector of construction of housing and edifications.
[0013] The production of the block of the invention is accomplished with the standard machinery present in the majority of the companies which manufacture concrete blocks, requiring only that the mold for the block of the invention is installed in the machinery.
SUMMARY OF THE INVENTION
[0014] The object of the present invention is to provide a block for the low-cost construction of housing units.
[0015] It is a further object of the present invention to provide a block made from an inexpensive material.
[0016] It is another object of the present invention to provide a block which enables the rapid erection of a building or structure which can be assembled on site using minimal skills.
[0017] The block itself, both as to its construction and its mode of operation, will be best understood, and additional objects and advantages thereof will become apparent, by the following detailed description of a preferred embodiment taken in conjunction with the accompanying drawings.
[0018] When the word “invention” is used in this specification, the word “invention” includes “inventions”, that is, the plural of “invention”. By stating “invention”, the Applicant does not in any way admit that the present application does not include more than one patentably and non-obviously distinct invention and Applicant maintains that the present application may include more than one patentably and non-obviously distinct invention. The Applicant hereby asserts, that the disclosure of the present application may include more than one invention, and, in the event that there is more than one invention, that these inventions may be patentable and non-obvious one with respect to the other.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 is a front view of the block of the invention;
[0020] [0020]FIG. 2 is a planar view of the joinder of two blocks in collinear form;
[0021] [0021]FIG. 3 is a planar view of the joinder of the edges of two blocks of the invention;
[0022] [0022]FIG. 4 is a planar view of a joinder of two blocks of the invention in T;
[0023] [0023]FIG. 5 is an elevation view of the use of the blocks of the invention as holders of doorways or windows;
[0024] [0024]FIG. 6 is a sectional view of the use of the blocks of the invention as elements of mezzanines or reinforced slab for floors;
[0025] [0025]FIG. 7 is a sectional view of the blocks of the invention as a bond-beam;
[0026] [0026]FIG. 8 is an isometric view of a wall in construction with the blocks of the invention.
[0027] The use of the same numerals in the different views of the drawings shall be a reference to the same structures, parts, or elements, as the case may be.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] The improvement to the block patented in MU 150, with the introduction of cavities of special geometry at the ends of the block, results in a new lightened concrete block produced by the technology of vibrocompaction. The production of this new block is performed in standard machinery present in the majority of the makers of concrete blocks, requiring only a mold that is created exclusively for the production of the block of the invention, which may be installed in conventional machinery.
[0029] The block of the invention comprises a lightened concrete block produced by the technology of vibrocompaction with the following characteristics:
[0030] a. Minimum length of 80 centimeters and maximum length which depends on the capacity of the block production equipment and the operational maneuverability of the element.
[0031] b. Modular geometry in its interior holes that allows the block to be cut in shorter dimensions without losing its application characteristics, to satisfy the different dimensions of housing and edification units.
[0032] c. Variable width according to the use preferences or the requirements of the legal codes of the places of application.
[0033] d. Variable height according to the use preferences or the requirements of the legal codes of the places of application.
[0034] e. Ends of special geometry, forming cavities of variable depth according to the use preferences or the requirements of the legal codes of the places of application, that allow the storage of the reinforcing steel and the concrete necessary to guarantee the structural rigidity. Optionally, and for its application as a bond-beam, the block may be reduced conveniently to the height of the transversal walls.
[0035] f. The rest of the dimensions and interior geometry of the concrete block respond to the structural design technical criteria, industrial production process, transportation, management, and placement of the blocks.
[0036] The lightened concrete block as shown in FIG. 1 to be used in reinforced masonry, has among its characteristics a minimum length (L) of 80 cm. The maximum length will depend on the capacity of the technological production of the blocks and the operational maneuverability of the element. The modular geometry present in the block's interior holes permits the cutting of the element in smaller dimensions without losing its application characteristics, which allows satisfying the different dimensioning in housing and edifications (d1-d2).
[0037] The width (A) and the height (H) of the block of the invention are variable according to the preferences of use or the requirements of the codes in the location of the application. The ends with special geometry, form cavities of variable depth (p) in accordance with the preferences of use or the requirements of the location of the application, as long as they permit the housing of the reinforced steel and the concrete necessary to guarantee the structural rigidity, optionally and for its application as a bond-beam, may be decreased conveniently to the height of the transversal walls to a value (t), the rest of the dimensions and interior geometry of the concrete block responds to technical structural design criteria, industrial production process, transport, manipulation and placement of the product (e1-e2).
[0038] The improvement of the lightened concrete block results in the following advantages in the prefabricated construction system:
[0039] a. Structural homogeneity due to the use of a single element that results in an improved behavior facing the seismic, wind, and earth pressure loads.
[0040] b. Lesser length of mortar junctions by square meter of masonry (vertical junctions are eliminated and the size of the block is increased), which produces a more reliable value of the prismatic resistance (f′m) of the block, by depending more on the value of the block's resistance (produced industrially with better control) and less than the cementing mortar's resistance (produced at the construction site with lesser control).
[0041] c. Contrary to the conventional reinforced masonry practice, this system eliminates the need to raise the blocks to introduce them through the vertical rods of the reinforcing steel, which produces a better structural behavior from the masonry, by eliminating possible vacuums inside the concrete in the cells, the cementing mortar is not fractured, and the ductility of the steel is not reduced, as it is known, that the movement or the folding of the vertical steel during the placement of the blocks in the conventional form produces these faults.
[0042] d. It eliminates the loss of resistance characteristic of the block in stack of conventional masonry as the cementing mortar in the vertical junctions does not exist, which also allows for increased productivity in the placement without losing resistance.
[0043] e. The use of a block of great size, allows the application of isolated foundations solutions, which constitutes an innovation in reinforced masonry, fundamentally in housing and single level edifications, with an important savings in excavations, reinforcement steel, forming systems, and concrete.
[0044] f. It allows the construction of door and windows carriers up to vessels of 1.8 meters using the block of this invention as a structural element, with the consequential savings in work force and materials forming systems, reinforcement steel, and concrete).
[0045] g. Having incorporated the cavities in special geometric form at the ends of the block protected by MU-150, allows for a high reduction in the use of forming systems in the construction of walls and structural elements.
[0046] h. The incorporation of the block to the system as a bond-beam element is accomplished by the convenient reduction of the height of the transversal walls of the block.
[0047] i. It allows the construction of a housing unit with a minimal work force index (possibly with only one worker) and, in addition, it increased the productivity in the placement by accomplishing a greater wall area by unit of masonry placed and with a lesser quantity of joinders.
[0048] j. The previously mentioned special geometry of the block, was conceived in such a way so that its dimensions are modular, allowing the diversity of dimensions required in housing and building construction, as the special geometric form cavity is repeated in each of its cells.
[0049] k. Advantages of other construction systems which are also present in the block of the invention, such as: smooth walls, low cost, versatility of application (from social interest housing to high level housing), excellent thermoacustic behavior, susceptibility to assimilate any type of finish, electromechanical installations hidden, use in contention walls and mezzanines or reinforced slabs for floors and compatibility to interact with other construction systems.
[0050] In addition, as it may be observed and confirmed in FIG. 8, the realization of a wall using the block of this invention. The method of construction begins either from isolated 3 or continuous 8 foundations, next the reinforcement steel is placed, which may consist of rods 2 or of armed columns 7 , which columns are embedded in said foundations. Next the entire 1 or cut 6 blocks are placed according to the dimensions of the edification and according to their position to conform the colineal joinders 11 , in L shape 10 or in T shape 9 . A horizontal reinforcement 4 is placed in the corners or spaced in accordance with the requirements of the structural design) Steel pins 5 reinforce the T unions 9 .
[0051] The block 1 is used as a load carrier for doors and windows by means of a provisional support frame 13 , the addition of steel hooks for suspension 12 and the incorporation of vertical reinforcement steel 14 .
[0052] The wall is closed in its top end with a crown beam 15 , designed in accordance with the structural requirements and to which all the elements that conform the vertical reinforcement steel are duly fixed. Optionally, the bond-beam described in FIG. 7 may be used for the construction of the crown beam 15 and windows and doors load carriers.
[0053] For the placement of the blocks 1 and 6 , a conventional cementing mortar is used.
[0054] [0054]FIG. 1 shows a lightened block produced by means of the technology of vibrocompaction, with minimum and maximum lengths, of modular geometry forming cavities of variable depths, which permit the storage of the reinforcing steel and the concrete necessary to guarantee the structural rigidity.
[0055] [0055]FIG. 2 shows a planar view of the union of two blocks in collinear form, indicating in schematic form the location of the reinforcing steel as well as the area to be filled with concrete.
[0056] [0056]FIG. 3 shows a planar view of the joinder of the edges of two blocks of the invention. It also shows the placement of the reinforcing steel and the area to be filled with concrete. It is noted that to effectuate this joinder one of the lateral faces of the cavity must be cut. This type of joinder requires, by exception, the placement of a small squad of forming systems in its exterior edge.
[0057] [0057]FIG. 4 shows a planar view of a T joinder. It also shows the zone of reinforcing steel placement and the concrete filling area. In addition, FIG. 4 shows the cut zones in the block to effectuate this joinder.
[0058] [0058]FIG. 5 shows an elevation view and the form to use the blocks of the invention as load carriers for windows and door frames.
[0059] [0059]FIG. 6 is a sectional view of the use of the blocks of the invention as elements of mezzanines or reinforced slabs for floors. It also shows the reinforcing steel and concrete filling zone.
[0060] [0060]FIG. 7 is a sectional view of the blocks of the invention as a bond-beam.
[0061] [0061]FIG. 8 is an isometric view of a wall in the construction phase with the blocks of the invention.
[0062] Thus, there has been shown and described a concrete block and system for its use in the construction of housing units which fulfills all the objects and advantages sought therefor. The invention is not limited to the precise configuration described above. While the invention has been described as having a preferred design, it is understood that many changes, modifications, variations and other uses and applications of the subject invention will, however, become apparent to those skilled in the art without materially departing from the novel teaching and advantages of this invention after considering this specification together with the accompanying drawings. For example, the particular shapes and proportions of the elements of the block may be varied as desired. Accordingly, all such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by this invention as defined in the following claims.
[0063] All of the patents recited herein, and in the Declaration attached hereto, if any, are hereby incorporated by reference as if set forth in their entirety herein. The details in such patents may be considered to be incorporable at applicant's option, into the claims during prosecution as further limitations in the claims to patentably distinguish any amended claims from any applied prior art. | A concrete block for the construction of housing units is disclosed. The block disclosed herein allows for an improved low cost manufacturing, without the use of forming systems and without special tools, an ample array of structural elements that serve for the construction of walls for housing units and edifications of one or various levels, contention walls, spaces between floors and load carriers for doors and windows in the field of reinforced masonry, thereby synthesizing and improving, with the use of just one element, the principal characteristics inherent of the existing constructive systems. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a 371 of PCT/IB2003/003698, filed 18 Aug. 2003, which claims priority from Great Britain Patent Application 0219639.2, filed 22 Aug. 2002.
TECHNICAL FIELD
The present invention relates to pamoate salts of certain 3-phenyl-3-dimethylaminoalkyl-4,4-dimethylpiperidin-2,6-diones and their use in the treatment of stress-related affective disorders. The term “stress-induced affective disorder” is used herein to include any disorder associated with elevated levels of 5-HT (5-hydroxytryptamine; serotonin) resultant from newly synthesised 5-HT.
BACKGROUND OF THE INVENTION
3-Phenyl-3-dimethylaminoalkyl-4,4-dimethylpiperidin-2,6-diones of the following Formula I and their acid addition salts have been known since 1974 (see BE-A-808,958; corresponding to GB-A-1,455,687 & U.S. Pat. No. 3,963,729):
wherein:
R 1 represents methoxy, ethoxy or hydroxy;
R 2 represents methoxy, ethoxy, hydroxy or hydrogen; and
n represents 2 or 3.
They have been reported to have a range of pharmacological activities (see U.S. Pat. Nos. 3,963,729; 4,461,771; 4,738,973; 4,835,151; 4,835,151; 4,918,084; 4,994,475; 5,1177,086; GB-A-2,196,251 & GB-A-2,206,491) but were primary of interest for the treatment of stress-related affective disorders, especially anxiety and depression. They are the only compounds presently known to block selectively the activation of tryptophan hydroxylase induced by depolarisation, metabolic inhibitors, methyl xanthine, or stress. The compound of choice for clinical investigation was 3(3-methoxyphenyl)-3-(3-dimethylaminopropyl)-4,4-dimethylpiperidine-2,6-dione, which has been variously identified as AGN 2979 (which designation will be used in this application); BTG 1501; MDL 72415 and SC 48274. A large number of acid addition salts of AGN 2979 have been proposed but the hydrochloride has been the salt of choice because hydrochloride acid addition salts are the most commonly used acid addition salts and can be readily and inexpensively prepared and there was no reason to believe that any other salts would have any advantage over the hydrochloride. There has been no previous proposal or suggestion to use a pamoate salt of AGN 2979, or of any other base of Formula I or other 3-phenyl substituted-3-dialkylaminoalkyl-4,4-dialkylpiperidin-2,6-dione, for any purpose.
A number of papers relating to clinical trials of the hydrochloride salt of AGN 2979 have been conducted and the results published. These showed the salt to be effective in the treatment of anxiety and depression at about 4 mg/kg/day (200-400 mg/day for human patients). However, a 1-year sub-acute toxicity study of the hydrochloride (200 mg/kg/day p o. (i.e. by mouth)) in rats showed that the animals suffered an immediate and continuing weight loss (40% over the 1-year period) and, as revealed by post-mortem examination, hepatocyte changes which had not been detected by routine transaminase determinations during the year. As a result, the USA Food and Drugs Administration (“F.D.A”) precluded the use of the dose levels previously used in the clinical trials. A subsequent clinical study by Cutler et al using an F.D.A. allowed dose of 1 mg b.i.d. (i.e. twice daily) (about 30 μg/kg/day) showed that the hydrochloride salt of AGN 2979 possessed only marginally effective anxiolytic properties at FDA permitted dose levels.
SUMMARY OF THE INVENTION
It has now surprisingly been found that the aforementioned problems of weight loss and hepatocyte changes can be overcome by the use of the pamoate salt instead of the hydrochloride, or other previously disclosed salt, of compounds of Formula I. These pamoate salts do not cause weight loss and the indications are that they will not cause hepatocyte changes over prolonged periods of treatment. Furthermore, it has been found that the pamoate salts of the compounds of Formula I, contrary to the known salts, are tasteless and allow the preparation of pharmaceutical compositions for the oral administration, especially in form of suspensions, syrups and the like. Thus, according to a first aspect of the present invention, there is provided the pamoate salts of 3-phenyl-3-dimethylaminoalkyl-4,4-dimethylpiperidin-2,6-diones of Formula I:
wherein:
R 1 represents methoxy, ethoxy or hydroxy;
R 2 represents methoxy, ethoxy, hydroxy or hydrogen; and
n represents 2 or 3,
and pharmacologically acceptable solvates thereof.
Pamoic acid is 4,4′-methylenebis[3-hydroxy-2-naphthalenecarboxylic acid] and is also known as embonic acid.
The compounds of Formula I exist in optical isomers and accordingly the pamoate salts can be used in racemate form or as individual (+) or (−) isomers. Presently the (−) isomer is preferred. The salts may exist in solvated, especially, hydrated, form and may hydrate on storage in a non-airtight environment.
In a second aspect, the present invention provides methods for the treatment or prophylaxis of stress-related affective disorders which comprise administering to a human or animal patient an effective amount of a pamoate salt of a compound of Formula I or a pharmacologically acceptable solvate thereof.
In a third aspect, the present invention provides pharmaceutical compositions comprising the pamoate salt of a compound of Formula I or a pharmacologically acceptable solvate thereof and a pharmacologically acceptable diluent or carrier.
In a fourth aspect, the present invention provides the pamoate salts of compounds of Formula I and pharmacologically acceptable solvates thereof for use in treatments of the human or animal body by therapy or diagnosis practised on the human or animal body.
In a fifth aspect, the present invention provides the use of pamoate salts of compounds of Formula I and pharmacologically acceptable solvates thereof in the manufacture of medicaments for the treatment or prophylaxis of stress-related affective disorders.
DETAILED DESCRIPTION
Examples of pamoate salts of compounds of Formula I include the following:
3-(3′-methoxyphenyl)-3-(2″-N,N-dimethylaminoethyl)-4,4-dimethylpiperidin-2,6-dione pamoate; 3-(3′-methoxyphenyl)-3-(3″-N,N-dimethylaminopropyl)-4,4-dimethylpiperidin-2,6-dione pamoate; 3-(3′-hydroxyphenyl)-3-(2″-N,N-dimethylaminoethyl)-4,4-dimethylpiperidin-2,6-dione pamoate; 3-(3′-hydroxyphenyl)-3-(3″-N,N-dimethylaminopropyl)-4,4-dimethylpiperidin-2,6-dione pamoate; 3-(3′-ethoxyphenyl)-3-(3″-N,N-dimethylaminopropyl)-4,4-dimethylpiperidin-2,6-dione pamoate; 3-(3′,5′-dimethoxyphenyl)-3-(3″-N,N-dimethylaminopropyl)-4,4-dimethylpiperidin-2,6-dione pamoate; 3-(3′,5′-dihydroxy)-3-(3″-N,N-dimethylaminopropyl)-4,4-dimethylpiperidin-2,6-dione pamoate; and 3-(3′,5′-diethoxy)-3-(3″-N,N-dimethylaminopropyl)-4,4-dimethyl-piperidin-2,6-dione pamoate.
The preferred pamoate salts are those of compounds of Formula I in which R 1 represents methoxy and R 2 represents methoxy or hydrogen. The most preferred salts are 3(3,5-dimethoxyphenyl)-3-(3-dimethylaminopropyl)-4,4-dimethylpiperidine-2,6-dione pamoate and, especially, 3(3-methoxyphenyl)-3-(3-dimethylaminopropyl)-4,4-dimethylpiperidine-2,6-dione (AGN 2979) pamoate.
The pamoate salts of the invention can be prepared by conventional techniques for converting a free base into an acid addition salt or for converting one acid addition salt to another. For example, the pamoate salt is prepared by treating an ethanol solution of a compound of Formula I with a cooled solution of pamoic acid in ethanol; evaporation of the solvent under reduced pressure and recrystallisation of the residue from ethanol. Alternatively, a salt of a compound of Formula I may be converted into the pamoate by neutralisation, for example with ammonium hydroxide, and subsequent treatment with pamoic acid.
The compounds of Formula I can be prepared by the processes disclosed in U.S. Pat. No. 3,963,729 or U.S. Pat. No. 5,104,990, the disclosure of which documents are incorporated by this reference. The optical isomers can be separated in conventional manner, for example the (−) isomers can be separated by crystallisation of their (+) binaphthyl phosphoric acid salts from a suitable solvent such as ethanol.
The pamoate salts of the compounds of Formula I have the same qualitative pharmacological activity as that previously reported for the free base and other acid addition salts, especially the hydrochloride, and is especially useful for the treatment or prophylaxis of any stress-induced affective disorder. As mentioned above, the term “stress-induced affective disorder” is used herein to include any disorder associated with elevated levels of 5-HT (5-hydroxytryptamine; serotonin) resultant from newly synthesised 5-HT. In particular, the pamoate salts can be used to treat or prevent those neurological and psychological diseases and conditions in which newly synthesised 5-HT is implicated and for which antidepressant, anxiolytic and antipsychotic drugs are presently indicated. Non-limiting examples of such diseases or conditions are agoraphobia; anorexia nervosa; anxiety; anxiogenisis associated with withdrawal from drugs of abuse; bulimia nervosa; chronic paroxysmal hemicrania; depression (including prevention of depressive recurrences); diminution of the immune response associated with anxiety, depression or bereavement; disorders of sleep initiation or maintenance; disorders of the sleep-awake schedule; dream anxiety attacks; Huntington's chorea; Kleine-Levin syndrome; memory disturbance; Ménière's disease, menstrual-associated sleep syndrome; migraine; motion sickness; nausea incompletely relieved by 5HT 3 antagonist administration, neurogenic pain; neuropathic pain; obsessive-compulsive disorder; panic attacks; posttraumatic stress disorder; pre-menstrual dysphoric disorder; recurrent brief depression; Restless Leg syndrome, schizophrenia; senile dementia; serotonin-irritation syndrome; sleep apnoea; sleep related cardiovascular symptoms; sleep related epileptic seizures; sleep-related cluster headaches; sleep-related myoclomus syndrome; social phobia; sudden infant death syndrome; and tinnitus.
The antidepressant action of AGN 2979 pamoate is believed to result from the inhibition of tryptophan hydroxylase activation, and the mechanism of this effect may involve blockade of K+ channels since other metabolic inhibitors, such as guanidine and sodium cyanide, which are known to open K+ channels, can activate tryptophan hydroxylase and this activation can be blocked by AGN 2979 pamoate.
The pamoate salts of the invention can be administered in any of the manners previously proposed for the hydrochloride salt. They can be administered alone or in the form of pharmaceutical preparations to the patient being treated either orally or parenterally, for example subcutaneously or intravenously. The amount of pamoate salt administered will vary and can be any effective amount. Depending upon the patient and the mode of administration, the quantity of pamoate salt administered may vary over a wide range to provide from about 0.1 mg/kg to about 20 mg/kg, usually about 0.5 mg/kg to about 10 mg/kg and preferably about 1 to about 5 mg/kg, of body weight of the patient per dose. Unit doses of these salts can contain, for example, from about 10 mg to about 500 mg, advantageously about 25 to about 200 mg. usually about 50 to about 100 mg of the pamoate salt and may be administered, for example, from 1 to 4 times daily. The term “unit dosage form” is used herein to mean a single or multiple dose form containing a quantity of the active ingredient in admixture with or otherwise in association with a diluent or carrier, said quantity being such that one or more predetermined units are normally required for a single therapeutic administration. In the case of multiple dose forms such as liquids or scored tablets, said predetermined unit will be one fraction, such as a 5 ml (teaspoon) quantity of a liquid or a half or quarter of a scored tablet, of the multiple dose form.
The pharmaceutical formulations in which form the pamoate salts of the invention will normally be utilised are prepared in a manner well known per se in the pharmaceutical art and usually comprise at least one active pamoate salt of the invention in admixture or otherwise in association with a pharmaceutically acceptable carrier or diluent therefor. For making those formulations, the active ingredient usually will be mixed with a carrier, or diluted by a diluent, or enclosed or encapsulated in a capsule, sachet, cachet, paper or other container. A carrier or diluent may be solid, semi-solid or liquid material that serves as a vehicle, excipient or medium for the active ingredient. Suitable carriers or diluents are well known per se. The formulations may be adapted for enteral or parenteral use and may be administered to the patient in the form of tablets, capsules, dragees, suppositories, syrups, suspensions or the like.
The invention is illustrated in the following non-limiting Examples.
EXAMPLE 1
Preparation of 3(3-methoxyphenyl)-3-(3-dimethylaminopropyl)-4,4-dimethyl-piperidine-2,6-dione pamoate (AGN 2979 pamoate)
(A) Preparation of diethyl 2-[2-cyano-5-(dimethylamino)-2-(3-methoxy-phenyl)-1,1-dimethylpentyl] propanedioate, monohydrochloride
A nitrogen atmosphere was applied to a reaction vessel and 50 ml of dry tetrahydrofuran is added. The solvent was cooled to less than −40° C. and 32 mmoles of lithium diisopropylamide in tetrahydrofuranne-heptane was added (16 ml of a 2 M solution). A solution of 6.97 g (30 mmoles) of α-[3-(dimethylamino) propyl]-3-methoxybenzeneacetonitrile in 30 ml of tetrahydrofuran was added at less than −20° C. and left at this temperature for 30 min. The mixture was then cooled to −50° C. and a solution of 6.62 g (33 mmoles) of diethyl isopropylidenemalonate in 30 ml of tetrahydrofuran was added to the reaction mixture at a rate such that the temperature did not exceed −50° C. The mixture was stirred at −50° C. for 30 min and the cold reaction mixture added to a stirred solution of 30 ml of aqueous hydrochloric acid (36% w/w) in 100 ml of water cooled to 10° C. The mixture was extracted twice with toluene and the toluene phase is back extracted with a solution of 2 ml of hydrochloric acid (36% w/w) in 8 ml of water. The aqueous acidic extract was combined with the aqueous acidic phase from above and extracted twice with 50 ml portions of methylene chloride. The combined methylene chloride extracts were washed with water and the methylene chloride phase filtered and concentrated to low volume by distillation at atmospheric pressure. A 100 ml portion of ethyl acetate was added and the resulting slurry cooled to 5-10° C. The resulting solid was collected by filtration, washed with ethyl acetate and dried at 50° C. to give 10.1 g of white powder.
(B) Preparation of 3-(3-methoxyphenyl)-3-(3-dimethylaminopropyl]-4,4-dimethyl-piperidine-2,6-dione bisulphate salt (anhydrous)
A 250 ml round-bottomed flask was charged with 10 g of the above-prepared diethyl 2-[2-cyano-5-(dimethylamino)-2-(3-methoxyphenyl)-1,1-dimethylpentyl]-propanedioate mono-hydrochloride, and a solution of 10.2 g of sulphuric acid (96% w/w) in 90 ml of water was added. The reaction mixture was refluxed for about 54 hours. When the reaction was complete (as indicated by thin layer chromatography) the solution was cooled to 25° C. The aqueous solution was washed with methylene chloride, the aqueous phase mixed with methylene chloride and basified with aqueous ammonium hydroxide (29% w/w) while maintaining the temperature at less than 30° C. After separation of the layers, the aqueous phase was extracted twice with methylene chloride, the combined organic phases concentrated and the residue crystallised in tert-butyl methyl ether to give 5.7 g of white powder. The crude compound was suspended in 200 ml of absolute ethyl alcohol, 1 equivalent of concentrated sulphuric acid added and the mixture is heated under reflux for 30 minutes to dissolve the salt. After cooling, most of the solvent was evaporated under reduced pressure and the residue was by crystallised means of a 50/50 mixture of diethylether-ethyl alcohol to give 6 g of white powder (melting point=159°-161° C.) and dried under reduced pressure.
(C) Preparation of 3-3-methoxyphenyl)-3-(3-dimethylaminopropyl]-4,4-dimethyl-piperidine-2,6-dione pamoate salt (anhydrous)
A solution of AGN-2979 bisulphate salt obtained in Step B (1 mmole, 430 mg) in 10 ml of water was mixed with methylene chloride (20 ml) and basified with aqueous ammonium hydroxide (29% w/w). After separation of the layers, the aqueous phase was extracted twice with methylene chloride. The combined organic phases were dried over anhydrous magnesium sulphate and the solvent was evaporated under reduced pressure. The residue was dissolved in ethanol (10 ml) and mixed with a hot solution of pamoic acid (embonic acid, 390 mg, 1 mmole) in hot ethanol (30 ml) and the mixture was heated to reflux. After cooling, the pamoate salt crystallised and the salt was recrystallised in hot ethanol to give a pale yellow powder (melting point=146°-150° C.
EXAMPLE 2
Tablets each having the following composition are prepared by conventional tabletting techniques:
Ingredient
mg per tablet
(a) AGN 2979 pamoate
50
(b) Lactose
51.5
(c) Maize starch dried
45
(d) magnesium stearate
1.5
EXAMPLE 3
Suppositories are formed from the following composition:
Ingredient
mg/suppository
(a) AGN 2979 pamoate
20
(b) Oil of Theobroma (cocoa butter)
980
The compound (a) is powdered and passed through a BS No. 100 sieve (0.125 mm) and triturated with molten oil of Theobroma at 45° C. to form a smooth suspension. The mixture is well stirred and poured into moulds each of nominal 1 g capacity to produce suppositories.
EXAMPLE 4
Pills each having the following composition are prepared by blending the active (a) and the corn starch (b), then adding the liquid glucose (c) with thorough kneading to form a plastic mass from which the pills are cut and formed:
Ingredient
per pill
(a) AGN 2979 pamoate
50
mg
(b) Corn starch
45
mg
(c) Liquid glucose
7
cm 3
EXAMPLE 5
Gelatine capsules each containing 50 mg AGN 2979 pamoate and 20 mg talc are prepared by passing AGN 2979 and talc separately through a fine mesh screen, mixing the sieved powders and filling the mixed powder into hard gelatine capsules at a net fill of 70 mg per capsule. | Novel pamoate salts of certain 3-phenyl-3-dimethylaminoalkyl-4,4-dimethylpiperidin-2,6-diones and pharmacologically acceptable solvates thereof are devoid of the weight loss and hepatocyte changes in the rat which limited to marginally effective levels the permitted clinical doses of the corresponding hydrochlorides in the treatment or prophylaxis of stress-related affective disorders such as anxiety, depression, migraine and sleep apnoea. The preferred pamoate salts are 3(3,5-dimethoxyphenyl)-3-(3-dimethylaminopropyl)-4,4-dimethylpiperidine-2,6-dione pamoate and, especially, 3(3-methoxyphenyl)-3-(3-dimethylaminopropyl)-4,4-dimethylpiperidine-2,6-dione pamoate. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation application of Ser. No. 488,298, filed July 12, 1974, now abandoned, which was a continuation application of Ser. No. 344,036, filed Mar. 22, 1973, now U.S. Pat. No. 3,842,047, which was a continuation-in-part application of Ser. No. 237,173 filed Mar. 22, 1972, now abandoned.
BACKGROUND OF THE INVENTION
There are numerous patents and prior art proposals relating to processes for the anionic polymerization of 2-pyrrolidone using a wide variety of catalysts, activators or initiators. Among the earliest patents are U.S. Pat. Nos. 2,638,463; 2,739,959; 2,809,958; 2,891,038 and 2,973,343.
Various activators are mentioned in U.S. Pat. Nos. 2,912,415; 3,016,366; 3,022,274; 3,028,369; 3,033,831; 3,040,004; 3,042,659; 3,060,153; 3,061,593; 3,135,719; 3,148,174; 3,158,589; 3,174,951; 3,180,855 and 3,210,324.
The most recent which claim CO 2 as the sole polymerization activator are U.S. Pat. Nos. 3,681,293; 3,682,869 and 3,683,046 relating to the polymerization of 2-pyrrolidone but either various grades of polymer or industrially unfeasible processes were obtained.
According to these and subsequent patents, the polymerization of 2-pyrrolidone was considered to be an anionic polymerization caused by the rupture of the 2-pyrrolidone ring between the C═O and N--H groups to form a linear polyamide polymer which has come to be known as Nylon-4;
HAVING THE STRUCTURE: ##STR1## This polymer is melt-spinnable to form fibers having the strength and wear resistance of synthetic fibers and the advantageous chemical properties of cotton, such as water-absorptivity and release, dye-receptivity and similar ironing capability.
Subsequently there have been proposals of hydrogen transfer processes for the polymerization of 2-pyrrolidone also based upon the rupture of the 2-pyrrolidone ring between the C═O and N--H group, as in U.S. Pat. Nos. 3,069,392 and 3,383,367.
It is not certain whether such known hydrogen transfer processes are based upon an inaccurate theory, but it is clear that such processes also provide a polymer which is relatively low in yield, are economically not feasible and/or provide a polymer which is modified by the reaction with the activators therewith to become a part of the polymer chain and cause other complications in further processing of the finished polymer.
It is clear that while there are numerous patents relating to a variety of processes proposed over the years for the polymerization of 2-pyrrolidone, such a polymer has never been produced commercially to the best of my knowledge at the present time.
SUMMARY OF THE INVENTION
It is the principal object of the present invention to provide a novel hydrogen transfer process for the polymerization of 2-pyrrolidone, which process is relatively simple and exceptionally efficient, resulting in an actual polymer yield of at least about 90 - 95% or more based upon the weight of 2-pyrrolidone and its salt subjected to polymerization.
It is another object of this invention to provide a commercially efficient method for the polymerization of 2-pyrrolidone where by pure polyamide polymers of great utility can be produced at the lowest possible cost.
It is still another object to introduce a novel process for polymerizing 2-pyrrolidone in which it can be proved that the 2-pyrrolidone ring is ruptured between the number 5 carbon atom and the nitrogen atom.
Single heterocyclic rings are numbered so as to give position "1" to the hetero atom that is most acidic (according to its position in the periodic table), and then numbered around the ring so as to give the other hetero atoms the lowest numbers possible ##STR2##
The process of the invention produces a much narrower molecular weight distribution, a longer, stable, linear, novel polyamide polymer which is useful for the commercially available melt-spinning process and having the structure: ##STR3##
The novel process of the present invention involves three essential steps.
1. Preparation of the metal salt of 2-pyrrolidone.
2. Rupture of the heterocyclic ring of the 2-pyrrolidone salt.
3. Hydrogen transfer polymerization.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The commercially available 2-pyrrolidone must be purified in known manner or, most preferably, according to the novel and economically most efficient purification process of my co-pending application, Ser. No. 224,274, filed Feb. 7, 1972, using an alkali metal hydroxide reactant.
Step 1
The substantially pure and anhydrous 2-pyrrolidone is reacted with an alkaline reagent which is an alkali metal (Li, Na, K), an alkali metal hydroxide (LiOH, NaOH, KOH) or an alkali metal bicarbonate (NaHCO 3 , KHCO 3 ) under very closely controlled conditions. The molar ratio of 2-pyrrolidone to alkaline reagent in the starting mixture should be between 10:1 to 27:1, preferably 13:1.
The reaction temperature should be between 100° and 120° C. under vacuum. The lower temperatures requiring higher vacuum are preferred.
The following reactions take place: ##STR4##
Vigorous agitation and cooling is required. In general this reaction requires the shortest time and the lowest temperature. ##STR5## In general this reaction requires moderate time and temperature. ##STR6## In general to complete this reaction requires the longest time and a much higher temperature.
The most economically feasible way to produce the metal salt of 2-pyrrolidone is to use potassium hydroxide. ##STR7##
The reaction should preferably be carried out between 100° - 110° C and 0.05 - 20.0 mm mercury pressure. The mole ratio between the 2-pyrrolidone and alkali metal hydroxide is preferably 13:1 or 20:1 parts by weight using KOH in the starting mixture. The preferred molar ratio assures the best results. A lower amount of KOH increases the polymerization time and decreases the conversion. As the amount of KOH is increased, it is not only uneconomical but the additional water (from the KOH) and alkali tend to promote hydrolysis of the 2-pyrrolidone to 4-aminobutyric acid and inhibit polymerization. At the end of the reaction the mole ratio between the 2-pyrrolidone and the 2-pyrrolidone salt is about 11.5:1 or approx. 18:1 parts by weight, about 10% by weight of the system being removed by high vacuum distillation from the system to insure anhydrous conditions which are essential.
TABLE I
The alkali metal, alkali metal hydroxide and alkali metal bicarbonate requirements for efficient 2-pyrrolidone salt preparation, based on 300g or 3.53 moles of purified 2-pyrrolidone.
______________________________________Compounds Mol.wt.: Moles: Grams:______________________________________Li 6.94 0.27 1.87Na 22.99 0.27 6.21K 39.10 0.27 10.56LiOH . HOH 41.96 0.27 11.33NaOH 40.00 0.27 10.80NOH 56.11 0.27 15.15NaHCO.sub.3 84.01 0.27 22.68KHCO.sub.3 100.10 0.27 27.03______________________________________
The conditions used for preparing the 2-pyrrolidone salt are very mild. Therefore the metal ion will replace one of the hydrogens attached to the number 5 carbon atom according to the equation: ##STR8## and not replace the hydrogen atom attached to the nitrogen atom as previously supposed.
The following evidence supports the above proposed mechanism:
(a) It has been established by means of the mass spectrograph that the first hydrogen atom loss occurs on the C - 5 carbon atom, and that this occurrence puts a charge on the nitrogen atom to provide the immonium ion, as follows: ##STR9##
(b) It has also been confirmed by the infra-red spectrophotometer that in the isolated, entirely pure 2-pyrrolidone salt, the metal atom is attached to the number 5 carbon atom rather than to the nitrogen atom.
(c) As further substantiation of the attachment of the metal atom to the number 5 carbon atom of 2-pyrrolidone it has been determined that 5-methyl-2-pyrrolidone and 1,5-dimethyl-2-pyrrolidone ##STR10## wherein the number 5 carbon atom is substituted, cannot be polymerized. On the other hand even when the nitrogen is substituted, such as in 1-methyl-2-pyrrolidone ##STR11## wherein the number 5 carbon atom is unsubstituted, this monomer can be polymerized following the regular polymerization process.
I have found that the metal atom will not attach to the nitrogen atom unless concentrated caustic is present in a molar ratio of 1:1 with respect to the 2-pyrrolidone. It is essential to avoid this condition.
The loss of hydrogen from the number 5 carbon atom forms a double bond between the number 5 carbon atom and the nitrogen atom and it is this bond which ruptures during the present polymerization process.
Step 2
The anhydrous 2-pyrrolidone and its salt solution from the previous step which has been cooled down to between 25° - 45° C is treated with the activator (economically dry CO 2 ), dry SO 2 , dry NO 2 or other suitable initiator in order to cause the heterocyclic ring of the 2-pyrrolidone salt to rupture.
It is important that the temperature of the solution mixture be maintained above the freezing point of 2-pyrrolidone, preferably between 25° and 35° C., and not exceed about 52° C., to avoid possible formation of short chain polymer. It has not been found possible to obtain good yields at the higher temperatures taught in U.S. Pat. Nos. 3,681,293 and 3,682,869 and, in addition, the polymer becomes discolored. Lower temperatures result in a longer reaction time.
The dry gas introduction to the cooled solution mixture causes an exothermic reaction, due to the energy released by rupturing the heterocyclic ring between the number 5 carbon and the nitrogen atom to form a temporary intermediate product having the structure: ##STR12## It is a very rapid process and a complex polymeric mixture. The amount of gas added to the reaction mixture is not important providing it is stoichiometrically sufficient to combine with the alkali metal ions present. Its function is to pull out the metal ion from the ring and to provide sufficient energy to split the created weak double bond. Excess gas does no harm but is uneconomical.
It 1 mole of the 2-pyrrolidone salt was formed in the solution mixture, 1/2 mole of CO 2 or SO 2 or 1 mole of NO 2 and a slight excess amount which will be absorbed by the large excess of anhydrous 2-pyrrolidone is required.
The reaction mixture should be protected from water. The temporary CO 2 , SO 2 or NO 2 product is extremely hygroscopic and it breaks down rapidly with water to form the corresponding alkali metal salt or the water will react with the 2-pyrrolidone and form an undesirable amino acid product, as mentioned previously. ##STR13## Either form is capable of stopping the polymerization.
After completing the gas addition to the system a drying agent is added to the mixture in order to remove any trace amounts of water present in the solution mixture and/or generated during the subsequent polymerization. The drying agent also stabilizes the viscosity of the solution during polymerization and causes the reaction to proceed more evenly and completely than is the case when the drying agent is omitted. In the absence of a drying agent, polymerization proceeds very rapidly during initial polymerization with an immediate increase in viscosity as short polymer chains are rapidly formed and a substantial amount of unreacted 2-pyrrolidone is trapped within the solidified polymer and remains unpolymerized because the hydrogen transfer process is blocked. Preferred drying agents are the anhydrous alkali metal bicarbonates, carbonates and sulfates (NaHCO 3 , KHCO 3 , Na 2 CO 3 , K 2 CO 3 , Na 2 SO 4 and K 2 SO 4 ). The amount of drying agent is based upon the weight of the reaction mixture. The use of about 5% is preferred to insure proper drying, and an excess does not interfere with the polymerization reaction. Other conventional drying agents may also be used provided that they are inert with respect to the reaction mixture. Anhydrous calcium sulfate, calcium and magnesium oxides are satisfactory but are more difficult to wash from the final polymer. Phosphorous pentoxide and chlorides are not suitable because they are reactive with the 2-pyrrolidone at the elevated temperatures used.
Step 3
In the final step of the polymerization process, the reaction mixture which includes the drying agent is subjected to controlled heating in a closed container at a temperature maintained at 48° - 52° C, preferably 50°± 1/2° C to cause progressive hydrogen transfer polymerization.
Complete polymerization occurs gradually over a period of several hours during which time the molecular weight and viscosity of the reaction mixture increase evenly and gradually as hydrogen transfer progresses.
The polymerization is substantially complete after a period of 48 hours or less and the white solidified polymer is ground and washed to neutral pH with water to remove the drying agent, metal salt formed from the metal ion and gas, and unreacted 2-pyrrolidone, if any.
The washed polymer is dried at 115° - 120° C temperature in an electrically controlled oven. The obtained polymer is white, odorless and has the following structure: ##STR14## The valve of x has not been accurately determined but it is presumed to be in the range of 1500 to 2500.
The following examples are set forth to illustrate the criticality of the amount of alkali metal compound used to react with the pure 2-pyrrolidone monomer in the first step of the present process.
EXAMPLE 1
300 Grams (3.53 moles) of pure, substantially anhydrous 2-pyrrolidone, purified according to the purification process of my afore-mentioned co-pending U.S. application (using potassium hydroxide as reactant), were mixed with 15 grams (0.27 mole) of analytical grade potassium hydroxide (to keep the water content in the KOH constant) in a 3-necked flask. The mixture was heated up slowly under a reduced pressure and in the presence of an inert atmosphere (nitrogen). At 60° C the potassium hydroxide was dissolved in the 2-pyrrolidone at 30 mm mercury pressure. At 86° C dehydration began and the vacuum was 30 mm mercury. At 102° C the 2-pyrrolidone began to distill and the vacuum dropped to 20 mm mercury, evidencing the completion of dehydration. However, this does not insure anhydrous conditions since pyrrolidone hydrate will not release all the bound water under the effects of heat alone. The temperature was raised to 107° C under 20 mm mercury pressure and approximately 10% of the 2-pyrrolidone was distilled off. At this point sufficient 2-pyrrolidone had been distilled to insure the best anhydrous conditions possible and heating was discontinued and the solution mixture cooled down to 38° C.
Next, bone dry carbon dioxide gas (most economical) was added to the solution in the flask by bubbling the gas into the solution over a 5 minute period. During the CO 2 addition, the temperature of the solution increased from 38° to 48° C, evidencing the dissociation energy released by the rupture of the 2-pyrrolidone salt ring. The weight gain of the solution was 1.8 grams.
After the CO 2 addition, the cloudy, milky solution mixture was poured into a bottle which contained approximately 5%, based upon the weight of the solution, of anhydrous potassium sulfate. The bottle was sealed and put into a constant temperature incubator maintained at 50° ± 1/2° C for 48 hrs. to polymerize.
The white polymer obtained was ground to chips and washed to a neutral pH with water and dried in an electrically heated oven at 105° C. The weight of the pure polymer was 224 grams, equaling a yield of 93.5% based upon the weight of the 2-pyrrolidone and its salt which had been subjected to CO 2 treatment. The viscosity of the polymer in solution at room temperature (approx. 25° C), 1/2% solution in formic acid, was 8.84 stokes.
EXAMPLE 2
To illustrate the criticality of the starting ratio of potassium hydroxide to 2-pyrrolidone, the above procedure was repeated exactly except that only 7.5 grams (0.13 mole) of analytical grade potassium hydroxide was used together with 300 grams of the purified 2-pyrrolidone. During the CO 2 addition, the temperature of the solution increased from 38° C up to only 44° C, evidencing less dissociation energy, and after heating for 48 hours at the constant temperature of 50°± 1/2° C in the presence of approx. 5% drying agent, the weight of ground, washed and dried polymer was only 90.6 grams equaling a yield of 37.8% based upon the weight of 2-pyrrolidone and its salt which had been subjected to CO 2 treatment. The viscosity of the polymer in 0.5 formic acid solution at room temperature was 2.75 stokes.
EXAMPLE 3
In another experiment to show criticality of the alkaline reagent concentration, 150 grams (1.77 moles) of pure 2-pyrrolidone and 5.6 grams (0.1 mole) of analytical grade potassium hydroxide were mixed following the procedure of Example 1. The molar ratio was about 17.7:1. After reaction the solution mixture was cooled down to 31° C then the CO 2 gas was introduced. During CO 2 addition the temperature of the solution increased to 39° C and the weight gain was 0.7 gram.
After the CO 2 addition the solution was divided into two equal portions each of which was poured into a bottle containing approx. 5%, based upon the weight of solution, of anhydrous potassium sulfate. The bottles then were sealed and held at a constant temperature at 50° ± 1/2° C to polymerize.
Bottle 1 was polymerized for 48 Hrs. 70.2 sol. mixt.
Bottle 2 was polymerized for 96 Hrs. 70.1 sol. mixt.
After 48 Hrs. bottle 1 yield: 37.8 g equal to 53.8% conversion viscosity: 5.46 stokes (at room temp. approx. 25° C) as an 0.5% solution in formic acid.
After 96 Hrs. bottle 2 yield: 59.3 g equal to 84.5% conversion; viscosity: 8.15 stokes (at room temp. approx. 25° C) as an 0.5% solution in formic acid.
The above results clearly indicate that the polymerization rate is very dependent on the initial concentration of alkaline reagent used. Outside the preferred concentration, the polymerization required a longer time to complete which is economically not feasible for production purposes.
The following experiments were carried out to prove that CO 2 is not the sole polymerization activator as supposed in British Pat. No. 1,267,446 and U.S. Pat. Nos. 3,681,293; 3,682,896 and 3,683,046.
EXAMPLE 4
300 Grams (3.53 moles) of pure, anhydrous 2-pyrrolidone were mixed with 15 grams (0.27 mole) of analytical grade potassium hydroxide. The procedure of Example 1 was followed except that the CO 2 gas was replaced with dry NO 2 (nitrogen dioxide) gas. The gas addition time was 5 min. During the NO 2 addition the temperature increased from 30° to 44° C and the weight gain was 1.9 grams. After the NO 2 addition, the white, milky solution was divided into two equal parts, and polymerized 48 Hrs. at 50°± 1/2° C.
4/1 was polymerized without the drying agent.
4/2 was polymerized with the drying agent. The obtained white polymer in both cases was ground, washed with H 2 O and dried. The weight of the polymer was
______________________________________4/1 79.4 grams 56.7% conversion4/2 132.0 grams 94.3% conversion______________________________________
based upon the weight of the 2-pyrrolidone and its salt after NO 2 addition subjected to polymerization (140 grams). The obtained viscosity at room temperature (approx 25° C) as a 0.5% solution in formic acid was
______________________________________ 4/1 6.41 stokes 4/2 8.90 stokes______________________________________
EXAMPLE 5
300 Grams (3.53 moles) of pure, anhydrous 2-pyrrolidone was mixed with 15 grams (0.27 mole) of analytical grade potassium hydroxide. The procedure of Example 1 was followed except that the CO 2 gas was replaced with dry SO 2 (sulfur dioxide) gas. The period of gas addition was 5 min. During the SO 2 addition the temperature increased from 32° C to 44° C and the weight gain was 1.8 grams. After the SO 2 addition the white, (no discolorization occurred), milky solution was divided in two equal parts and polymerized 48 Hrs. at 50°± 1/2° C.
5/1 was polymerized without the drying agent.
5/2 was polymerized with the drying agent.
After 48 Hrs. the obtained white polymer in both cases was ground, washed with H 2 O and dried. The weight of the polymer
______________________________________5/1 71.5 grams 50.7% conversion5/2 126.76 grams 89.9% conversion______________________________________
based upon the weight of the 2-pyrrolidone and its salt after SO 2 addition subjected to polymerization (141 grams). The obtained viscosity at room temperature (approx. 25° C) was
______________________________________ 5/1 5.11 stokes 5/2 7.52 stokes______________________________________
To further illustrate the criticality of anhydrous conditions to the polymerization the following work was carried out.
EXAMPLE 6
Example 1 was repeated using 250 grams of the purified 2-pyrrolidone and 12.5 grams of analytical grade potassium hydroxide to produce a solution which, after the CO 2 treatment, weighed 215 grams and was divided into four substantially equal portions, A, B, C and D. No water was added to portion A. One drop of water (0.05 ml) was added to portion B, two drops of water (0.10 ml) were added to portion C, and three drops of water (0.15 ml) were added to portion D. The four portions were placed in separate bottles without any drying agent, sealed and heated at 50°± 1/2° C in a constant temperature oven for 48 Hrs. Based upon the weight of the starting portions, portion A underwent a polymer conversion of only 54.6% and had a viscosity of 6.28 stokes, indicating that the solution mixture was not anhydrous after the CO 2 reaction; portion B underwent a polymer conversion of only 36.6% and had a viscosity of 5.06 stokes; portion C underwent a polymer conversion of only 2.1% and had a viscosity of 0.26 stoke; and portion D did not polymerize.
The results are in sharp contrast to the results obtained when water is excluded from the system and a drying agent is included to tie up any water formed during the reaction, in which event the polymer conversion is over 90% (based upon the weight of the 2-pyrrolidone and its salt prior to CO 2 , HO 2 or SO 2 treatment and the viscosity is at least 8 stokes and preferably as high as 12-14 stokes as measured at room temperature as a 0.5% solution in formic acid. The higher the viscosity the greater the molecular weight of the polymer.
EXAMPLE 7
The following procedure is to illustrate an economically feasible high molecular weight polymer preparation. 300 Grams of the pure, substantially anhydrous 2-pyrrolidone were mixed with 15 grams of analytical grade potassium hydroxide. A vacuum of 40 mm and a nitrogen atmosphere was established and heat was applied whereby the potassium hydroxide dissolved at 63° C and the vacuum dropped to 30 mm. Dehydration began at 83° C and 104° C distillation of 2-pyrrolidone began and the vacuum dropped to 20 mm. Heating was discontinued when the temperature reached 107° C and the amount of distillate was 30.5 grams, equaling 9.7% of the weight of the mixture.
The solution mixture, weighing 284.5 grams, was cooled to 29° C and bone dry CO 2 was bubbled through the solution. The solution mixture picked up 1.4 grams of CO 2 and its temperature increased to 40° C.
Next, 14 grams of potassium sulfate (about 5% based upon the weight of the CO 2 reaction mixture) were added to the mixture and the combination was sealed in a bottle and heated to 50°± 1/2° C for 48 Hrs. The white polymer weighed 298 grams, and was ground into chips and washed to neutral pH with water to remove the drying agent, potassium carbonate and the unreacted 2-pyrrolidone. The dried polymer chips weighed 277 grams, equaling a yield of 97.3% based upon the weight of the 2-pyrrolidone and its salt subjected to the CO 2 treatment. The viscosity of the polymer in solution at room temperature (approx 25° C.), 1/2% solution in formic acid, was 12.9 stokes, evidencing high molecular weight.
The temperature increase which occurs during treatment with CO 2 or the other gases generally will not heat the solution mixture higher than about 48° C. In any case, the solution mixture should be cooled, if necessary, to maintain a suitable temperature as explained in Step 2.
Although an inert atmosphere, e.g. nitrogen, is generally used in the process as a precaution against undesirable side reactions, it has been determined that this is not essential when using substantially pure 2-pyrrolidone.
The polymers obtained by the claimed process have too high a viscosity to be measured in hexafluoroisopropanol. They can be extended and woven under the same conditions and using the same equipment as with nylon type polyamides. They can also be molded or solvent-coated in substantially the same manner as conventional nylon-type polyamides.
Variations and modifications may be made within the scope of the claims. | Process for polymerizing 2-pyrrolidone in high yield to produce a high molecular weight polymer having the advantageous physical properties of synthetic polymers, such as strength and wear-resistance, and the advantageous chemical properties of cotton, such as water-absorptivity and release, dye-receptivity and similar ironing capability. The process is a hydrogen transfer which is catalyzed by an anion and bone dry carbon dioxide, nitrogen dioxide or sulphur dioxide gas and pushed to high yield with drying agents. Pure anhydrous 2-pyrrolidone is first reacted with an analytical grade alkali metal or its hydroxide or bicarbonate as an anion source to form a mixture comprising 2-pyrrolidone and the metal salt of 2-pyrrolidone; the mixture is then treated with the bond dry CO 2 , NO 2 or SO 2 gas as a catalyst to open the ring of the lactam salt; a drying agent is then added; and finally the hydrogen transfer polymerization is accomplished under controlled heating conditions to produce a high yield of polymer. | 2 |
CROSS REFERENCES TO RELATED APPLICATIONS
This application claims priority on Finnish Application No. 20000873, Filed Apr. 12, 2000, the disclosure of which is incorporated by reference herein.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
Not applicable
BACKGROUND OF THE INVENTION
The invention relates to a method for measuring slide bearing pressure in a deflection-compensated roll with a fixed shell.
In paper and board machines, deflection-compensated rolls (TK) are in general used which are formed from a stationary support structure and a tubular shell arranged to rotate therearound, said shell being bearably carried on the ends to a support structure by end bearings. Between the shell and the support structure, hydraulically loaded loading elements are moreover provided, being supported to the support structure and acting on the inner face of the shell in a radial direction, wherewith the profile of the shell can be adjusted in the axial direction. A row of loading elements to be used for adjusting the profile of the shell is positioned in the nip plane and with said loading elements, the bending of the shell of the TK roll and the backing roll is compensated so that the force acting on the web in the nip plane is equal across the entire axial direction of the shell. To intensify the profiling, so-called loading elements forming a counterzone can in addition be used on the opposite side of the support structure in relation to the nip in the TK roll. The loading elements of the counterzone can be positioned in one row, whereby a row is in the nip plane, or in two rows, whereby the rows are located symmetrically on both sides of the nip plane. By means of the loading members of the counterzone the shell can also be loaded with a desired force, whereby the configuration of the shell is profiled to be as desired.
The TK rolls can be divided into rolls with a mobile shell and rolls with a fixed shell. In the present context the TK rolls with a mobile shell refer to rolls in which the end bearings can be moved in radial direction, that is, normally in the nip plane relative to the support structure, whereby also the shell moves together with the end bearings in the nip plane. Transferring of end bearings is normally carried out so that pressure spaces acting in the nip plane are arranged between the end bearings and the support structure. By conducting a pressure medium into said pressure spaces, the end bearings can be transferred in the nip plane. By means of said transfer of the end bearings relative to the support structure, the opening and closing of the nip can be carried out, as well as partial loading and relief of the TK roll against the backing roll.
The TK rolls with a fixed shell refer to rolls in which the shell is not, at least to a significant extent, moved in a radial direction relative to the support structure. On fixed-shell TK rolls, the opening and closing of the nip and the loading and relief of the TK roll against the backing roll are performed with hydraulically operating loading arms supported to the support structure of the TK roll. In fixed-shell rolls, mechanical rolling bearings or hydraulic slide bearings can be used as end bearings. In a fixed-shell roll provided with rolling bearings, the end bearings are locked in radial direction to the support structure and the shell is locked in radial direction to the end bearings. In a fixed-shell roll provided with hydraulic slide bearings, the shell is able to move slightly in a radial direction owing to the nature of the bearing.
In rolls with a mobile shell and a fixed shell, rolling bearings or slide bearings can be used for end bearings between the shell and the support structure.
The present invention can be embodied in fixed-shell TK rolls provided with hydraulic slide bearings, in which the slide bearing operation is carried out essentially without strokes.
In FI patent No. 76870 (Kleinewefers GmbH), a TK roll with a fixed shell is disclosed, in which the shell is bearably carried on the ends of a support structure with rolling bearings. Indicators are arranged in the area of the rolling bearings, the measurement values of which indicate loading of the end bearings in the nip plane. By means of a control device, pressures to be supplied to the loading shoes of the loading zone and the loading shoes of the backing zone are controlled, being dependent on parameters measured in operation and/or determined in advance, and depending on the measurements of the indicators so that the loading of the end bearings is approximately zero in the nip plane.
Instead of measuring the direct bearing force with the aid of indicators arranged in the area of the rolling bearings, the forces acting on the rolling bearings can be defined also indirectly. This can be carried out by measuring the forces acting on the support spots of the support structure of the backing roll, the forces acting on the support spots of the support structure of the TK roll and the forces caused by the loading devices on the shell of the TK roll. On the basis of said forces, the forces acting on the rolling bearings of the TK roll are calculated. In the loading spots in which the forces are generated with the hydraulic loading devices, the pressures of the hydraulic loading devices are measured and on the basis thereof and of the surface areas of the pressure chambers of the pistons of the hydraulic loading devices, the forces acting on the hydraulic loading devices are calculated. In the calculations, the masses acting in the support spots and the friction factors acting in different locations are moreover paid attention to. The bearing force calculated with this kind of method is naturally inaccurate.
FI patent No. 79177 discloses a deflection-compensated roll with a mobile shell provided with rolling bearings. Therein, the shell is bearably carried on both ends to the support structure with rolling bearings arranged on top of the annular parts. Between the annular parts and the support structure, hydraulic loading members are disposed. With the loading members, the shell can be transferred relative to the support structure for opening and closing the nip. By the loading members, the shell can also be loaded against the backing roll.
In the mobile-shell TK rolls, in which a transfer of the end bearings based on the rolling bearings is carried out with a hydraulics medium brought into the pressure spaces between the bearings and the support structure, the pressure of the pressure medium conducted into said pressure spaces can be measured. A certain nip profile requires the use of a bearing force of a given magnitude, whereby the pressure equivalent thereto is tried to be kept under the bearing. The bearing force is determined on the basis of the surface areas of the pressure spaces influencing the bearings.
SUMMARY OF THE INVENTION
With the method according to the invention, sufficiently precise information is achieved each time of the pressures acting on the slide bearings of the fixed-shell TK roll being carried with slide bearings, on the basis whereof the forces acting on the slide bearings can be calculated.
The slide bearing of a TK roll comprises main bearing elements acting in opposite directions in the nip plane and side bearing elements acting in a transverse direction relative to the nip plane. Immediately below the first main bearing element focussed on the nip, that is, the guiding main bearing element, a first control valve is positioned, which on the basis of the loading acting on the main bearing elements distributes the pressure medium between the main bearing elements. To that main bearing element on which a greater load is at each moment acting, a greater flow and pressure is fed and respectively, to an opposite main bearing element, a lesser flow and pressure is fed. The control of the side bearing elements is carried out in an equivalent manner with the aid of a second control valve. The control valves should be located right below the guiding bearing element so that their response to an external loading can be made as brief as possible.
The invention is described below in detail, referring to the example embodiments of the invention presented in the figures of the accompanying drawings, whereto the invention is not intended to be solely restricted.
Further objects, features and advantages of the invention will be apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 presents a schematic longitudinal section of one end of a fixed-shell, deflection-compensated roll provided with slide bearings, shown above the central axis.
FIG. 2 presents a schematic cross-section of the end of the roll of FIG. 1 at the hydraulic slide bearing.
FIG. 3 presents a schematic cross-section of an arrangement of measurement tubes used in measuring pressures of the slide bearings.
FIG. 4 presents a schematic longitudinal section of an arrangement of measurement tubes used in measuring pressures of the slide bearings.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 presents a schematic longitudinal section of one end of a fixed-shell, deflection-compensated roll 10 provided with slide bearings 13 shown above the central axis X—X. The roll 10 comprises a stationary support structure 11 and a shell 12 rotating therearound. The shell 12 is supported on the ends to the support structure 11 by means of hydraulic slide bearings 13 . Between the hydraulic slide bearings 13 , the shell 12 is moreover supported in the nip plane to the support structure 11 by means of hydraulic loading devices 14 . The end of the roll is closed with an end piece 15 supported in axial direction to the support structure 11 with a support member 16 . The support in axial direction may also be implemented in the other end of the roll only, whereby support members 16 are provided in axial direction on both sides of the end piece 15 of the roll. An individual supply duct 20 for pressure medium leads here to each loading device 14 , whereby each loading device 14 can be adjusted individually. The loading devices 14 may also be divided into groups so that one pressure medium supply duct 20 is inside the roll divided for a number of loading devices 14 so that each group forms one adjustment zone. In an extreme case, a group may extend onto the length of the entire nip, whereby the roll is provided with one zone and one supply duct 20 only. The control valves of the pressure medium ducts 20 leading to the loading devices 14 can be located in a separate control valve unit outside the roll (not shown in the figures) or they may be attached to the end part of the roll axle. On the other hand, the control valve 22 positioned in the pressure medium supply duct 21 leading to the slide bearings 13 may be located in the immediate adjacency to the slide bearings 13 .
The hydraulic end bearing shown in FIG. 2 is comprised of end bearing elements 13 a, 13 b acting in opposite directions in the main loading direction, that is, in the direction of the nip plane A—A, and of side bearing elements 13 c, 13 d acting transversely in opposite directions to the nip plane A—A. With the main bearing elements 13 a, 13 b, the position of the shell 12 is adjusted relative to the nip plane A—A. With the side bearing elements 13 c, 13 d, the shell 12 is kept in right position transversely to the nip plane A—A. With the main bearing elements 13 a, 13 b and the side bearing elements 13 c, 13 d, also the oscillations are attenuated in the direction of the nip plane A—A and respectively, in the transverse direction. A first main bearing element 13 a acting in the nip direction in the nip plane A—A is a so-called guiding bearing element and a second main bearing element 13 b acting in the opposite direction is a so-called slave bearing element. Respectively, a first side bearing element 13 c acting in transverse direction is a guiding bearing element and a second side bearing element 13 d acting in opposite direction is a slave bearing element.
The supply of pressure medium to the bearing elements 13 a, 13 b, 13 c, 13 d is carried out so that in a first supply line 21 a the pressure medium is supplied to a first control valve 22 a located immediately under the first main bearing element 13 a. Said first control valve 22 a distributes in turn the pressure medium to the first main bearing element 13 a and to the opposite second main bearing element 13 b. In addition, the pressure medium is supplied in a second supply line 21 b to a second control valve 22 b immediately under the first side bearing element 13 c, said valve distributing the pressure medium to the first side bearing element 13 c and the opposite second side bearing element 13 d. The control valves 22 a, 22 b distribute the pressure medium so that, irrespective of the external loading directed at the roll, a power balance is created between the bearing elements 13 a, 13 b; 13 c, 13 d being in opposite directions so that the shell 12 is kept in desired position relative to the bearing housing.
When loading is directed at the roll, e.g. in the direction of the nip at the first main bearing element 13 a, the first control valve 22 a increases the pressure and flow of the pressure medium supplied to the first main bearing element 13 a, and, respectively, decreases the pressure and flow of the pressure medium to the second main bearing element 13 b, whereby the shell 12 is kept stationary relative to the bearing housing.
In the arrangement shown in FIGS. 3 and 4 a measurement duct system 30 is shown, being conducted in a duct 31 formed in the support structure 11 into the roll at one end of the roll. Here, the measurement duct system comprises nine measurement ducts 30 , each being inside the roll connected to the object to be measured. The slide bearing on each roll end contains four bearing pressures, of which measurement data is desired and in addition, one measurement duct is used e.g. for measuring the pressure prevailing inside the roll. Each of the measurement ducts is connected inside the roll to a pressure space between a bearing element 13 a, 13 b, 13 c, 13 d and a control valve 22 a, 22 b in association with the bearing element, whereby the pressure acting on the pressure chamber under the piston of the bearing element can at all times be measured. FIG. 2 shows a measurement point M 1 in association with a first bearing element 13 a, a measurement point M 2 in association with a second main bearing element 13 b, a measurement point M 3 in association with a first side bearing element 13 c and a measurement point M 4 in association with a second side bearing element 13 d.
The measurement duct system is taken out of the roll through a flange structure 40 attached to an end of the roll. The measurement ducts are sealedly attached to the flange structure 40 and the flange structure is attached sealedly to the support structure of the roll in order not to release pressure medium and any overpressure possibly prevailing inside the roll. Outside the roll, the measurement ducts 30 can be connected to measurement connectors 50 attached to an appropriate base. On the other end of the measurement connector 50 , ducts 51 leading to measurement sensors 60 may in turn be connected [(not shown in the figures)].
The measurement duct system 30 can be comprised of individual measurement ducts arranged to pass in a space between the support structure 11 and the shell 12 . The measurement ducts or some portions thereof may also be implemented as borings made in the support structure 11 .
By means of the measurement arrangement of the invention, the pressure of each slide bearing element of the slide bearings on each end of the roll can be measured, on the basis whereof the force acting on said bearing element can be calculated. Bearing forces can be used for adjusting to a desired level the forces acting on the nip. In this manner, the rightfulness and controllability of the nip profile is brought to the same level as in slide-bearably carried rolls with a mobile shell.
The measured bearing forces may also be utilized in error diagnostics. When the forces acting on the slide bearings are moreover calculated in conventional fashion indirectly from other forces acting on the nip, a directly measured bearing force and an indirectly calculated bearing force are available. Hereby, calibration of parameters used in the calculation can be carried out so that the indirectly calculated bearing forces correspond to the directly measured bearing forces.
If the directly measured and the indirectly calculated calibrated bearing forces change thereafter as a function of time relative to each other, such conclusions may be drawn thereon that a valve or a sensor acting on the nip is faulty or requires calibration.
If, on the other hand, the thickness profile of a calendered web is deteriorating rapidly without any changes in the bearing force, the fault lies obviously in the thickness profile of the entering web, that is, before the calender.
On the basis of a measurement of the bearing force, also the condition of the rolls can be estimated. Variations in the bearing pressure synchronized with the speed of rotation of the TK roll are an obvious indication of a fault in the TK roll or in the banking roll 61 , of non-roundedness, of resemblance to a banana, of a coating being damaged or of dirt accumulated e.g. on the surface of the roll. Pressure measurement and pressure oscillation can be used, in addition to other measurement data, e.g to prevent a more serious roll damage or e.g. disengaging of the coating. In a situation in which a measurement of bearing force indicates damage, the nip can be opened in order to prevent more serious damage.
In the embodiments of the figures, one main bearing element 13 a, 13 b is provided in the nip plane A—A in both directions, though each main bearing element 13 a, 13 b may, in fact, be comprised e.g. of two partial bearing elements. The partial bearing elements are in such instance located symmetrically on both sides of the nip level A—A.
The claims are presented below, within the scope of the inventive idea determined by which various details of the invention may vary and deviate from what is described above only in exemplary fashion. | A deflection compensated roll has a stationary support structure and a shell rotatably arranged around it by means of slide bearings. The shell is additionally supported on the support structure with hydraulic loading devices by which the axial profile of the shell can be controlled. In the procedure, at least the pressure acting in the main bearing elements of the slide bearings effective in oppsite directions in the nip plane is measured by conducting pressure data from a pressure space between a control valve associated with the main bearing elements and each main bearing element by means of measurement ducts outside the roll where the pressure data is passed to a pressure sensor. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application contains subject matter that is related to the subject matter set forth in U.S. application Ser. No. 10/829,391, which was filed on Apr. 22, 2004.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates, in general, to a high strength aluminum alloy based on the Al—Zn—Mg—Cu alloy system and a process for forming the same. Although not limited thereto, the alloys are particularly suited for use in sporting goods and aerospace applications.
[0004] 2. Description of the Background Art
[0005] The highest strength aluminum alloys known at this time are based on the aluminum-zinc-magnesium-copper system. Commercial high-strength alloys currently being produced include AA7055 (nominally 8% Zn-2% Mg-2.2% Cu-0.10% Zr), AA7068 (nominally 7.8% Zn-2.5% Mg-2.0% Cu-0.10% Zr) and a Kaiser Aluminum alloy designated K749 (nominally 8% Zn-2.2% Mg-1.8% Cu-0.14% Zr). From the published phase relationships at 860° F. for an alloy containing 8% Zn, one can note that K749 is near a phase boundary, while the other two alloys are in multiple phase fields. In the latter case all the alloying elements are not in solid solution at 860° F., and are not only unavailable for age hardening, but the undissolved phases remaining after heat treatment detract from toughness. Although solution heat treating at a higher temperature than 860° F. will dissolve more of the solute, care has to be taken to ensure that the alloy does not undergo eutectic melting, which is a common problem in commercially cast alloys that have locally enriched regions as a result of microsegregation that occurred during casting.
[0006] There is a need in many applications, such as sporting goods and aerospace applications, for even stronger alloys based on the aluminum-zinc-magnesium-copper system that do not sacrifice toughness. However, this requirement presents a problem because, in general, as the tensile strength of an aluminum alloy is increased, its toughness decreases.
SUMMARY OF THE INVENTION
[0007] The present invention addresses the foregoing need in a number of ways. More particularly, there are three distinct avenues for increasing an alloy's strength while maintaining its toughness: rich alloy chemistries; processing to maximize alloying effectiveness; and preventing recrystallization. Rich alloys provide more solute, which is potentially available for age hardening to higher strength levels; effective processing ensures that the solute is available for strengthening and not out of solution as second phases, which detract from fracture toughness; and maintaining an unrecrystallized microstructure optimizes both strength and toughness.
[0008] To provide increased tensile strength without sacrificing toughness through the use of rich chemistries, the present invention comprises aluminum alloys based on the Al—Zn—Mg—Cu alloy system that preferably include high levels of zinc and copper, but modest levels of magnesium. As an option, small amounts of scandium can also be employed to prevent recrystallization. Each of the alloys preferably includes at least 8.5% Zn and 2.25% Cu by weight. Higher levels of each of these elements up to about 10.5% Zn and 3.0% Cu can be used. However, modestly lower amounts of Mg (max 1.85%) are preferably used to allow higher levels of the Cu. The preferred ranges of all elements in the alloys include by weight, 8.5-10.5% Zn, 1.4-1.85% Mg, 2.25-3.0% Cu, and at least one element from the group Zr, V, or Hf not exceeding about 0.5%, the balance substantially aluminum and incidental impurities. In the preferred embodiments, 0.05-0.30% Sc is also included in the alloys to prevent recrystallization. Additionally, it has been found that toughness decreases as the total weight percentage of magnesium and copper increases. Experiments have established that the ideal range of these two elements be between 4.1 and 4.5% combined. Still further, the total weight percent of Zn, Cu and Mg is ideally between 13.0 and 14.5%.
[0009] To maximize alloying effectiveness during formation of the alloys, a homogenization process is preferably employed after alloy ingot casting in which a slow rate of temperature increase is employed as the alloy is heated as near as possible to its melting temperature. In particular, for the last 20-30° F. below the melting temperature, the rate of increase is limited to 20° F./hr. or less to minimize the amount of low melting point eutectic phases and thereby further enhance fracture toughness of the alloy. Once the ingot is formed into finished shape using extrusion and rolling steps, for example, the product is preferably solution heat treated at 870 to 900 degrees F. and then artificially aged. The aging process can be carried out by exposing the product to a one, two or three step heat treatment process. In the first step, the product is exposed to a temperature range of 175-310 degrees F. for 3 to 30 hours. In the optional second step, the first step is followed by heating at 310 to 360 degrees F. for 2 to 24 hours. Finally, in the third optional step, the product is heated at 175 to 300 degrees F. for 1 to 30 hours. As a still further option, the second and third aging steps can be used without the first aging step.
[0010] The foregoing alloys and processing operations enhance the properties of the Al—Zn—Mg—Cu alloy system, such that they can be more effectively employed in numerous applications. Specific products or items in which the subject alloys can be employed include, among others, sporting goods including baseball and soft ball bats, golf shafts, lacrosse sticks, tennis rackets, and arrows; and aerospace application including aerospace components such as wing plates, bulkheads, fuselage stringers, and structural extrusions and forgings; and ordnance parts such as sabots and missile launchers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The features and advantages of the present invention will become apparent form the following detailed description of a preferred embodiment thereof, taken in conjunction with the accompanying drawings, in which:
[0012] FIG. 1 is a graph depicting T6 strength (YTS and UTS) as a function of the total alloy content in weight percent for a number of sample alloys formed in accordance with the preferred embodiments;
[0013] FIG. 2 is a graph depicting fracture toughness as a function of combined percentages of Cu and Mg for sample alloys formed in accordance with the preferred embodiments;
[0014] FIG. 3 is an equilibrium diagram which depicts the phase relationships at 885° F. as a function of percentages of Cu and Mg for an alloy formed in accordance with the preferred embodiments that contains 9% Zn;
[0015] FIG. 4 is a graph illustrating the effect of the ratio of Mg to Cu on fracture toughness for the alloys formed in accordance with the preferred embodiments;
[0016] FIG. 5 is a graph depicting second phase volume percent as a function of heating rate in a formation process for Alloy AA7068; and
[0017] FIG. 6 is a graph illustrating the effect of scandium on strength of an Al-8% Zn-2.2% Mg-1.9% Cu alloy.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The following examples illustrate how alloy modifications and efficient processing operations can be used to enhance the properties of the Al—Zn—Mg—Cu alloy system in accordance with the preferred embodiments of the present invention, such that they can be more effectively utilized in sporting goods and aerospace applications.
Example 1
[0019] A heretofore unexplored region of the Al—Zn—Mg—Cu alloy system consists of compositions comprising about 9% to 10% zinc, 2.2% to 2.8% copper, and 1.6% to 2.0% magnesium. The alloy compositions listed in Table 1 were cast as 9-in. diameter billets: note that all these alloys contain about 0.05% scandium, an element which in combination with zirconium is effective in preventing recrystallization.
[0000]
TABLE 1
Alloy compositions
Percent by Weight
Alloy
Si
Fe
Cu
Mg
Zn
Zr
Sc
179
0.04
0.07
2.47
1.83
8.87
0.14
0.06
180
0.04
0.09
2.71
1.89
8.95
0.13
0.06
189
0.04
0.08
2.14
1.89
8.60
0.12
0.05
190
0.03
0.09
2.31
1.86
9.21
0.13
0.05
191
0.03
0.11
2.35
1.81
9.63
0.13
0.05
192
0.04
0.10
2.33
1.87
10.13
0.12
0.05
200
0.04
0.09
2.58
1.64
8.84
0.12
0.05
202
0.04
0.12
2.46
1.66
8.87
0.13
0.05
203
0.04
0.10
2.69
1.78
8.94
0.13
0.05
204
0.03
0.10
2.88
1.58
8.78
0.12
0.05
209
0.04
0.08
2.64
1.49
8.78
0.14
0.05
213
0.03
0.07
2.42
1.63
9.65
0.13
0.05
214
0.03
0.09
2.56
1.44
9.50
0.14
0.05
215
0.04
0.09
2.57
1.73
9.82
0.12
0.05
216
0.03
0.10
2.81
1.60
9.65
0.13
0.05
[0020] The billets were homogenized at 880 F (F means degrees Fahrenheit) and extruded to seamless 4-in. diameter tubes with a 0.305 in. wall thickness. The extrusions were solution heat treated at 880 F, quenched in cold water and “peak” aged to the T6 temper (24-hr soak at 250 F). They were tested for tensile properties in the longitudinal direction and sections from all of the extrusions were cut and flattened to pieces about 12″ square, which were also solution heat treated at 880 F, quenched in cold water and peak aged. These flattened sections were tested for fracture toughness (ASTM B645) in the T-L orientation. The tensile and fracture toughness properties are listed in Table 2.
[0000]
TABLE 2
Tensile and fracture toughness properties
Strength
Toughness
(ksi)
(ksi rt.in)
% Zn
% Cu
% Mg
UTS
YTS
Kq
Kp
8.60
2.14
1.89
97.1
88.5
25.2
30.5
9.21
2.31
1.86
100.1
93.9
22.4
27.5
9.63
2.35
1.81
99.9
94.2
20.9
25.4
10.13
2.33
1.87
103.2
97.8
21.2
24.0
8.87
2.47
1.83
101.1
92.2
20.9
23.9
8.95
2.71
1.89
102.9
93.7
20.1
20.5
8.84
2.58
1.64
98.6
93.8
23.1
25.8
8.87
2.46
1.66
98.4
92.8
25.3
22.2
8.94
2.69
1.78
100.0
94.2
24.2
22.4
8.78
2.88
1.58
99.1
93.8
24.8
21.9
8.78
2.64
1.49
96.4
91.9
24.8
22.9
9.65
2.42
1.63
100.3
96.3
24.7
21.3
9.50
2.56
1.44
98.5
94.9
26.2
21.2
9.82
2.57
1.73
102.6
98.2
21.9
18.2
9.65
2.81
1.60
100.6
97.1
20.0
18.4
[0021] As can be seen from Table 2, tensile yield strengths well in excess of 90 ksi were obtained in most of the alloys, with two compositions achieving about 98 ksi. As shown in FIG. 1 , strength correlated well with the total alloy content, with each wt. pct. adding about 4.8 ksi to the yield strength. The equilibrium phase relations at the homogenizing and solution heat treatment temperature explain the reason for this behavior. FIG. 3 shows how the compositions listed in Table 1 relate to the magnesium and copper solubility limits at 885 F for alloys containing a nominal zinc level of 9%. Compositions lying below the demarcation line between the solid solution and the Al+S phase regions (i.e., the solvus) are single phase alloys, which have superior fracture toughness values for a given strength level, compared to those in the 2-phase region. The best combinations of strength and toughness are associated with alloys near the solvus line, which is why the 2.7% Cu/1.9% Mg composition has a relatively low toughness level. The preferred compositions therefore lie within the dashed lines that run approximately parallel to the solvus. These relationships are defined by controlling the total copper plus magnesium concentrations between 4.1% and 4.5%.
[0022] Although the properties described above were obtained with a “standard” T6 temper aging treatment by exposing the shaped products to heat of between 175 and 310 F for 3 to 30 hours (24 hr at 250 F was specifically used), as with most Al—Zn—Mg—Cu alloys, other practices may also be advantageous, depending on the desired combination of properties. For example, a tube from composition #213, when drawn to a tube 2.625″ in diameter with a 0.110″ wall thickness and aged by a 2-step practice of 8 hr at 250 F plus 4 hr at 305 F had yield and tensile strengths of 100.9 ksi and 102.6 ksi, respectively. Similarly, the subject alloy can be over aged beyond peak strength in a second step at temperatures in the 310-360 F temperature range for 2 to 24 hours to provide a desirable combination of strength and corrosion resistance. Another preferred embodiment includes a final aging treatment in a third step at a lower temperature in the range 175-300 F for 1 to 30 hours, which provides an additional strength benefit with no loss in corrosion properties. As yet another alternative, the alloy can be subjected only to the aforementioned second and third aging steps by skipping the first step.
Example 2
[0023] To compare the invention alloy with other commercial high-zinc alloys such as AA7036, AA7056 and AA7449, which have higher Mg/Cu ratios in the range 1.0 to 1.4, the following alloys were prepared as described in Example 1.
[0000] TABLE 3 Compositions of Comparative Alloys Percent by Weight Alloy No. Si Fe Cu Mg Zn Zr Sc 36 0.03 0.06 1.91 2.17 9.02 0.15 0.05 39 0.04 0.05 1.28 2.74 9.02 0.13 0.06 43 0.03 0.03 1.44 2.62 9.04 0.13 0.05 47 0.04 0.06 1.59 2.34 8.95 0.14 0.06
The yield strengths and toughness values for these alloys are listed in the following table.
[0000]
TABLE 4
Mechanical Properties of Comparative Alloys
Mg/Cu
Yield
Kpmax
Alloy
Ratio
% (Mg + Cu)
Strength (ksi)
(ksi rtin.)
36
1.14
4.08
94.9
24.5
47
1.47
3.93
93.9
22.7
43
1.77
3.99
93.9
21.3
39
2.14
4.02
92.7
20.2
[0024] FIG. 4 compares the toughness levels of these alloys on the basis of Mg/Cu ratio with the invention alloys, using those compositions that have similar strength levels (93-95 ksi) and total Mg+Cu contents (4.0-4.2%).
Example 3
[0025] As noted earlier it is important that undissolved second phases do not remain after processing so that fracture toughness can be maximized. This is especially important in alloys that are rich in alloy content, and lie near an equilibrium solvus phase boundary. To illustrate how homogenizing practice can affect the amount of such undissolved phase(s), samples of as-cast AA7068 alloy billet were heated from 850 F at various rates in a differential scanning calorimeter (DSC), and the energy associated with eutectic melting, which started at about 885 F was measured. This energy measurement is directly proportional to the amount of undissolved second phase remaining at the incipient melting point, and the relationship between these factors has been determined by quantitative microscopy. FIG. 5 shows how heating rate affects the amount of this phase as determined from the DSC data.
[0026] Note that a slow heating rate of about 10 F/hr reduces the amount of second phase to a level below 1 vol. %. One would expect that a ˜5 F/hr heating rate would reduce the “soluble” portion to near zero. We also note that for heating rates of 10-20 F/hr, the volume fraction of undissolved eutectic is no greater than the amount of insoluble Fe-containing constituent (independent of heating rate or homogenization temperature) at a nominal 0.12% Fe level (approx. 1 vol. %).
Example 4
[0027] It has been recognized for a number of years that scandium in combination with zirconium is an effective recrystallization inhibitor. A Russian review article states “it is desirable to add scandium to aluminum alloys in a quantity from 0.1 to 0.3% together with zirconium (0.05-0.15%)”. However, “the greatest effect . . . is observed for alloys not containing alloy elements combining with scandium in insoluble phases . . . ; with a limited copper content [scandium combines with copper] alloying with scandium together with zirconium of Al—Zn—Mg—Cu and Al—Cu—Li alloys is possible”. As such, “commercial alloys based on Al—Zn—Mg—Sc—Zr (01970, 01975) have been developed”.
[0028] Two potential drawbacks to scandium additions to 7XXX alloys containing about 2% copper are evident:
[0029] 1) the copper level is high enough to combine with scandium, thereby rendering it ineffective, and
[0030] 2) the high price of scandium; at the 0.2% level it would add about $10 a pound to the cost of the aluminum alloy.
[0031] It would therefore be economically and technically attractive if scandium levels could be effectively used below those recommended in the Russian literature.
[0032] Alloys of the compositions listed in the following table were prepared as 5″ diameter billets, which were processed as described below. Although the sample alloys contained more Mg and less Cu than the preferred alloys discussed previously, it is believed that the effect of Sc addition to the alloys would be essentially the same for the preferred alloys.
[0000]
Alloy
% by wt.
No.
Si
Fe
Cu
Mg
Zn
Zr
Sc
A
0.03
0.04
1.95
2.20
8.07
0.11
0.00
B
0.03
0.05
1.86
2.17
8.05
0.00
0.22
C
0.03
0.05
1.89
2.18
8.09
0.11
0.06
D
0.03
0.04
1.84
2.12
8.11
0.12
0.11
E
0.03
0.05
1.95
2.18
8.08
0.11
0.22
[0033] The ingots were homogenized at 875 F using a 50 F/hr heating rate and air cool, and then reheated to 800 F and extruded to a 0.25″ by 3″ flat bar. Sections of each extrusion were annealed at 775 F for 3 hr, cooled 50 F/hr to 450 F, held 4 hr and cooled 50 F/hr to room temperature. The sections were then cold rolled to 0.040″ sheet using five pass reductions (84% total reduction). The sheets were solution heat treated at 885 F for 30 min, quenched in cold water, and then aged to the peak strength condition (10 hr at 305 F). The as-extruded bars were also heat treated similarly and both products were tested for transverse tensile properties, as listed below. The specific effects of scandium on strength are also shown in FIG. 6 .
[0000]
Alloy
UTS (ksi)
Yield Strength (ksi)
No.
% Zr
% Sc
Extrusion
Sheet
Extrusion
Sheet
A
0.11
0
94.7
90.7
91.4
87.8
B
0
0.22
88.2
92.0
86.1
88.4
C
0.11
0.06
95.7
97.1
92.2
93.3
D
0.12
0.11
95.2
96.6
92.2
93.3
E
0.11
0.22
94.5
96.5
91.1
92.5
[0034] A number of points are evident from these results:
1. The strongest alloy in both extrusion and sheet form contains 0.06% Sc (with 0.11% Zr) 2. At the 0.1% Zr level, 0.06% Sc is effective in raising the strength of the sheet product by about 6 ksi. 3. 0.22% Sc in the absence of zirconium raises the strength of the sheet product by only 1 ksi, and lowers the extrusion strength by about 6 ksi. The effectiveness of only 0.06% Sc in preventing recrystallization was confirmed by comparing the microstructures of the sheet products containing (a) 0.11% Zr, (b) 0.11% Zr+0.06% Sc, and (c) 0.22% Sc (no Zr). In view of the foregoing, the preferred range in the alloys for Sc is 0.05-0.30%, with a more preferred range of 0.05-0.10%.
[0038] Although the present invention has been described in terms of a number of preferred embodiments and variations thereon, it will be understood that numerous additional variations and modifications may be made without departing from the scope of the invention. Thus, it is to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described above. | High strength aluminum alloys based on the Al—Zn—Mg—Cu alloy system preferably include high levels of zinc and copper, but modest levels of magnesium, to provide increased tensile strength without sacrificing toughness. Preferred ranges of the elements include by weight, 8.5-10.5% Zn, 1.4-1.85% Mg, 2.25-3.0% Cu and at least one element from the group Zr, V, or Hf not exceeding about 0.5%, the balance substantially aluminum and incidental impurities. In addition, small amounts of scandium (0.05-0.30%) are also preferably employed to prevent recrystallization. During formation of the alloys, homogenization, solution heat treating and artificial aging processes are preferably employed. | 2 |
The present application is a continuation of application Ser. No. 66,190 filed Aug. 13, 1979 now abandoned.
This invention relates to an improved direct plug-in electrical device having integral means for supporting the device from a conventional outlet. More particularly, it relates to a new and improved support system for a transformer/charging device whereby rechargeable batteries are connectable to the non-electrical components of a charge current source of the type described in U.S. Pat. No. 4,009,429 and in commonly assigned copending application Ser. No. 877,299, filed Feb. 13, 1978, both of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
There is an increasing number of consumer products being operated by rechargeable cells such as nickel cadmium cells. These products require cells with a plurality of physical sizes and electrical characteristics. The above-mentioned patent, U.S. Pat. No. 4,009,429 and application, Ser. No. 877,299, describe charging systems for AA, C, D and 9 volt size batteries which employ battery carrying modules adapted to close couple with a charge current source or with such a source and an adapter. In any case, the charge current source is provided with the familiar two blade electrical contacts for insertion into the sockets of a standard duplex wall outlet, which serves as a source of 110-120V AC current.
The total suspended weight of a direct plug-in electrical device, such as a battery charger or a specialty transformer as used with toys, is limited by the ability of the blades of the electrical device to directly support the weight of the device through their frictional engagement with the socket receptacle of the outlet. In fact, Underwriters Laboratories' standards limit this weight generated torque to 9 inch ounces. In those instances where the torque generated by the weight of the plug-in electrical device is in excess of 9 inch ounces, additional support means must be provided. It is recognized in the Underwriters Laboratories standards that the center screw which attaches the cover plate to the outlet may be used to support additional weight, on the order of an additional twenty ounces. However, the disadvantage in the use of the cover plate attachment screw is the inconvenience in removing and replacing the screw each time the electrical device such as a transformer/charger is used. Generally, such devices are plugged in and removed in repeated cycles, and thus the inconvenience associated with removing and replacing the cover plate screw, as well as the cover plate, is readily apparent.
SUMMARY
The present invention pertains to providing an electrical device with an integral auxiliary support means that detachably mates with a fastener means attached to the wall plate, the wall plate screw, or to the outlet box itself. The auxiliary support means permits even a relatively heavy electrical device to be plugged into the outlet source with simultaneous mechanical support being achieved. Detaching and unplugging can be simultaneously accomplished at will. The auxiliary support means may take the form of a "Velcro" fastener, one part of which is affixed to the electrical device, while the other part thereof is affixed to the cover plate; said -Velcro" portions being mounted for engagement when the electrical device is plugged into the outlet receptacle. In alternate embodiments, the cover plate screw may be replaced with a specially designed anchoring post which cooperates with a recessed portion formed in the housing of the electrical device, while in a still further embodiment, a snap fastener may be provided, the respective portions of which are secured to the cover plate and the electrical device for simultaneously providing auxiliary support to the electrical device when it is plugged into the electrical outlet.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be more readily understood by reference to the appended drawings in which:
FIG. 1 is an exploded perspective view of a first embodiment of an electrical device made according to the subject invention, a battery carrying module, a typical battery, and an outlet and cover plate source for 120V AC;
FIG. 2 is a side elevational view, partially in section, of the electrical device of FIG. 1, with the various components thereof being in assembled condition and with the electrical device being plugged into the outlet;
FIG. 3 is an elevational view, partially in section, of an electrical device according to a second embodiment of the subject invention; and
FIG. 4 is an elevational view, partially in section, of a third embodiment of an electrical device according to the subject invention.
DETAILED DESCRIPTION OF THE INVENTION
While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will hereinafter be described in detail a preferred embodiment of the invention, and modifications thereto, with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiments illustrated. Furthermore, while the several preferred embodiments of the invention will be described with reference to a battery charger, it is readily apparent that the invention has application for use in connection with any type of electrical device adapted to be plugged into an outlet, and wherein simultaneous auxiliary support for the electrical device is desired.
The overall system 20 of which the present modified sources form elements is shown in FIG. 1. System 20 includes a charge current source 22 and a conventional outlet source 24 of 120V AC. A battery carrying module 60 is releasably connected to the charge current source and is adapted to accommodate a plurality of batteries 62, 62. To aid in understanding the invention, FIG. 1 shows in exploded form charge current source 22, module 60 and batteries 62 as generally located when assembled for charging. FIG. 2 shows an assembled unit with two batteries in place for charging. While the charger is shown hanging down from the lower socket, obviously, it can be arranged to stand upwardly, and the top socket can be used.
THE CHARGE SOURCE
The charge current source 22 is comprised of a conventional high impedence center tap transformer. Two blades 26 and 28 are provided in one face of the charger housing for connection to a socket receptable 38 of the source 24 of 120V AC. Source 22 is available commercially from the assignee, General Electric Company, under the designation BC-3 miniature charger, and is described in the above-identified U.S. Pat. No. 4,009,429. Charge current source 22 comprises a transformer to make available from the standard 110-120 volt, 60 cycle AC line an output current of appropriate magnitude for the load provided. A terminal 30 of the charge current source 22 is centrally tapped to the secondary transformer, while terminals 32 and 34 are end tapped to the secondary of the transformer. Terminals 30, 32, and 34 are one-way, snap-type "male" terminals attached to a surface of the charge current source 22. The terminals 30, 32 and 34 are adapted to be connected to the snap-type "female" terminals 50, 52 and 54 (see FIG. 2), provided on the top surface of the battery carrying module 60 which is adapted to accommodate the plurality of batteries, designated by the numerals 62, 62.
Fastening means are provided on the charge current source 22 for purposes of providing auxiliary support for the source 22 when it is engaged with the receptacle 38 of outlet 24. The fastener means may take the form of a locking pin arrangement, snap fastener device, a pair of mating hooks, a "Velcro" connector, or the like. In the embodiment of FIGS. 1 and 2, the fastening means comprises a patch of "Velcro" designated by the numeral 36a, which is in the form of a plurality of substantially rigid outwardly facing tiny plastic, e.g., nylon hooks. "Velcro" is available commercially. In the embodiment of FIG. 3, the fastening means for the charge current source comprises a socket recess 36b, while the embodiment of FIG. 4, the fastening means comprises the female portion 36c of a snap fastener.
THE OUTLET SOURCE OF 120V AC
Source 24 comprises a conventional dual outlet receptacle 38, a cover plate 40, and a screw 42 for mounting the cover plate to the outlet receptacle 38.
In the embodiment of FIGS. 1 and 2, a small patch of "Velcro" 44a in the form of a plurality of substantially rigid, outwardly facing tiny plastic loops is bonded or otherwise secured to the cover plate 40 in the vicinity of the cover plate screw 42. The "Velcro" patch 44a is positioned so as to be in alignment and juxtaposed to the "Velcro" patch 36a secured to the charge current source 22 when the latter is plugged into outlet 24. At such time, the plastic hooks of the "Velcro" patch 36a mate with and interlock with the loops of the "Velcro" patch 44a secured to the cover plate. Alternatively, the hooks and loops of the "Velcro" patches 36a and 44a can be reversed, and the location of the respective patches may be modified, as long as they are in alignment and in abutting relationship when the charge current source 22 is plugged into the receptacle 38. The "Velcro" patches 36a and 44a may be respectively secured to the charge current source 22 and the cover plate 40 by other forms of mechanical means, instead of with adhesive.
In operation, as the charge current source 22 is fully inserted into the socket portions of receptacle 38, the hooks and loops of the "Velcro" patches 36a, 44a interlock so as to simultaneously provide support for the suspended charge current source 22 and battery holder 60, in addition to the frictional support provided by the interengagement of blades 26, 28 and the socket receptacle 38. Accordingly, greater support is provided for the charge current source 22, and the attachments thereto, than would otherwise be provided by the mere frictional engagement of the blades 26, 28 and the socket receptacle 38.
In the embodiment of FIG. 3, the cover plate attachment screw is replaced with an anchoring pin post 70 including a shank 72 which extends beyond the front surface of the cover plate 40 and terminates with an enlarged shoulder portion 74. The face of the charge current source 22 from which the blades 26, 28 extend includes the recess 36b terminating in an enlarged detent portion which cooperates with the shoulder 74 of post 70 for providing additional support to the assembly of the charge current source 22 and the depending battery carrier 60. The shank portion 72 of the anchoring pin may be of sufficient diameter for bearing against the front face of the cover plate 40 for maintaining same in fixed position.
In the embodiment of FIG. 4, the cover plate locking screw is replaced by an anchor screw 90 having a shank 92 which extends beyond the face of the cover plate 40 and terminates with a male snap fastener portion 94. The latter is adapted to cooperate with the female portion 36c on the charge current source 22 for providing auxiliary support for the source 22 and the depending battery carrier 60. Shank 92 may be of sufficient diameter to include a shoulder portion for maintaining the cover plate 40 in place. The male and female snap portions 36c, 94, may be reversed, and if desired, the female snap portion 36c may be molded directly in the plastic housing of the charge current source 22.
Obviously, many variations will suggest themselves to those skilled in the art in light of the above, detailed description without departing from the scope and spirit of the appended claims. | A direct plug-in electrical device, such as a charging system including a transformer in a housing, is provided with fastening means adapted to engage anchoring means on a conventional outlet, thereby enhancing the load-carrying capability of the outlet. | 7 |
BACKGROUND OF THE INVENTION
This disclosure relates to the distribution of lubricant on the gauge face or inside of the rail of railroad tracks through the use of an automatic sensor driven hydraulic system. The system allows for distribution of a greatly reduced amount of lubricant or grease to a targeted area.
Due to the enormous weight and centrifugal force involved with locomotives and rolling stock, a surprising amount of cohesion exists. This cohesion is between the wheel flange and the rail gauge face. Tiny flakes of steel from the rail and wheels are removed as a train's inside wheel contacts the rail. The only way to prevent such an occurrence is to apply lubrication to reduce cohesion.
Generally lubricant, or grease, is applied to the gauge face or inside of the rails at the point of wheel and rail contact. Currently, lubricant is applied by a wayside lubrication system that pumps lubricant to a distribution bar. This lubrication bar has many grooves from the top of the bar to a distribution port. This method piles large amounts of grease or lubricant toward the top of the rail. When the pile gets large enough the train wheels will contact the pile of grease or lubricant and spread the grease down the track. This method causes excessive throw off of grease or lubricant.
A problem occurs in lubricant application in that the excess amount of lubrication currently used coats an unnecessarily thick layer on the rail. This layer covers the tops of the rails and the lubricant is then inadvertently carried by the wheels to inclines or to other non-curved sections of the track. At areas where the tracks are inclined, friction is needed and the excess lubrication has an adverse effect on traction. In addition, the amount of lubricant currently required for minimum coverage is expensive.
This excess lubricant also covers the earthen area surrounding the rail section. As lubricant is applied now, a large amount is pumped in order to make sure the small area that needs lubrication is actually covered when a wheel comes in contact with it. This excess lubricant ends up not only coating the entire rail, but the ground surrounding it. While there may occasionally be pads laid down to absorb some of this excess lubricant, much of the excess seeps into the ground and migrates. This has negative impacts on the environment. Considering that major portions of railroad are set away from city areas, the lubricant can migrate into the environment near the tracks. Negative effects on the environment are compounded when the rails need to be repeatedly lubricated over time. Reducing the amount of lubricant needed will not only save money, it can reduce, if not eliminate any negative impact on the environment.
SUMMARY OF THE INVENTION
This disclosure relates to an apparatus for applying lubrication to a rail road track. The apparatus comprises a control module, a housing, a lubricant distribution block, and a plurality of tubes for connecting the control module to the housing. The housing houses the lubricant distribution block and the housing is connected to the control module by the plurality of tubes. The control module is positionable in close proximity to the rail road track and the housing is positionable adjacent to and along a section of rail road track to be lubricated.
This disclosure also relates to a method for applying lubricant to a section of rail road track. The method comprises storing lubricant in a vessel in a control module, the control module positioned proximate the section of rail road track and pumping lubricant from the control module to a lubricant distribution nozzle connected to a housing. The housing is positioned adjacent to and along the section of rail road track and sliding the lubricant distribution nozzle along the section of rail road track in a first direction will distribute lubricant along the section of rail road track.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the present invention as in place for use.
FIG. 2 is a schematic view of the invention.
FIG. 3 is a perspective view of a process of the invention.
FIG. 4 is a perspective view of still a further component of the invention.
DETAILED DESCRIPTION OF THE INVENTION
This invention relates to the application of lubrication to only a limited portion of rail where lubrication is actually needed. Large amounts of lubrication and money will be saved by applying a limited amount of lubricant at a more precise time of applying lubrication. Applying lubrication just before a wheel comes in contact with the rail will reduce the amount of lubricant needed. The lubricant will be carried by the wheels immediately after application rather than migrating to other portions of the rail, or the ground.
As illustrated in FIG. 1 , the present invention is generally comprised of three major components. The first is a control module 10 . The control module 10 houses the major pressure, power and lubrication storage components of the invention. The control module 10 is stationed adjacent to a portion of railroad track. Second, the linear slide rack 30 houses the lubrication application components. The linear slide rack 30 is positioned in the track in close proximity to the surface in need of lubrication. The linear slide rack 30 is secured to the rails. Third, a series of steel tubes 68 and 70 , for pressure and return lines, connects the control module 10 to the linear slide rack 30 . The steel tubes 68 and 70 for pressure and return lines are to be buried at a depth under the tracks, deep enough to allow for track and ballast maintenance. When connected, the lubrication process is initiated in the control module 10 . The control module is equipped for manual initiation as well as automatic initiation of the lubrication process. The linear slide rack 30 contains the components that then carry out the lubrication distribution process.
Illustrated in FIG. 1 is the control module housing 10 . FIG. 2 is a schematic of the internal components of the housing 10 . A control module housing 10 contains an electric motor, gas engine, LP engine, or diesel engine 14 . A hydraulic reservoir 16 in the control module 12 provides storage for hydraulic oil. A dual section hydraulic pump 22 provides 23 GPM @ 2300 PSI for the large section and 3 GPM @ 1400 PSI for the small section. The module housing 10 includes a Programmable Logic Control that provides for the control of all of the electrical functions necessary. Illustrated in further detail in FIG. 2 is a hydraulic flow diagram of the components from the control module 10 to the application process in the linear side rack 30 .
The electric motor or fueled engine 14 provides mechanical motion to drive a hydraulic pump 22 . The hydraulic pump 22 provides pressure and volume. The hydraulic pump directs pressure to a hydraulic directional valve section 62 and accepts and directs return hydraulic pressure to a hydraulic reservoir 16 . The hydraulic directional valve section 58 directs hydraulic pressure and flow to a hydraulic grease pump 28 . The hydraulic directional valve also directs hydraulic pressure and flow to the hydraulic cylinder.
In further detail, as can be seen in FIGS. 3 and 4 the linear slide rack 30 is an enclosure made from suitable material, preferably aluminum. The linear side rack 30 has a removable cover for easy access to the inside components. The linear slide rack 30 is secured to the base of a portion of rail by mounting brackets or other suitable fasteners (not shown). The lubricant is distributed to the gauge face side of the railroad track by a lubricant distribution nozzle 32 . The term “lubricant” as used herein means the type of lubricant used to effect rail adhesion and rail and wheel wear protection. Preferably, such lubricant has some rain resistance and ability to be “carried” down a rail by a wheel engaging the rail. The words “lubricant” and “grease” are used interchangeably herein. Suitable lubricants are made from a variety of materials and are available commercially as “rail lubricants”.
The lubricant distribution nozzle 32 is attached to a lubricant distribution block 34 in which lubricant is delivered to the gauge face of the rail. The lubricant distribution block 34 is comprised of a small aluminum or other suitable metal box or riser to raise the nozzle 32 to the height of the intended lubrication surface. The lubricant distribution block 34 can be secured to a plate 38 on the lubrication surface facing side of the plate 38 . The lubricant distribution block 34 extends upward or outward from a connection with the plate at a height equal to the inside or gauge face of the area targeted for lubricant distribution. The application nozzle 32 is oriented to face the intended distribution surface. In a further embodiment, the applicant nozzle 32 may extend toward the surface to be lubricated. The plate 38 with the application nozzle 32 together form the lubricant distribution block 34 . The lubricant distribution block 34 is secured by a mounting attachment 42 or other suitable mechanism to an end of a piston rod or hydraulic cylinder 44 .
The lubricant distribution block 34 is connected to a flexible hydraulic hose 46 . A solenoid operated hydraulic valve section 54 provides hydraulic pilot pressure to shift the lubricant distribution block 34 . The hydraulic activation valve section 58 provides hydraulic pressure to operate the hydraulic reciprocating lubrication pump 28 . The lubrication pump 28 provides pressurized grease to the lubricant distribution block 34 . The lubrication distribution block 34 provides pressurized grease for distribution to the rail.
As further illustrated in FIGS. 3 and 4 , the piston rod or hydraulic cylinder 44 is connected to the grease distribution block 34 . The piston rod or hydraulic cylinder for lubrication distribution 44 is also connected to the hydraulic cylinder barrel 60 . The hydraulic cylinder barrel 60 lies along the length of the linear side rack. The hydraulic pressure reducing and directional valve section 62 provides bi-directional hydraulic pressure to operate the hydraulic cylinder barrel 60 . The hydraulic cylinder barrel 60 provides the linear bi-directional motion for the lubricant distribution block 34 . The hydraulic directional valve section 62 provides hydraulic pressure to operate the hydraulic cylinder 44 . The hydraulic cylinder 44 moves the grease distribution block 34 into the application or stored position. The hydraulic valve section 56 provides a heating circuit that goes through entire conduit that goes out to the slide rack and back to the control module.
In further detail a flow line for each element, lubrication and pressure and return, connects the control module 10 and the linear side rack 30 . The flow lines are comprised preferably of a steel tube 68 and 70 for each pressure function. Each steel hose is set externally underground, between the control module 10 and the linear side rack 30 . Each opposing end of each steel tube 68 and 70 is connected to an adapter. The opposing end of each adapter is then connected to a flexible hose. Hoses (not shown) are connected to the control module 10 . Additional hoses 76 and 78 are connected to the linear slide rack 30 completing the flow line. Each connection of a flexible hose 76 and 78 to steel tube 68 and 70 is completed by a suitable adapter or fastener 80 to seal the connection from potential leaks. Each corresponding flexible hose 76 and 78 inside the linear slide rack 30 connects to the corresponding application component. An additional steel tube 82 is connected in the same fashion as described above to a flexible hose 46 in the linear slide rack 30 for lubrication flow.
A metal detecting proximity switch (not shown) allows for automatic lubrication, reset and reverse sliding of the applicator slide 40 . The lubrication process can additionally be initiated manually on demand. Operation begins when a signal, whether automatic or on demand, is sent to the hydraulic pump 22 . The hydraulic pump 22 will then initiate the flow of lubrication to the grease distribution block 34 and pressure to initiate movement of the application slide through the process described above.
The process begins as a train approaches the area of track in need of lubrication. Automatic lubrication is initiated by the metal detecting switch, which is triggered by a train's proximity to the linear side rack 30 . Sliding extension of the lubrication application block 34 and application of the lubricant begins immediately prior to train wheel contact with the rails. The full lubrication application process of the selected area of track is carried out quickly. The process is initiated when the train is in close proximity to the portion of track and is complete immediately prior to train wheel contact. Further, on demand lubrication follows the same process, however an operator using a switch (not shown) in the control module 10 initiates lubrication. Lubrication can be bi-directional or set automatically for reset and reverse sliding to the initial position.
In a further embodiment the module 10 is equipped to send information to rail road personnel regarding maintenance and care of the module 10 as well as conditions of the system including lubricant levels, fuel level, operational condition and any other pertinent information regarding operation of the system. System updates may be sent from the control module to a mobile device or computer via text, voice or e-mail message.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. | An apparatus and method for applying lubricant to a rail road track. The apparatus comprising a control module; a housing; a lubricant distribution block; and a plurality of tubes for connecting the control module to the housing wherein the housing houses the lubricant distribution block. The control module is positionable in close proximity to the rail road track and the housing is positionable adjacent to and along a section of rail road track to be lubricated. The lubricant is stored in a vessel in the control module and pumped from the control module to a lubricant distribution nozzle connected to the housing and wherein sliding the lubricant distribution nozzle along the section of rail road track in a first or second direction distributes lubricant along the section of rail road track. | 5 |
BACKGROUND OF THE INVENTION
The invention relates to a method and to its devices making it possible to measure the tension and/or travel speed of an insulating filament, fibre, thread or wire without any contact with the latter. This device has numerous applications in all fields where it is necessary to know the value of the tension or travel speed of an insulating filament. More specifically, the invention applies to the textile field and more specifically to the spinning of textile filaments.
There are various methods for determining the movement or transit speed of a filament. One of these methods consists of evaluating the linear speed of the filament on the basis of the radius of the grooved pulley serving as the filament guide and the number of revolutions per second carried out around said grooved pulley.
The main disadvantage of this method is that it introduces significant errors on the measurement when the grooved pulley is worn. Moreover, it does not make it possible to take account of possible slipping of the filament on said grooved pulley.
Another known method makes it possible to measure the tensions of a textile structure held taut on one site. Such a method consists of supplying an excitation sinusoidal signal on a circular textile surface and measuring the displacement response with the aid of a contactless sensor or transducer. A transfer function curve or spectral signature can then be deduced. This method is more specifically defined in the article entitled "Measure tensions within the cloth" by Jean-Yves Catherin, published in BUREAUX D'ETUDES, No. 76. However, this method only applies to woven structures.
SUMMARY OF THE INVENTION
The present invention therefore has the advantage of proposing a method and its performance devices making it possible to measure one or other of the filament movement speed and the tension of said filament or both simultaneously, whilst obviating the disadvantages of the previously described, known methods.
More specifically, the invention relates to a method for the contactless measurement of the tension and/or movement speed of an insulating filament with the aid of a contactless sensor, characterized in that said sensor having first and second flat conductor means separated by an air layer of permittivity p in which the filament moves, it consists of determining disturbances to the permittivity of the air layer due to fluctuations in the weight per unit length and the position of the filament during its movement in said air layer.
A first device for performing this method is a device for the contactless measurement of the tension of an insulating filament. In said device, the first flat conductor means have a common electrode and the second flat conductor means have a pair of electrodes forming with the common electrode a capacitive dipole of respective capacitances C1 and C2, said electrode pair having a first and a second electrodes, each having a complementary right-angled triangle shape.
Advantageously, said device has processing means for determining, by a spectral analysis of a signal ##EQU2## a vibration frequency of the filament travelling in the air layer located respectively between the common electrode and the first electrode of capacitance C1 and between the common electrode and the second electrode of capacitance C2.
A second device for performing said method is a device for the contactless measurement of the movement speed of an insulating filament. In the case of said device, the first flat conductor means have at least two common electrodes and the second flat conductor means have a first and a second pairs of electrodes forming, with their respective common electrode, a first and second capacitive dipoles arranged in parallel and at a distance D from one another, each electrode of said electrode pairs being rectangular and positioned perpendicular to the filament travel direction.
Advantageously, said device has processing means for determining the movement speed V defined by V=D/ΔT, in which ΔT is a time shift between a first random signal x(t) produced by the first capacitive dipole and a second random signal y(t) produced by the second capacitive dipole and is determined on the basis of an intercorrelation relation Cxy(T) between the first and second random signals defined by Cxy(T)=Cxx(T-ΔT).
A third device for performing this method is a contactless measuring device for the tension and movement speed of an insulating filament. In the case of this device, the first flat conductor means have a first, a second and a third common electrodes and the second flat conductor means have a first, a second and a third pairs of electrodes, each electrode pair forming with its respective common electrode a first, a second and a third capacitive dipole, the electrodes of the first and third capacitive dipoles having a rectangular shape and are positioned perpendicular to the filament travel direction and are able to ensure, with the aid of processing means, the determination of the movement speed of said filament, the electrodes of the second capacitive dipole placed between the first and third capacitive dipoles having in each case a complementary right-angled triangle shape and being able to ensure, with the aid of the processing means, the determination of the filament tension.
Moreover, with said device, the first, second and third common electrodes are produced on the same substrate and the first, second and third electrode pairs are produced on the same second substrate. In the same way, the first and second flat conductor means of the first, second and third performance devices can be screen process printed on an epoxy glass.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail hereinafter relative to non-limitative embodiments and with reference to the attached drawings, wherein show:
FIG. 1 is a perspective view of the insulating filament tension contactless measuring device.
FIG. 2 is a front view of the same device on which are shown the vibrations of the filament during its movement.
FIG. 3 is a perspective view of the insulating filament movement speed contactless measuring device.
FIG. 4 is a perspective view of the complete device, i.e. the device making it possible to measure in contactless manner the tension and movement speed of the insulating filament.
FIG. 5 is the synoptics of the latter device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the device permitting the contactless measurement of the tension of an insulating filament during its movement. It is possible to see a sensor or transducer having two flat conductor means 2 and 4 separated by an air layer 6 (i.e. a dielectric layer). Between the said two flat conductor means 2 and 4 travels the insulating filament, thread or wire 8. Together these two flat conductor means 2,4 form air capacitances. The method according to the invention consists of analysing the disturbance to the permittivity of the=air layer 6 due to the movement of the filament 8 in said layer. Thus, the random fluctuations of the weight per unit length of the filament 8 travelling in the air layer 6 produce, over a period of time, random variations with respect to the capacitance value with respect to the flat conductor means 2 and 4
Advantageously, the flat conductor means 4 incorporate two electrodes 4a,4b, each of which is shaped like a right-angled triangle. These two right-angled triangles 4a,4b are complementary of one another and their hypotenuses are as close together as possible, but without sticking together. The existence of these two electrodes 4a,4b offers the advantage of permitting a measurement of the difference on the sum of the two capacitances C1,C2 (relative to the two electrodes 4a,4b) of the same dimension, which makes it possible to detect limited relative capacitance variations.
The flat conductor means 2 are also constituted by an electrode 2 referred to hereinafter as the common electrode. The structure constituted by the two electrodes 4a,4b and by the common electrode 2 will be referred to hereinafter as the capacitive dipole 3.
The two electrodes 4a,4b are screen process printed in the vicinity of one another onto the same substrate. The electrode 4a is supplied by a voltage -V and the electrode 4b by a voltage +V. The common electrode 2 then assumes the potential Vs with respect to earth or ground.
The method according to the invention consists of studying the oscillating frequencies of the filament when it is held taut between two fixed points in order to determine its tension. Thus, during its movement the filament vibrates without external excitation. However, this vibration is increased by guiding the filament across possible fixed points. According to an embodiment, these fixed points can be grooved pulleys or a V-guide. Moreover, said fixed points serve to prevent any contact between the filament and any of the electrodes, because such a contact would be liable to prejudice the free oscillation of the filament. These fixed points are very diagrammatically represented in FIG. 1 by triangles 10a,10b.
From the capacitive dipole 3 is obtained a signal whose spectrum is calculated. This spectrum reveals the fundamental mode and the harmonics of the signal. A spectral analysis by parametric modelling makes it possible to again find the filament tension.
Thus, during these vibrations, the filament 8 is largely located either in the space between the common electrode 2 and the electrode 4a, i.e. in the capacitance C1, or in the space between the common electrode 2 and the electrode 4b, i.e. in the capacitance C2. This position of the filament 8 in one or other of the spaces of the capacitive dipole 3 alternates every half-cycle of the filament vibration. This alternation effect occurs both for the fundamental mode and for certain harmonics of the signal. The signal obtained at the output of the dipole 3, namely the signal ##EQU3## is modulated as a function of the oscillating frequency of the filament and therefore as a function of the tension of the filament 8.
In a front view, FIG. 2 shows the said filament 8 when vibrating in the space 6 between the common electrode 2 and the electrodes 4a,4b. A double dotted line shows the filament 8 when it is largely located in the space between the common electrode 2 and the electrode 4a, which corresponds to the capacitance C1. The mixed line configuration shows the position of the filament 8 when it vibrates and is largely in the space between the common electrode 2 and the electrode 4b, which corresponds to the capacitance C2. It is also possible to see the filament guides 10a,10b making it possible to increase the natural vibration of the filament 8.
It is clear that in order to obtain a better sensitivity of the vibrations of the filament 8 in the space 6 between the electrodes 2 and 4a/4b, it is advantageous for the space between the hypotenuses of the electrodes 4a,4b to be as small as possible. In this case, the vacuum capacitance value C1 and C2 is: ##EQU4## in which po and pr are respectively the permittivity of the vacuum, the relative permittivity of the ambient medium (close to 1 when the ambient medium is air) and e the distance between the common electrode 2 and the electrodes 4a,4b.
FIG. 3 shows the device making it possible to measure in contactless manner the travel speed of the filament 8. This device has two capacitive dipoles 13,17 separated by a fixed distance D. As in FIG. 1, each dipole 13, 17 has two flat conductor means respectively 12, 14 and 16, 18 separated by an air layer respectively 15 and 19.
More specifically, the flat conductor means 14 have two rectangular electrodes positioned perpendicularly to the direction of the filament 8. These two electrodes 14a,14b are raised to a respective potential +V and -V.
In the same way, the flat conductor means 18 have two rectangular electrodes 18a, 18b perpendicular to the direction of the filament 8 and parallel to the electrodes 14a,14b of the dipole 13. These electrodes 18a, 18b are respectively raised to the potential -V and +V.
On either side of the assembly constituted by the capacitive dipoles 13 and 17 are filament guides 10a, 10b, whose function was explained during the description of FIG. 1.
When the filament 8 passes into the first dipole 13, it produces a first random signal x(t). The random signal y(t) comes from the second dipole 17 and is identical to the random signal x(t), except that it has a time shift ΔT defined by the expression ΔT=D/speed.
The intercorrelation of the random signals x(t) and y(t) is written: ##EQU5##
Where C xy is the intercorrelation of the signals x and y, and T 0 is the duration of the signal obtained for calculating the intercorrelation.
For the device according to the invention y(t) is equivalent to x(t-ΔT), which makes it possible to simplify the expression giving the intercorrelation of the random signals x(t) and y(t) to Cxy(T)=Cxx(T-ΔT), the time shift ΔT being determined by the position of the peak or maximum of the intercorrelation C xy (T). When this time shift has been determined, the filament movement speed can be obtained from the expression speed=D/ΔT.
In order to make it possible to detect small longitudinal irregularities, the electrodes 12,16,14a/14b and 18a/18b are produced with limited widths.
FIG. 4 shows the complete device permitting the measurement of both the tension and the movement speed of the filament 8. This device has the dipole 3 of the filament tension measuring device and the dipoles 13, 17 of the filament movement speed measuring device. In said device, the dipoles 13 and 17 are positioned on either side of the dipole 3. Moreover, at each end of said array of dipoles 13, 3 and 17 are provided filament guides 10a and 10b. It is clear that each of these dipoles 3, 13 and 17 will not be described in greater detail because they are identical to the dipoles described respectively in FIGS. 1 and 3.
Advantageously, the electrodes 14a,14b,4a,4b and 18a and 18b are produced on the same substrate. In the same way, the common electrodes 12,2 and 16 are produced on the same substrate. Such a construction has the advantage of being simple to use, but more particularly it automatically compensates any mechanical deformations which would introduce capacitance variations. Thus, any deformation which occurred and affected one of the capacitances of a dipole would act in the same way on the dual capacitance of said dipole. Thus there is no system sensitivity loss.
According to an embodiment of the invention, these copper electrodes are screen process printed onto epoxy glass. The glass plates containing on the one hand the common electrodes 2,12 and 16 and on the other the electrodes 14a,14b,4a,4b,18a,18b are kept at a distance e from one another by an insulating plate of thickness e positioned below the flat conductor means. The assembly of said array takes place through three epoxy glass plates. The electric wires for connecting to each of the dipoles are twisted together.
FIG. 5 shows in functional manner the synoptics of the device according to FIG. 4. In FIG. 5, the sinusoidal generator represented by the block 100 supplies the array of the device with sinusoidal signals. The signals from the generator 100 are amplified by the amplifier 102, whose input is connected at the output of said generator 100 and whose output is connected to a mixer 104. The signal from the amplifier 102 is of form V(t)=Sin(Wt). Via the mixer 104, it is introduced into a phase shift circuit .O slashed.=π. The phase shift circuit is produced by means of a phase locked loop 103. Thus, the signal is introduced into the loop 103 by means of the mixer 104. It is then filtered by the low-pass filter 106 and is then again amplified by the amplifier 108 and is finally applied to the input of a voltage-controlled oscillator 110. At the output of said oscillator 110, the signal obtained has the value -V(t), i.e. sin(wt+π). This signal -V(t) is introduced into the return link of the loop 103 in order to undergo in 105 the phase shift of value π before being reintroduced into the mixer 104. This signal -V(t) obtained at the output of the block 110 excites one of the electrodes (e.g. the electrode 4a of capacitance C1) of the capacitive dipole D3 described in FIGS. 1 to 4 and in which it is designated 3. The second electrode of this capacitive dipole D3 (the electrode 4b of capacitance C2) is connected to the output of the amplifier 102 and is therefore excited by the signal +V(t). It is also connected to the capacitance C1 formed by the electrode 4a. These two capacitances C1 and C2 are bridge connected to the amplifier 112. The signal obtained at the output of said bridge is: ##EQU6##
As the information of interest for determining the tension of the filament is contained in the amplitude of the signal Vs(t), an amplitude demodulation takes place by means of a multiplication of the signal Vs(t) by the pure sinusoid Sin(wt) of constant amplitude, said multiplication being carried out by the amplifier 112. The sought signal ##EQU7## is then obtained by low-pass filtering of the high frequency sinusoidal component.
More specifically, the output of the amplifier 102 is connected to the input of an amplifier 114. The outputs of the amplifiers 112, 114 are connected to the mixer 116, whose output signal is filtered by a low-pass filter 118. The signal Vout(t) then obtained at the output of said filter 118 is the sought signal and has for expression: ##EQU8##
Then, in 120 a spectral analysis of said signal Vout(t) is carried out and on the basis of this the filament tension value is determined.
Parallel to the capacitances C1 and C2 of the capacitive dipole D3, the capacitances C1 and C2 of the capacitive dipole D13 (13 in FIGS. 3 and 4) are respectively connected to the output of the loop 103 and to the output of the amplifier 102. These capacitances are also bridge connected to the input of the amplifier 122, whose output is connected to a mixer 124. The shape of the signals obtained at the output of the bridge connections of C1 and C2 has already been described in connection with the dipole D3 and will therefore not be described again for the dipoles D13 and D17. On a second input, the mixer 124 receives the signal from the amplifier 114. The signal obtained at the output of the mixer 124 is filtered in a low-pass filter 126 and then introduced into the intercorrelation circuit 134.
In the same way as for the capacitive dipole D13, the capacitances C1 and C2 of the capacitive dipole D17 (17 in FIGS. 3 and 4) are respectively connected to the output of the loop 103 and to the output of the amplifier 102. In the same way, these capacitances are bridge connected to the input of the amplifier 128. The output of the amplifier 128 is connected to one input of the mixer 130, which receives on a second input the signal from the amplifier 114. The output of the mixer 130 is connected to a low-pass filter 132. The signal obtained at the output of said filter 132 is introduced into the intercorrelation block 134, in which the function Cxy(t) is calculated. The circuit 136 makes it possible to determine the position of the intercorrelation peak and thus deduce therefrom the filament movement speed.
The synoptics of FIG. 5 correspond to a device permitting both the measurement of the tension and the measurement of the movement speed. However, it is clear that the synoptics of the device for the measurement of the tension will be described by the references D3 and 100 to 120 and the device for measuring the movement speed by the references 100 to 110, 114, D13, D17 and 122 to 136. | Method and its devices for the contactless measurement of the tension and/or travel speed of an insulating filament, thread or wire. The method consists of processing the signal ##EQU1## in which C1 and C2 are the capacitances of a capacitive dipole. For the filament tension measuring device, the dipole (3) is defined by a pair of electrodes (4a/4b) of the same size and having a triangular shape and by a common electrode (2), processing consisting of extracting the vibration frequency of the filament between two supports by a spectral analysis. The speed measuring device comprises two dipoles (13,17), each defined by a pair of rectangular electrodes (14a/14b, 18a/18b) and a common electrode (12,16), processing consisting of extracting the passage time, between the two dipoles, of microscopic irregularities of the filament by an intercorrelation. The invention has application to the textiles field and particularly to the spinning of textile filaments. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit, under 35 U.S.C. §119(e), of the filing date of U.S. provisional application Ser. No. 60/571,731 entitled “Irrigated Catheter,” filed May 17, 2004, which is hereby incorporated herein by reference in its entirety.
FIELD OF INVENTION
The invention relates generally to methods and apparatus for irrigating an electrode of an electrophysiology catheter.
BACKGROUND
The human heart is a very complex organ, which relies on both muscle contraction and electrical impulses to function properly. The electrical impulses travel through the heart walls, first through the atria and then the ventricles, causing the corresponding muscle tissue in the atria and ventricles to contract. Thus, the atria contract first, followed by the ventricles. This order is essential for proper functioning of the heart.
In some individuals, the electrical impulses of the heart develop an irregular propagation, disrupting the heart's normal pumping action. The abnormal heartbeat rhythm is termed a “cardiac arrhythmia.” Arrhythmias may occur when a site other than the sinoatrial node of the heart is initiating rhythms (i.e., a focal arrhythmia), or when electrical signals of the heart circulate repetitively in a closed circuit (i.e., a reentrant arrhythmia).
Techniques have been developed which are used to locate cardiac regions responsible for the cardiac arrhythmia, and also to disable the short-circuit function of these areas. According to these techniques, electrical energy is applied to a portion of the heart tissue to ablate that tissue and produce scars which interrupt the reentrant conduction pathways or terminate the focal initiation. The regions to be ablated are usually first determined by endocardial mapping techniques. Mapping typically involves percutaneously introducing a catheter having one or more electrodes into the patient, passing the catheter through a blood vessel (e.g. the femoral vein or artery) and into an endocardial site (e.g., the atrium or ventricle of the heart), and deliberately inducing an arrhythmia so that a continuous, simultaneous recording can be made with a multi-channel recorder at each of several different endocardial positions. When an arrythormogenic focus or inappropriate circuit is located, as indicated in the electrocardiogram recording, it is marked by various imaging or localization means so that cardiac arrhythmias emanating from that region can be blocked by ablating tissue. An ablation catheter with one or more electrodes can then transmit electrical energy to the tissue adjacent the electrode to create a lesion in the tissue. One or more suitably positioned lesions will typically create a region of necrotic tissue which serves to disable the propagation of the errant impulse caused by the arrythromogenic focus. Ablation is carried out by applying energy to the catheter electrodes. The ablation energy can be, for example, RF, DC, ultrasound, microwave, or laser radiation.
SUMMARY OF THE INVENTION
One embodiment of the invention is directed to an electrophysiology catheter comprising a shaft portion including a fluid passage to conduct fluid, an electrode coupled to a distal end of the shaft portion, and a handle portion coupled to a proximal end of the shaft portion. A portion of the fluid passage defines an opening in the shaft portion, and the opening is constructed and arranged such that when fluid is conducted through the fluid, at least some of the fluid will contact the electrode after passing through the opening in the shaft portion.
Another embodiment of the invention is directed to an electrophysiology catheter comprising a shaft portion comprising a fluid passage, a fluid reservoir coupled to the fluid passage, and a plurality of channels coupled to the fluid reservoir. The fluid passage has a first diameter and the reservoir has a second diameter that is larger than the first diameter. The electrophysiology catheter further comprises an electrode coupled to a distal end of the shaft portion and a handle portion coupled to a proximal end of the shaft portion. Each channel of the plurality of channels coupled to the fluid reservoir defines an opening in the shaft portion configured and arranged such that fluid exiting the channel through the opening will contact the electrode.
A further embodiment of the invention is directed to an electrophysiology catheter comprising a shaft portion comprising a fluid passage and a channel coupled to the fluid passage, wherein the channel defines an opening in the shaft portion. The electrophysiology catheter further comprises an electrode assembly coupled to the shaft portion and movable in a longitudinal direction along the shaft portion. The electrode assembly comprises an opening and is positionable such that fluid may flow from the channel through both the opening in the shaft portion and the opening in the electrode assembly. The electrophysiology catheter further comprises a handle portion coupled to a proximal end of the shaft portion.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like reference character. For purposes of clarity, not every component may be labeled in every drawing. In the drawings:
FIG. 1A illustrates a portion of a catheter according to one embodiment of the invention;
FIG. 1B illustrates a view of the distal end of the catheter shown in FIG. 1A ;
FIG. 2A illustrates a portion of a catheter according to another embodiment of the invention;
FIG. 2B illustrates a view of the distal end of the catheter shown in FIG. 2A ;
FIG. 3A illustrates a portion of a catheter according to another embodiment of the invention;
FIG. 3B illustrates a view of the distal end of the catheter shown in FIG. 3A ;
FIG. 4 illustrates a portion of a catheter according to another embodiment of the invention;
FIGS. 5A-C illustrate one exemplary method for constructing a catheter in accordance with the embodiment of FIG. 4 ;
FIG. 6A illustrates a portion of a catheter according to another embodiment of the invention;
FIG. 6B illustrates a view of the distal end of the catheter shown in FIG. 6A ;
FIG. 7A illustrates a side view of portion of a catheter according to a further embodiment of the invention;
FIG. 7B illustrates top view of the distal end of the catheter shown in FIG. 7A ;
FIG. 8A illustrates a side view of a portion of a catheter according to another embodiment of the invention;
FIG. 8B illustrates top view of the distal end of the catheter shown in FIG. 8A ;
FIG. 9 illustrates a portion of a catheter according to another embodiment of the invention; and
FIG. 10 illustrates a portion of a catheter according to another embodiment of the invention.
DETAILED DESCRIPTION
To effectively treat a cardiac arrhythmia, a lesion having a sufficient size and depth must be created at a chosen location in the heart. It is known that for a given electrode size and tissue contact area, the size of a lesion created by radio frequency (RF) energy is a function of the RF power level and exposure time. At higher power levels, however, the exposure time can be limited by an increase in impedance that occurs when the temperature at the electrode-tissue interface approaches 100° C. One way of maintaining the temperature at the electrode-tissue interface below or equal to this limit is to irrigate the ablation electrode with an irrigation fluid such as saline. The saline provides convective cooling, which controls the electrode-tissue interface temperature and thereby prevents an increase in the impedance. Various embodiments of a catheter having an irrigated ablation electrode will now be described.
FIGS. 1A and 1B illustrate a first embodiment of the invention. FIG. 1A illustrates a catheter 2 comprising a shaft 1 having an ablation electrode 3 coupled at a distal end thereof. The shaft 1 includes an opening 5 on a distally facing surface 7 of the shaft 1 . A fluid 9 , such as saline, may be released from the shaft 1 via opening 5 and may be directed towards the electrode 3 to promote convective cooling of the electrode 3 . A groove 11 is included on a portion of electrode 3 that is adjacent to the opening 5 so as to channel fluid exiting opening 5 along the electrode 3 . The groove 11 may be configured such that the fluid 9 is directed towards portions of the electrode 3 where cooling is desired.
FIG. 1B illustrates a view of the distal end of the catheter 2 . As shown, three openings 5 are included on the distal facing surface 7 of the shaft 1 , and three corresponding grooves 11 are included on the electrode 3 adjacent openings 5 . However, it should be appreciated that the invention is not limited in this respect, and that different numbers of grooves and/or openings (e.g., two, four, five, six, or some other number of grooves/openings) may alternatively be used. Further, the number of grooves 11 and openings 5 need not be the same. For example, no grooves need be included on the electrode 3 . In addition, the illustrated configurations of openings 5 and grooves 11 are merely exemplary. Although openings 5 are shown as semicircular, these openings may alternatively be circular, linear, oval, or another suitable shape. In addition, while groove 11 is shown as having a generally semicircular cross section, the groove 11 may assume other configurations. Specifically, the groove 11 need not be uniform along the length of electrode 3 . For example, only a proximal portion of electrode 3 may include grooves, while a distal portion of the electrode 3 may include no grooves.
FIGS. 2A and 2B illustrate another embodiment of the invention. As shown in FIG. 2A , catheter 14 comprises a shaft 13 and an electrode 15 coupled at a distal end thereof. Shaft 13 has a larger diameter than that of electrode 15 . Thus, shaft 13 includes a distal facing surface 17 at the interface of the shaft 13 and electrode 15 . An opening 19 is provided on the surface 17 from which fluid 21 may be released. The fluid 21 may be channeled by a groove 23 on the electrode 15 to direct the fluid 21 towards desired portions of the electrode 15 .
FIG. 2B illustrates a view of the distal end of the catheter 14 . As shown, three openings 19 are included on the distal facing surface 17 of the shaft 13 , and three corresponding grooves 23 are included on the electrode 15 adjacent openings 19 . As with the embodiment of FIGS. 1A-1B , it should be appreciated that the number of grooves 23 and openings 19 illustrated in FIGS. 2A-2B , and the configurations of such grooves and openings, is merely exemplary and that other implementations are possible.
FIGS. 3A and 3B illustrate a further embodiment of the invention. The embodiment of FIGS. 3A and 3B is similar to that of FIGS. 2A and 2B , except that the openings that are provided for the release of irrigation fluid are located on the catheter shaft at a radius outside that of the ablation electrode. FIG. 3A illustrates a catheter 25 comprising a shaft 27 and an ablation electrode 29 coupled at a distal end thereof. A distal facing surface 31 of the catheter shaft 27 includes a plurality of openings 33 that release fluid 30 about ablation electrode 29 . Although electrode 29 is not shown as including any grooves, grooves may be included on the electrode 29 to direct the fluid released from openings 33 , if desired.
FIG. 3B illustrates a view of the distal end of the catheter 14 . As shown, four circular openings 33 are included on the distal facing surface 31 of the shaft 27 . However, the number of openings 19 and the configuration of the openings 19 shown in FIG. 3B is merely exemplary. For example, a different number of openings or differently shaped openings may alternatively be provided in accordance with this embodiment.
FIG. 4 illustrates another embodiment of the invention. According to this embodiment, fluid openings are provided in the portion of the surface of the catheter shaft that is substantially cylindrical. FIG. 4 illustrates a catheter 35 including a shaft 37 having an ablation electrode 39 at a distal end thereof. Electrode 39 has a diameter that is approximately equal to a diameter of the shaft 37 . Shaft 37 includes an outer surface 41 having a substantially cylindrical shape. An opening 43 is provided in the surface 41 for the release of irrigation fluid 45 . The opening 43 may be configured such that the irrigation fluid 45 is generally directed towards the distal end of catheter 35 (i.e., towards ablation electrode 39 ). If desired, grooves may also be included in the ablation electrode 39 to direct the irrigation fluid 45 as it exits opening 43 .
FIGS. 5A-5C illustrate one exemplary method for constructing a catheter in accordance with the embodiment of FIG. 4 . The catheter 49 of FIG. 5A is substantially the same as the catheter 35 of FIG. 4 , however, a distal portion 47 of the shaft 37 is formed of epoxy. As shown in FIG. 5B , a channel 51 in the distal portion 47 of the shaft 37 is coupled between an opening 33 in the shaft and a reservoir 53 disposed within the shaft. The reservoir 53 is in turn coupled to a fluid lumen 55 disposed along a central longitudinal axis of the catheter 49 .
The fluid lumen 55 may conduct irrigation fluid (e.g., saline) into reservoir 53 , and fluid may exit the shaft 37 from the reservoir 53 via the channel 51 and opening 33 . It should be appreciated that while only one channel 51 and corresponding opening 33 is shown in catheter 49 , a plurality of channels 51 and corresponding openings 33 may be provided. For example, a plurality of channels 51 may be coupled to the reservoir 53 and may be associated with corresponding openings 33 in the outer surface 41 of the shaft 37 . Although not illustrated, it should be appreciated that a catheter handle may be provided at a proximal end of the shaft 37 . Fluid may be introduced into the fluid lumen 55 , for example, via a port provided on or near the handle. In addition, while only a single fluid lumen 55 is illustrated, a plurality of fluid lumens may be used to conduct fluid to openings 33 . For example, each opening 33 may be associated with a corresponding fluid lumen that runs the length of the shaft 37 , and reservoir 53 may be eliminated.
The distal portion 47 of shaft 37 may function to attach the electrode 39 to the remainder of the shaft 37 . In addition, the distal portion 47 may be moldable such that channels 51 may be formed therein. It should be appreciated that while the distal portion 47 is described as being formed of epoxy, other adhesive materials through which channels may be formed may also be suitable. FIG. 5C illustrates a method of forming the channel 51 in the distal portion 47 of shaft 37 . In particular, FIG. 5C illustrates a cylindrical rod 57 that may be used to form channels in the epoxy of distal portion 47 . The rod 57 may be disposed within distal portion 47 , between the reservoir 53 and the exterior of the shaft 37 , during hardening of the epoxy used to form the distal portion 47 . It should be appreciated that the rod 57 may be solid or have a tubular shape or have any other configuration that enables channels 51 to be formed.
FIGS. 6A and 6B illustrate a further embodiment of the invention. According to this embodiment, the ablation electrodes includes protrusions, each having a fluid channel therein. FIG. 6A illustrates a catheter 59 comprising a shaft 61 and an ablation electrode 63 coupled at a distal end thereof. The electrode 63 includes a plurality of protrusions 65 , each having an irrigation channel 67 therein. Each irrigation channel 67 defines an opening 69 at a surface of the electrode 63 . The openings 69 release fluid 71 about the ablation electrode 63 . Although electrode 63 is not shown as including any grooves, grooves may be included on the electrode 63 to direct the fluid released from the openings 69 , if desired. Each irrigation channel 67 in electrode 63 may be coupled to a fluid lumen 73 in shaft 61 (as shown for one fluid lumen 73 in FIG. 6A ). Fluid lumen 73 conducts fluid along the length of the catheter shaft 61 to the ablation electrode 63 .
FIG. 6B illustrates a view of the distal end of the catheter 59 . As shown, three protrusions 65 and three corresponding openings 69 are included on the ablation electrode 63 . However, the number of openings 63 and protrusions 65 shown is merely exemplary. Moreover, the configuration of the openings 63 and protrusions 65 shown in FIG. 6B is merely exemplary. For example, a different number of openings and/or protrusions and differently shaped openings and/or protrusions may alternatively be provided in accordance with this embodiment.
FIGS. 7-10 illustrate embodiments of the invention that include an irrigated movable electrode. FIGS. 7A and 7B illustrate a side view and top view of a catheter 77 comprising a shaft 79 and an ablation electrode 81 movably coupled to the shaft 79 . For example, the electrode 81 may be slid longitudinally along the shaft 79 . Exemplary mechanisms for moving the electrode are described in U.S. Pat. No. 6,178,354 to Gibson, U.S. Pat. No. 6,461,356 to Patterson, and U.S. Pat. No. 6,464,698 to Falwell, each of which is assigned to C.R. Bard Inc. and incorporated herein by reference. The shaft 79 includes a fluid lumen 87 that conducts fluid along the length of the catheter shaft 79 . The shaft 79 further includes a plurality of irrigation channels 85 coupled to the fluid lumen 87 . Each irrigation channel 85 defines an opening 83 at a surface of the shaft 79 . The openings 83 release fluid 89 along the shaft 79 and about the ablation electrode 81 . Electrode 81 may be solid such that the openings 83 a obscured by electrode 81 at a given position of the electrode do not release fluid. Alternatively, electrode may be hollow such that the openings 83 a obscured by electrode 81 at a given position of the electrode release fluid into the electrode to cool the electrode from within. The fluid may also be withdrawn from the electrode (e.g., via a movable lumen coupled thereto) as in “closed circuit” cooled electrode configurations.
FIGS. 8A and 8B illustrate an embodiment of the invention that is similar to the embodiment of FIGS. 7A and 7B , but wherein the movable electrode includes openings for the release of irrigation fluid. Catheter 91 comprises a shaft 79 and an ablation electrode 93 movably coupled to the shaft 79 in the manner discussed in connection with FIGS. 7A-7B . The shaft 79 includes a fluid lumen 87 that conducts fluid along the length of the catheter shaft 79 , and a plurality of irrigation channels 85 coupled to the fluid lumen 87 . Each irrigation channel 85 defines an opening 83 at a surface of the shaft 79 . The openings 83 release fluid 97 along the shaft 79 and about the ablation electrode 93 . Electrode 93 also includes openings 95 that release fluid 97 about the ablation electrode. Electrode 93 may be hollow such that fluid 97 passes through openings 83 in the shaft into the electrode 93 and then exits through openings 95 in the electrode 93 . Alternatively, channels in the electrode 93 may correspond with channels in the shaft 79 such that when the electrode 93 is properly positioned, fluid flows from the channels 85 in the shaft into channels in the electrode 93 that are coupled to openings 95 . The openings 95 in the electrode 93 may assume a number of different configurations. The openings 95 may be included about the circumference of the electrode 93 or on one side of the electrode 93 . The openings 95 may also be in any pattern or number on the electrode 93 .
FIGS. 9 and 10 illustrate further embodiments of a catheter comprising a movable electrode. The catheters of FIGS. 9 and 10 are operable in substantially the same manner as the catheter of FIGS. 8A and 8B , but include electrodes having different configurations than that of FIGS. 8A and 8B . The catheter 99 of FIG. 9 comprises a shaft 79 and an ablation electrode 101 movably coupled to the shaft 79 in the manner discussed in connection with FIGS. 7A-7B . Electrode 101 has a dumbbell shape such that the diameters of the electrode at the longitudinal ends of the electrode are greater than the diameter at the center of the electrode. The shaft 79 includes a plurality of openings 83 that release fluid 103 along the shaft 79 and about the ablation electrode 101 . Electrode 101 also includes openings 105 that release fluid 103 about the ablation electrode 101 . Electrode 101 may be hollow such that fluid 103 passes through openings 83 in the shaft 79 into the electrode 101 and then exits through openings 105 in the electrode 101 . Alternatively, channels in the electrode 101 may correspond with channels in the shaft 79 such that when the electrode 101 is properly positioned, fluid flows from the channels in the shaft into channels in the electrode 101 that are coupled to openings 105 . The openings 105 in the electrode 101 may assume a number of different configurations. The openings 105 may be included about the circumference of the electrode 101 or on one side of the electrode 101 . The openings 105 may also be in any pattern or number on the electrode 101 .
The catheter 107 of FIG. 10 comprises a shaft 79 and an electrode assembly 109 movably coupled to the shaft 79 in the manner discussed in connection with FIGS. 7A-7B . Electrode assembly 109 comprises electrodes 111 and 113 coupled to a sleeve 115 . One or both of electrodes 111 and 113 may be ablation electrodes. At least one electrode may be a mapping electrode. The sleeve 115 includes openings 117 between electrodes 111 and 113 that release fluid between the electrodes. The shaft 79 includes a plurality of openings 83 that release fluid 103 along the shaft 79 and about the electrode assembly 109 . A portion of sleeve 115 may form a reservoir about the shaft 79 such that fluid 119 passes through openings 83 in the shaft 79 into the reservoir then exits through the openings 117 in the sleeve 115 . Alternatively, channels in the sleeve 115 may correspond with channels in the shaft 79 such that when the sleeve 115 is properly positioned, fluid flows from the channels in the shaft into channels in the sleeve 115 that are coupled to openings 117 . The openings 117 in the sleeve 115 may assume a number of different configurations. The openings 117 may be included about the circumference of the sleeve 115 or on one side of the sleeve 115 . The openings 117 may also be in any pattern or number on the sleeve 115 .
Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description and drawings are by way of example only. | Apparatus for irrigating an electrode of a catheter are disclosed. Among other things, a catheter is disclosed that comprises a shaft portion including a fluid passage to conduct fluid, an electrode coupled to a distal end of the shaft portion, and a handle portion coupled to a proximal end of the shaft portion. A portion of the fluid passage defines an opening in the shaft portion. The opening is constructed and arranged such that when fluid is conducted through the fluid passage, at least some of the fluid will contact the electrode after passing through the opening in the shaft portion. | 0 |
TECHNICAL FIELD
This invention pertains to apparatus for continously sensing the strata boundary of mined product and parting material during the mining process so that the cutting depth of a continuous excavator may be controlled relative thereto. Characteristic properties of the strata are sensed by probes which penetrate the materials in situ to determine the boundary location. Contamination of the product by parting material is thus minimized while mining, and the loss of product is minimized while removing the parting material.
BACKGROUND AND SUMMAY OF THE INVENTION
This invention pertains to the control of the cutting depth for continuous excavators of the general type shown in Satterwhite U.S. Pat. Nos. 3,896,571 or 3,974,580 or any continuous excavator having excavating means mounted on a structural support at the leading end of the machine. The excavating means has two or more sections which are mounted on either side of extended frame members, making it wider than the undercarriage of the excavator. Such machines have the capability of passing through a trench under excavation and advancing along its bottom so that the bottom of the cut is not visible to the operator. Closely following the excavating means on the main frame is a separately mounted moldboard/skid plate assembly. The entire machine is supported on a crawler track or rubber tired undercarriage which can be raised or lowered relative to the digging wheel to adjust its cutting depth. The moldboard blade breaks up uncut material left between the excavating means sections and scrapes the bottom of the cut clean, crowding excess materials forward. The excavating means, which works in an undercutting manner, takes these materials, along with the freshly dug material, to be discharged onto a conveyor.
Mining, and most particularly open pit mining such as for coal, typically finds the product in stratified deposits separated by "parting materials" such as clay or shale. The product can be mined in situ and loaded by a continuous excavator if contamination of the product by parting material can be minimized while mining. The parting materials may be removed by the same excavator if it can be done with minimal loss of product. Both operations have been controlled heretofore by regulation of the digging depth according to the color of the excavated material being discharged. This method is approximate at best and demands close attention by the operator.
It is notable that the parting materials in general have a lower resistivity than lignite and a higher resistivity than anthracite coals. Generally, but not necessarily, parting materials are also harder, having a higher compressive strength than either lignite or coal. The hardness, brittleness and abrasive properties of each material in combination produce a distinctive bit vibration and sound as the formation is penetrated. Most significantly, as we dig through the strata, all of these properties change with each material change. The resistivity characteristic is widely used for wireline logging of boreholes to determine the thickness and content of strata for mine evaluation and planning.
The resistivity and compressive strength values shown below may vary for the cited materials, and materials other than these may be present in a given mine however, every material encountered will have a characteristic value.
______________________________________TABLE OF TYPICAL PROPERTY VALUESFOR VARIOUS MINE MATERIALS COMPRESSIVE STR. RESISTIVITYMATERIAL lb./sq. in. ohms/sq. cm/cm______________________________________lignite 800 400,000anthracite 3,000 100shale 6,000 5,000combustible 4,000 1,500shalesandstone 13,000 80,000clay 100 1,500marl 250 50,000siltstone 7,500 20,000limestone 8,000 40,000______________________________________
In the present invention, either tabulated property of the mined product and parting materials may be selected as a control index, comparing the measured values of the in situ material contacted by the probes to the known values for the strata. Other properties, such as dielectric strength, vibration or sound may be used as a control variable, but resistivity and compressive strength are readily measured. Resistivity, in particular, can be related directly to logging data.
An object of the present invention is to sense the location of the strata boundary of mined product and parting material relative to the cutting plane in a reliable and durable manner while excavating. A second object is to aquire this sense of the strata boundary location in a form usable for accurate control of the cutting depth of a continuous excavator.
In the present invention, probes penetrating the virgin formation enable direct measurement of material properties for the purpose of sensing stratum boundries. Copending Bryan patent application No. 07/522,467 teaches the use of a moldboard/skid plate assembly which is inherently positioned to follow the digging depth of a forwardly mounted excavating means, facilitating the use of the moldboard as a reference location for mounting such probes. Thus, the contact velocity of the probes is the forward travel rate of the excavator.
The previously mentioned Satterwhite type excavators, with their ability to travel on the floor of the trench, leave standing on the floor an undisturbed portion of the formation which passes between the digging wheel sections. This allows moldboard mounted probes to be positioned to penetrate virgin material that is above as well as below the nominal floor level.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a track mounted bucket wheel type excavator utilizing the present invention.
FIG. 2 is a detailed side view of the moldboard/skid plate assembly of FIG. 1 showing a preferred embodiment of the present invention.
FIG. 3 is a detailed front view of the moldboard/skid plate assembly of FIG. 1 showing a preferred embodiment of the present invention.
FIG. 4 is a detailed front view of the moldboard/skid plate assembly of FIG. 1 showing a second embodiment of the present invention.
FIG. 5 is a detailed front view of the moldboard/skid plate assembly of FIG. 1 showing a third embodiment of the present invention.
FIG. 6 is a detailed cross section view of a probe.
FIG. 7 is an enlarged detail view of that portion of the cross section of FIG. 6 showing the electrical contact pick-up means.
FIG. 8 is an enlarged detail view of that portion of the cross section of FIG. 6 showing the piezoelectric pick-up means.
FIG. 9 is an enlarged detail view of that portion of the cross section of FIG. 6 showing the microphonic pick-up means.
FIG. 10 shows the display of resistivity as seen by the excavator operator when digging coal with the probe means mounted on the moldboard assembly as shown in FIG. 2.
FIG. 11 shows the display of bit vibration or sound as seen by the excavator operator when digging at the lower boundary of a seam of coal with the probe means mounted on the moldboard assembly as shown in FIG. 2.
FIG. 12 shows the display of compressive strength as seen by the excavator operator when digging at the lower boundary of a seam of coal with the probe means mounted on the moldboard assembly as shown in FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
While the present invention is capable of application to a variety of excavating machine designs, it is particularly suited to those adapted for control of the excavated grade in accordance with copending Bryan patent application Ser. No. 07/522,467, however, the invention is not so limited and can be used on any suitable excavator application where strata interface sensing is required.
A preferred embodiment of the present invention is used with a continuous excavator as shown in FIG. 1. The excavator 100 has a vehicle main frame 22 with an operator cab 24 mounted thereon and a digging wheel 10, rotating in a clockwise or undercutting sense as shown by arrow R, mounted to the front end thereof. The digging wheel 10 is made in portions that straddle extensions of the frame 22. The excavator 100 is supported on an undercarriage 14, which is attached to the main frame 22 for vertical movement by means of right and left front hydraulic cylinders 34 and 35 and right and left rear hydraulic cylinders 36 and 37. A moldboard and skid plate assembly 40, incorporating the present invention, is mounted to the main frame 22 immediately behind the digging wheel 10 to clean the floor of the excavation.
Lateral conveyors 42 and 43 are mounted adjacent the digging wheel 10 to receive material discharged from the outer portions thereof for transfer to the central main conveyor 44. Any shortfall is directed by the crumbing plate 45 so that it falls in front of the moldboard and skid plate assembly 40 and is recirculated. The discharged material is carried by the main conveyor 44 to the chute 46 at the rear of the machine where it is transferred to the slewing load conveyor 48 which off-loads the material as required by a given application.
FIGS. 2 through 5 show how, in the invention, lower probe means 52 are fixed to the moldboard blade 60 so as to penetrate slightly below the plane 70 cut by blade edge 60 into the underlying material 92 as material 90 is excavated. Similar upper probe means 54 are positioned in the gaps between the digging wheel 10 portions, where they are placed slightly above the surface 70 cut by digging wheel 10 and the moldboard blade 60 and sufficiently in advance of the moldboard blade 60 so as to contact undisturbed material 90' (unshown in FIG. 2), left between portions of digging wheel 10.
FIGS. 3, 4 and 5 show alternate embodiments of the probe means of FIG. 2. In FIG. 3, lower probe means 52A are shown to comprise closely spaced pairs of probe inserts 80 near each outboard end of moldboard blade 60. Upper probe means 54A are shown to comprise similar pairs of probe inserts 80 located on that portion of moldboard blade 60 that contacts the undisturbed material 90'. Pairing of the inserts 80 in this manner is most suitable for determination of electrical properties of a stratum such as resistivity or capacitivity since readings can be taken across a stable fixed dimension. It also is useful for the other property measurements in that more data signals allow averaging for enhanced reliability.
FIG. 4 shows a second alternate arrangement wherein upper and lower probe means 54B and 52B are shown to comprise single probe inserts 80, with the locations on the moldboard blade 60 as in FIG. 3. This arrangement is less suited to measurement of the electrical properties of the strata, but is suitable for sound or vibration and compressive strength data. Such property data signals from each probe insert 80 are monitered and the readings from upper and lower probe means 54B and 52B then matched to the known properties of the upper and underlying strata respectively by adjusting the digging depth of the excavator 100.
FIG. 5 shows a third alternate arrangement wherein the combined probe means 52/4C, positioned in the gaps between digging wheel 10 portions, comprise inserts 80 in closely spaced pairs arrayed vertically so that the lowermost inserts 80 penetrate slightly below the plane 70 cut by moldboard blade 60 into the underlying material 92. The uppermost probe inserts 80 are placed above the surface 70 cut by digging wheel 10 and the moldboard blade 60 and contact the undisturbed material 90' left between portions of digging wheel 10. This arrangement is adaptable to measuring any of the aforementioned property data. When working with resistivity the digging depth is adjusted to keep the measured resistivity value in between the known strata values. When both vertically arrayed inserts 80 penetrate the same formation, the indication is for the known resistivity value of that stratum and an appropriate grade correction is made. When working with sound, vibration or compressive strength, digging depth control is the same with this arrangement as it is for that of FIG. 4.
Caride tipped replaceable rock bits of a standard type such as the No. 1-93 by THE BOWDIL CO. of Canton, Ohio are preferred as replaceable probe inserts 80. FIG. 6 shows such an insert 80 mounted by means of a high strength plastic bushing 85 in socket 82, made so that the shank end 81 of the insert 80 is isolated mechanically and electrically from socket 82. The shank 81 of insert 80 is thus protected and accessible for contact with a pick-up means 86. By in this manner, direct contact of insert 80 with the material being excavated allows property data signals to be sensed by pick-up means 86 and transmitted by insulated wire 84 to remote measurement and display means 95. The insert 80 is held in place and urged against pick-up means 86 by retainer 88 and the housing 82 is mounted to the moldboard blade 60 by means of bolts (not shown), thus providing access for replacement of parts. Upper probe means 54A, 54B and 54C are functionally identical to lower probe means 52A, 52B and 52C respectively, differing only in shape and position.
The remote measurement and display means 95 is adapted to display the readings from the lower probe means 52 and the upper probe means 54 side-by-side for comparison, as on a split screen CRT, so that any required digging depth adjustment is readily apparant to the operator.
FIGS. 7-9 are enlarged views of the circular area D designated in FIG. 6, showing alternate forms of pickup means 86 comprising an electrical contact 86A as shown in FIG. 7, a microphonic device 86B as shown in FIG. 8 and a piezoelectric device 86C as shown in FIG. 9. The electrical contacts 86A are pick-up means suitable for evaluation of electrical properties, such as resistivity or capacivity of a material, the microphonic device 86B for evaluation of the penetration sound or vibratory "signature" of materials, and the piezoelectric device 86C for evaluation of the penetration force, hence compressive strength of a material.
FIG. 10 shows the measurement and display means 98A, a split screen CRT, showing a value base line 96. Lower probe means 52A transmit data signals to be measured and displayed on the left hand side of the screen of 95A as resistivity trace 97, in this case having an intermediate value typical of sandstone parting materials. Upper probe means 54A transmit data signals to be measured and displayed on the right hand side of the screen of measurement and display means 95A as resistivity trace 98, which shows a significantly higher value typical of lignite.
So long as the values displayed by trace lines 97 and 98 remain as shown, the excavator 100 is taking the full depth of the lignite stratum with minimal intrusion into the underlying sandstone.
As an example of the operation of the preferred embodiment of the invention, the excavator 100 is set to dig on a descending grade, making an increasingly deeper cut, until the outermost, lower probe means 52A register a changing of resistance to a different value from that registered by the upper probe means 54A. The grade is then reduced and corrected until the resistance values are stabilized, with the lower and upper means penetrating the different strata, and picking up distinctly different resistance readings. From then on, whenever the lower and upper resistance readings become similar the value will indicate whether a positive or negative grade correction is needed. The procedure is virtually the same whether mining product or removing parting material except for a reversal of the grade correction response. A machine operator will soon become skilled in responding to these indications, or if desired, a grade control response sequence can be programmed for computerized stratum boundary excavation.
The depth control technique is much the same regardless of the material property used to distinguish the stratum boundary. FIG. 11 shows the split screen measurement and display means 98B. Lower probe means 52B, with microphonic pick-up means 86B, send noise and vibration signals to be measured and displayed on the left hand side of the screen of measurement and display means 95B as vibratory trace 101, the frequency and intensity of which are characteristic of abrasive sandstone. Upper probe means 54A send noise and vibration signals to be measured and displayed on the right hand side of the screen of measurement and display means 95B as vibratory trace 102, the frequency and intensity of which (showing a significantly reduced amplitude and frequency), are characteristic of coal. Amplitude of these traces relates roughly to the material hardness while frequency relates roughly to the abrasive characteristic of the material. Again, so long as trace lines 101 and 102 remain as shown, the full depth of the coal stratum is being excavated with minimal intrusion into the underlying sandstone.
FIG. 12 shows the split screen measurement and display means 95C, again showing a value base line 96. Lower probe means 52C, with piezoelectric pick-up means 86C, transmit data signals to be measured and displayed on the left hand side of the screen of measurement and display means 95C as compressive strength trace 103, in this case having a rather high value typical of sandstone parting materials. Upper probe means 54C transmit data signals to be measured and displayed on the right hand side of the screen of measurement and display means 95C as compressive strength trace 104, which shows a significantly lower value typical of coal.
So long as the values displayed by trace lines 103 and 104 remain as shown, the excavator 100 is taking the full depth of the coal stratum with minimal intrusion into the underlying sandstone.
It will be understood that the invention is not limited to the disclosed embodiments, but is capable of rearrangement, modification, and substitution of parts and elements without departing from the spirit of the invention. | Probes attached to the moldboard blade penetrate in situ formations while digging with a continuous excavator, thus enabling the direct and simultaneous sensing of characteristic strata property data signals both above and below the digging depth of the excavator. The data signals are evaluated to provide a reference for control of the digging depth so that product contamination by parting material can be minimized while mining, as well as the loss of product while removing the parting material. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of and claims priority to patent application Ser. No. 11/677,642, filed on Feb. 22, 2007, entitled “Fluid Nutrient Delivery System and Associated Methods,” which itself is a continuation-in-part of patent application Ser. No. 11/126,073, filed on May 10, 2005, entitled “Irrigation System and Associated Methods,” now U.S. Pat. No. 7,198,431, which itself claims priority to provisional application Ser. No. 60/569,262, filed on May 10, 2004, entitled “Irrigation System,” all of which are incorporated by reference hereinto.
FIELD OF INVENTION
The present invention generally relates to systems and methods for watering and supplying nutrients to plants, and, in particular, to such systems and methods for minimizing water use and maximizing potential crop density by delivering water and nutrients “on demand.”
BACKGROUND
The need for a self-watering system for plants is well established, since agriculture utilizes approximately 70% of the world's fresh water resources, and many products have been designed and built to satisfy this need to varying degrees. Some systems supply a small continuous amount of water, often referred to as drip irrigation or trickle irrigation, which supply water to the root zone irrespective of the plants' needs. Other systems rely on the moisture level in the soil to signal the need for water. Still others use wicks that bring water to the plant as a result of surface tension and the capillary rise effect.
Drip irrigation or trickle irrigation is a well-established method of growing crops in arid areas. It is claimed to be 90% efficient in water usage compared to 75-85% for sprinkler systems. The basic drip irrigation system generally consists of a surface tube from which small dripper tubes/emitters are fitted to take water from the supply tube to the roots of the plant on either side of the supply tube. The dripper tube/emitter limits the flow of water to the roots drop by drop based on the viscous resistance to water flow within the emitter/dripper tube. The drip rate is determined by the calculated needs of the specific plants, the soil conditions, anticipated rain fall, and evapotranspiration rate, and can vary from 1 to 4 L/hr per plant.
The need to estimate the water requirements of the crops or the amount of nutrients to be supplied in the water is seldom exact and invariably leads to wastage of water. It was shown that the roots of plants can control the release of water that is stored behind a thin porous hydrophilic membrane that is believed to become hydrophobic due to the adsorption of organic impurities in the water. The mechanism is not fully understood, though it has been speculated that among the root exudates is a surfactant that opens the pores of the membrane that became hydrophobic due the adsorbed organic impurities in water. The hydrophobic membrane inhibits the flow of water to the plants. However, the roots of the plants exude a variety of chemicals that include a surfactant that open the pores of the membrane by making it hydrophilic. Thus water can now flow to the roots and the membrane becomes hydrophobic when the plant has had enough water.
It has also been shown that when two reservoirs (one with water and the other containing nutrient solution) with membranes are presented to a plant, the plant can distinguish between the two sources, taking as much water as it needs and as much nutrients as it requires. The ratio of water to nutrient can vary from 2-5 to 1 depending on the concentration of the nutrient solution.
Several sub-surface systems have been developed that include tubes that are porous or are perforated to permit the continuous slow release of water. However, these hydrophobic tubes, which require a water pressure of up to two atmospheres, do not automatically stop the delivery of water when the plants have had enough or, for example, when it rains.
One possible reason for the absence of a commercial irrigation system using the membrane system may be the difficulty of obtaining a membrane that can supply the necessary amount of water for new plants or seedlings as well as a fully grown and mature plant that is sprouting and producing fruit and produce. Another possible reason may be the reliance on constant trace amounts of organic solutes in the water, which become adsorbed on the exit walls of the hydrophilic pore channels of the membrane, converting the membrane into a hydrophobic system, which then stops or greatly reduces the flow of water through the membrane. Another reason may be the difficulty of obtaining hydrophilic tubes of suitable wall thickness and diameter that are sufficiently durable to make the process economical.
The Russian SVET space plant growth system consists of a box greenhouse with 1000 cm 2 growing area with room for plants up to 40 cm tall. The roots were grown on a natural porous zeolite, with highly purified water keeping the roots at the required moisture level. Zero-gravity growth chambers used by NASA have included a microporous ceramic or stainless steel tube through which water with nutrient is supplied to irrigate the greenhouse plants. Systems using porous ceramic, stainless, or hydrophobic membranes to deliver water and/or nutrients to plants are basically a form of drip irrigation where the water/nutrients are always delivered whether the plants need it or not. As will be apparent to one of skill in the art, the ceramic or stainless tubes are thicker and the organic components are adsorbed onto the full length of the channels and cannot be removed by the plant's exudates.
FIG. 7 shows the flow of water and nutrient solution for a single plant. FIG. 7 , in particular, is a daily record of water flow (in mL/day) through 12 cm 2 of microporous Amerace A-10 fitted to the bottom of two 285-mL identically sized and shaped reservoirs (No. 1 for water and No. 2 for nutrient solution) that were embedded in the potting soil of a well-established Ficus indica (insert), showing the effect on the pattern of water flow when (i) root contact with the membrane was established, and (ii) when the total flow ceased to be greater than the rate of water uptake (after day 24 ). In general, the flow of water is about three times larger than from nutrient solution. It has been shown that a change in the concentration of the nutrient alters the ratio of flow from the two reservoirs. In FIG. 7 , the exudates from the plant's roots convert step 3 back to step 1 in FIG. 8 . This has been shown in an experiment by allowing a membrane to close after a specified volume of water was passed through an Amerace-10 membrane. The exit side of the membrane was then washed with alcohol and the water flow through the membrane resumed and eventually stopped when all the alcohol was washed away and the organic impurities were allowed to be adsorbed onto the exit wall of the pores shown in FIG. 8 .
Again referring to FIG. 8 , in step 1 , as water leaves the pore of the membrane, it spreads out onto the membrane's surface, which is hydrophilic. A large drop forms and leaves the surface. As the surface becomes coated by the adsorbed hydrophobic impurities in water, the water leaving the capillary pore of the membrane cannot spread out over the surface and a smaller drop can be formed (step 2 ). When further coating continues, there is no room for the water to spread out onto the surface and a greater force is required to push the water through the hydrophobic area shown in step 3 . The membrane is converted from the hydrophilic state to a hydrophobic state. It is made hydrophobic by the adsorption of the organic impurities in the water and/or nutrient solution. This closes the pores and prevents water from leaving the membrane under the prevailing pressure conditions. If the pressure is increased, it becomes possible for the liquid to flow again because the surface tension of water no longer can prevent the water from breaking through the pores.
SUMMARY OF THE INVENTION
The present invention is directed in one aspect to a system for efficiently delivering an aqueous solution to plants. The system comprises hydrophilic means having a distal portion positionable adjacent a root system of a plant. The hydrophilic means have a lumen therethrough for channeling an aqueous solution from an inlet to the distal portion. The hydrophilic means further have a wall encompassing the lumen. At least a portion of the wall along the distal portion has a porosity adapted for permitting a flow of the aqueous solution therethrough when acted upon by a surfactant root exudate generated by the plant roots' experiencing water stress.
The system also comprises a reservoir that is adapted for holding the aqueous solution therein. The reservoir is situated in fluid communication with the hydrophilic means inlet.
The present invention is also directed in another aspect to a method for efficiently delivering an aqueous solution to plants. This aspect of the method comprises the step of positioning a distal portion of hydrophilic means adjacent a root system of a plant as described in the system above. The aqueous solution is introduced into an inlet of the hydrophilic means, and the aqueous solution is channeled from the hydrophilic means inlet to the distal portion.
The present invention is further directed in another aspect to a method for establishing an efficient system for delivering an aqueous solution to plants. This aspect of the method comprises the step of positioning a distal portion of hydrophilic means adjacent a root system of a plant, as described above.
A reservoir for holding the aqueous solution therein is provided, with the reservoir in fluid communication with an inlet of the hydrophilic means. A channel is also provided for establishing a flow of the aqueous solution from the reservoir to the hydrophilic means inlet.
The features that characterize the invention, both as to organization and method of operation, together with further objects and advantages thereof, will be better understood from the following description used in conjunction with the accompanying drawing. It is to be expressly understood that the drawing is for the purpose of illustration and description and is not intended as a definition of the limits of the invention. These and other objects attained, and advantages offered, by the present invention will become more fully apparent as the description that now follows is read in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1A and 1B illustrate a dual irrigation tube for supplying water and nutrient to plant roots, in top plan view and cross-sectional view, respectively.
FIG. 1C is a cross-sectional view of tubing having a supporting spiral inserted thereinto.
FIG. 2 is a cross-sectional view of a system for irrigating grass.
FIG. 3 illustrates an exemplary system for growing plants that is operable in a gravity-free environment.
FIG. 4 is a side perspective view of an embodiment of a tube having holes covered with a hydrophilic membrane.
FIGS. 5A and 5B illustrate a growth system that includes both surface and subsurface portions, in top plan view and cross-sectional view, respectively.
FIG. 6 is a chemical diagram of polyhydroxystyrene.
FIG. 7 (prior art) graphs the flow of water and nutrient solution for a single plant. (•), Water uptake from reservoir No. 1; (∇), nutrient uptake from reservoir No. 2. (From L. A. Errede, Ann. Botany 52, 22-29, 1983.)
FIGS. 8A-8L (prior art; collectively referred to as FIG. 8 ) are schematic representations of water flow through a microcapillary pathway of a microporous membrane as a function of the extent of hydrophilic area that surrounds the microcapillary outlet, and show how the organic impurities in water are more likely to stick at the exit end of a capillary. In step 1 ( FIGS. 8A-8D ) is shown the initial hydrophilic state of the area that surrounds the microcapillary outlet. D 1 is the diameter of the hydrophilic area, and R 1 is the radius of the drop emerging from the outlet, which is much greater than r, the radius of the microcapillary outlet. Step 2 ( FIGS. 8E-8H ) occurs after some accumulation of hydrophobic solutes at the outer perimeter of the hydrophilic area that rings the microcapillary outlet. Here D 1 >D 2 >2r, and R>R 2 . Step 3 ( FIGS. 8I-8L ) is the ultimate end state when the diameter D f of the hydrophilic area that surrounds the outlet shrinks to twice the radius r of the outlet. Water flow at a given outlet stops when ΔP=2y/R f becomes greater than P f , the applied pressure, where γ is the surface tension of the water. (From L. A. Errede, J. Colloid Interface Sci. 100, 414-22, 1984.)
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A description of the preferred embodiments of the present invention will now be presented with reference to FIGS. 1-8L .
As used herein, the words “tubes” or “tubing” refer to supply lines for providing water and/or nutrients. As will be appreciated by one of skill in the art, such “tubes” or “tubing” do not necessarily need to be cylindrical, but may be of any suitable shape, and no limitation is intended by the use of these words.
Described herein are a system and method of supplying water and/or nutrients to the roots of growing plants wherein the water and/or nutrients are released to the plants as needed by the individual plants. Herein the term “plants” should be construed broadly, and can include, for example, grasses. Although not intended as a limitation on the invention, it is believed that when under water stress, plant roots can emit exudates or surfactants that promote the release of water and/or nutrients stored under the conditions described below. Specifically, the plants are supplied water and/or nutrients from supply lines or feeder tubes, at least portions of which are hydrophilic.
In some embodiments, the tubing may include a plurality of holes that are covered by hydrophilic membranes; in other embodiments, the entire tubing, the below-surface portion thereof, or a significant portion thereof is hydrophilic. In yet other embodiments, the system may include a surface tube that is water-impermeable or hydrophobic, the tube being connected to a plurality of hydrophilic tubes that can be inserted into a support medium for supplying the roots.
One or more hydrophilic tubes may be inserted into a quantity of support medium such that the tubes are at least partially below the surface of the support media. The support media may be selected from any suitable medium or mixture of media suitable for supporting growing plants and roots. Examples, which are not intended as limitations, of such support media can include sand, soil, Rockwool, polyurethane foam, Fleximat™, SRI cellulose-based growth media, and the like. Other suitable media known in the art, such as continuous-fiber growth media, may also be used.
In particular embodiments, plants are planted in the support medium and the respective tubes are connected to reservoirs containing water, nutrients, or a mixture thereof. In some embodiments, two tubes may feed a row of plants: a water tube and a nutrient tube. As discussed above, it has previously been shown that the plants are capable of distinguishing between these tubes. Alternatively, nutrient(s) can be added to a water reservoir for distribution through a unitary tube.
Thin-walled microporous hydrophilic tubes are not known at present to be commercially available for use as irrigation tubing. In a particular embodiment, hydrophilic materials, including Cell-Force™ and Flexi-Sil™, may be made into hydrophilic tubes. Alternatively, some existing hydrophobic thin-walled tubes can be made hydrophilic by a process that uses a water-insoluble hydrophilic polymer (e.g., polyhydroxystyrene, U.S. Pat. No. 6,045,869, incorporated herein by reference; structure illustrated in FIG. 6 ) as a surface coating. Such solutions applied as a coating to and impregnated with microporous hydrophobic plastic tubing have been shown not to clog the pores and to remain hydrophilic for many years. Thus continuous tubes of Tyvek® (a microporous polyethylene material made from very fine, high-density polyethylene fibers, DuPont, Richmond, Va.) in a radius of 5-10 mm (Irrigro-International Irrigation Systems) have been used after being made hydrophilic and have been shown to act as a membrane that is responsive to the roots of plants in a subsurface irrigation system.
Tyvek® is available in a plurality of styles, each having different properties. Although not intended to be limiting, two particular types have been found to be most beneficial for use in the present invention: 1059B and 1073B.
As discussed above, it has been shown that hydrophilic membranes can become hydrophobic over time owing to organic impurities in the water adsorbed onto the membrane. Because of the variability of the impurities in water, we have added organic substances to the water which can be adsorbed onto the exit pore walls, making the membrane hydrophobic, and thereby reducing the flow of water or nutrient solution through the membrane. Examples of suitable organic substances include, but are by no means limited to, humic acid, kerosene, turpentine, pinene, paraffin, and hexadecane. In other embodiments, other suitable C8-C16 saturated hydrocarbons may be used. The amounts added ranged from 10 ppb to 10 ppm to the irrigating medium. As will be appreciated by one of skill in the art, in some embodiments, the addition of the organic substance may not be essential, depending on the quality of the water.
When growing crops in soil, the addition of nutrient on a continuous basis is not essential; however, when growing crops in sand, Fleximat, or Rockwool, a nutrient solution, for example, any suitable nutrient solution known in the art such as those commonly used in hydroponic systems, e.g., Hoegland Solution, Peter's Solution, Miracle-Gro, or other less dyed fertilizer such as Schultz Export may be added to the water supply or may be fed directly to the plants in a separate tube, as described above, and thus the roots of the plant can be allowed to take as much water and nutrient as required. However, for growth in artificial media the inclusion of nutrients and micronutrients is important.
FIGS. 1A and 1B illustrate a system 10 that uses twin irrigation tubes 11 , 12 for delivering water and nutrient solution to plants 13 growing in a growing medium 14 . In this embodiment 10 , the tubes 11 , 12 are running through the root systems 15 of the plants 13 . It has been found in experiments in both sand and potting soil that the higher the concentration of nutrients used, the smaller the volume of the nutrient solution that is released to the roots 15 , which is illustrative of the water conservation achieved by the current invention.
It will be understood by one of skill in the art that the tubes 11 , 12 could be provided as a single composite double-lumen tube without departing from the spirit of the invention. The diameters of the two portions could be in a proportion commensurate with a plant's requirements for water versus nutrient, for example, double the size for the water tube, although this is not intended as a limitation.
In some embodiments, since subsurface thin-walled microporous tubing can be collapsed if sufficient pressure is applied, a spiral 60 comprising, for example, plastic, can be incorporated into a tubing such as tubing 11 or 12 to form a tube 61 that is more resistant to collapsing ( FIG. 1C ).
FIG. 2 illustrates a system 20 for the irrigation of grass 21 where the subsurface tubes 22 are spaced 1-2 feet apart and are substantially continuously fed with water under low constant pressure, with nutrients added to the aqueous solution as desired.
The irrigation systems and methods described herein are believed superior to any other watering system currently in use, and further are independent of atmospheric pressure, making them usable for astroculture or micro-gravity conditions, as well as others. In one embodiment of the invention 30 ( FIG. 3 ), for example, a continuous fiber growth medium 31 such as Rockwool or the spongy Fleximat (from Grow-Tech) can be used to support the plants 32 and their roots 33 . In this embodiment 30 , both of the reservoirs 34 comprise a container 35 that has an interior space 36 for holding the water and nutrient solution therein. The containers 35 are formed similar to a bellows, and are movable between an expanded state when containing solution and a retracted state when solution has been removed.
The containers 35 also comprise a filling inlet 37 that is in fluid communication with the containers' interior space 36 for adding solution thereto. Distribution tubes 38 are also in fluid communication with the containers' interior spaces 36 and with inlets 39 of the hydrophilic tubes 40 . This arrangement provides solution to the tubings' lumina 40 . The distribution tubes 38 also have check valves 41 therein for preventing backflow of solution from the tubes 40 toward the containers' interior spaces 36 .
Support for plants and their roots can be provided for in the present system under zero gravity, for example, with the use of a monolithic contiguous material such as Rockwool or Fleximat, a spongy hydrophilic porous material made by Grow-Tech or the newly developed artificial sponge such as, for example, Agri-LITE (SRI Enviro-Grow). By using these materials to surround twin microporous hydrophilic irrigating tubes, one supplying water while the other supplying a nutrient solution, it is possible to achieve complete conservation of water and nutrients supplied to growing plants. Such a system can also be applied to arid or desert environments where water conservation is desirable.
Early laboratory tests showed that using nutrients in water, it was possible to grow tomatoes in sand with Amerace A10 membranes 42 (50% silica gel in polyethylene) glued over holes 43 in a subsurface PVC tube 44 ( FIG. 4 ). The holes 43 in the PVC tube 44 were 12 mm in diameter, spaced 10 cm apart, drilled in 17-mm-ID rigid PVC tubing. The holes 43 are believed to have limited the amount of water and nutrient available to the growing plant, and the system proved to be inadequate when the plants began to bear fruit and needed more membrane area to supply the plants' requirements. Increasing the total surface area of the membrane by drilling and covering more holes improved the system. However, a best mode of practicing the invention at the present time favors the use of a continuous tube. Because of the brittle nature of Amerace, membrane tubes made of this material tended to crack and leak.
Tyvek® (DuPont) in tube form has been used for irrigation purposes under elevated water pressure for gardens and row crops. However, the hydrophobic nature of the polyethylene material permits it to act as a drip source of water for plants without any control by the exudates of the plant roots. The conversion of a hydrophobic surface to hydrophilic has been described (U.S. Pat. No. 6,045,869) and can be used to make Tyvek® tubing hydrophilic and responsive to the water and/or nutrient needs of the plant. When the tubing has been made hydrophilic by coating and impregnating it with an alcohol solution of polyhydroxystyrene, the tubing was found to be permeable to water at much lower pressures, and showed a decrease in water permeability as the organic compounds in water are adsorbed onto the exit pore walls. This can be considered a “conditioning phase,” during which permeability can be decreased by as much as 80% by the addition of hydrocarbons to the tap water.
The present invention is believed to be the first to provide a plurality of feeding tubes arranged to extend beneath the surface of a support medium to feed a plurality of plants or a row of plants. Furthermore, a clear advantage of tubes comprising a hydrophilic material is that a greater area of the support medium is fed water and nutrients compared to a single horizontal membrane.
The invention will now be described by way of examples; however, the invention is not intended to be limited by these examples.
Example 1
A 4 ft. length of Tyvek® tubing (#1053D) was made hydrophilic with an alcoholic solution of polyhydroxystyrene and submerged in a 4.5 ft by 13 cm wide by 10 cm deep planter, covered with soil and connected to a constant supply of nutrient solution at a constant head of 35 cm of water. Ten cherry tomato (Lycopersicon sp.) seedlings were planted at even distances next to the tube where water and nutrients were supplied. Fluorescent lighting was supplied to the plants for 18 hours per day. The average consumption of water was 75±10 mL/hr when the plants were 15 cm high and 125±20 mL/hr when the plants were 25 cm high. When rainfall was simulated by spraying the bed with 100 mL of water, the consumption of water dropped to zero for 2 hours and slowly over the next 3 hours returned to the normal rate. The plants grew to two feet in height, and numerous tomatoes were harvested.
At the end of the experiment, the system was examined to determine if there was any competition between the plants for space on the membrane. An examination of the root system indicated that the roots encircled the membrane only within about 1-2 inches from the plant stem. This indicates that it should be possible to increase the density of plant growth to an extent that would only be limited by the photochemical flux available and mutual interference.
When a dual-tube system was used to supply both water and nutrient separately, the ratio of water consumed to nutrient solution consumed was approximately 2.5 to 1 for 8 cherry tomato plants in sand. Again, little or no fluctuations were observed when the size of the plants reached a height of 35 cm.
Example 2
A continuous irrigation tube can be unnecessary for plants such as grape vines or kiwi vines that are spread apart from each other by distances as much as 20 to 40 cm. In these situations 50 , it is more practical to use a main flexible surface distributing tube 51 of from 20-30 mm ID, out of which are drawn satellite tubes 52 that feed a short length of from 10 to 30 cm, depending of the size of the vine, of thin-walled microporous hydrophilic irrigating tube 53 , closed at its end 54 , surrounding the roots 55 of the vine or bush 56 , as illustrated in FIGS. 5A and 5B .
Example 3
A tomato plant was planted in potting soil, into which was also placed two 20-cm-long microporous hydrophilic tubes of 1 cm radius. The tubes were connected to reservoirs of water and nutrient which were kept full. The soil remained dry while the plant grew to produce numerous tomatoes.
Example 4
Another experiment was conducted with Tyvex® tubing (#1053B), 1.25 m long and 1 cm radius. The tubing was sealed at one end that was made hydrophilic with a 3% solution of polyhydroxystyrene (Novolac grade from TriQuest) in ethanol. The tubing was submerged in a 1.4-m planter, covered with soil, and connected to a supply of nutrient solution at a constant head of 35 cm of water. Ten cherry tomato (Lycopersicon sp) seedlings were planted at even distanced next to the tube, by which water and nutrients were supplied. The plants grew during the conditioning phase while exposed to fluorescence lighting for 16 hr/day. The average consumption of water was 75±10 mL/hr when the plants were 15 cm in height and 125±20 mL/hr when the plants were 25 cm in height.
Rainfall was simulated by spraying the bed with 100 mL water, following which the consumption of water dropped to zero for 2 hours and then slowly, over the next 3 hours, returned to the normal rate.
The plants grew to 60 cm in height, and an abundance of tomatoes was harvested. At the completion of the experiment, the system was examined to determine if there had been any competition between the plants for space on the membrane. An examination of the root system indicated that the roots encircled the membrane only within about 2.5-5 cm from the plant stem. This finding would seem to indicate that it should be possible to increase the density of plant growth to a level only limited by the light flux available and mutual interference.
It has also been shown that different plants requiring different rates of water and nutrient can grow together with each being satisfied individually without monitoring.
Example 5
When a dual membrane system was used to supply both water and nutrient separately, the ratio of water consumed to nutrient solution consumed was approximately 2.5 to 1 for 8 cherry tomato plants in sand. Once again, there was little or no fluctuation observed when the size of the tomato plants reached a height of 35 cm.
A planter 115 cm long, 13 cm wide, and 10 cm deep, was set up in a greenhouse with dual-feed membrane tubes for water and nutrient through the center of a bed comprising 50 cm of Flexmat and 50 cm of rockwool separated by 15 cm of polyurethane foam. The seeds or seedlings of canola ( Brassica sp), beans ( Phaseolus sp), corn ( Zea Mays sp), and tomatoes ( Lycopersicon sp) were planted in each of their respective media and their growth patterns observed. Growth, which was favored in the Fleximat, proceeded normally, except for the polyurethane foam, with each crop growing at its own rate under a light flux of 50-60 mW/cm 2 . Root crops such as carrots ( Daucus carota var sativa sp), radishes ( Raphanus sativus sp), beets ( Beta vulgaris sp), and onions ( Allium sp) were grown in soil and peat, while potatoes ( Solanum tuberosum sp), parsnips ( Pastinaca sativa sp), and parsley ( Petroselinum sativum var tuberosum sp) were grown successfully in vermiculite. A cellulose material (SRI Petrochemical Co.) can also be used as an artificial growth medium.
It was determined that grass ( Gramineae sp) can be successfully irrigated for 3 successive years with submerged tubular membranes spaced 40-50 cm apart.
Example 6
In another case, two hydroponic planters (30×30×30 cm) were fitted with a membrane tube for a water/nutrient solution approximately 7 cm from the bottom. The media comprised a soil-less mixture approximately 25-26 cm deep in the planters. This depth allowed the root crops to produce straight tap roots, which is of concern to consumers when purchasing vegetables. One planter was seeded with parsnips ( Daucus carota var. sativa sp). The other planter was seeded with parsley ( Petroselinum sativum var. tuberosum var. tuberosum sp), a dual-purpose crop of foliage and root stocks. Plant competition controlled the over-seeding issue with each planter. The plants received only natural sunlight, reducing the risk of “bolting.” Extreme warm temperatures were a concern for the health of the plants.
The parsnip roots were straight in growth, and produced a total weight of 38.9 g. The texture and flavor were excellent. The parsley produced straight tap roots, giving a total weight of 38.3 g. The foliage produced had longer petioles than usually purchased, yet the total weight was 58.9 g.
It will be appreciated by one of skill in the art that plants with varying water requirements can be satisfied by the embodiments of the present invention, wherein one continuous porous hydrophilic irrigating tube is used to allow each plant to take its water requirements independently of the other plants. Such requirements are often needed in greenhouses, where many different plants are cultivated under one roof.
It has also been shown that a hydrophilic irrigation tube with two channels, one for water and the other for nutrients, can fully satisfy the plants' requirements and also increase the density of the plants, limited only by the sunlight available.
It has also been shown that commercially available thin-walled microporous hydrophobic tubes can be converted to hydrophilic tubes and thereby become responsive to plants and their roots. Such tubes may include, but are not intended to be limited to, high-pressure irrigation hoses, although their use in the present invention does not require the use of high pressure.
It has also been shown how a dual-membrane tube can be incorporated into a container for one or more plants so that the plants can be fed on demand both water and nutrients from separate reservoirs and thereby require no attention or supervision as long as there is water available in the tube reservoirs. In a particular embodiment, a diametric ratio of 3:1 for the water tube over the nutrient tube is optimal, although this is not intended as a limitation, and obviously is dependent upon nutrient concentration and plant type.
It has additionally been shown that water systems that are free of contaminated organic substances and unresponsive in the irrigation system can, by the addition of trace amounts of one or more hydrocarbons to the water supply, become responsive to the irrigation system.
It has also been shown that the irrigation system of the present invention can be used to replace the emitter in a drip irrigation system, thereby making the release of water and/or nutrient responsive to the roots. In a particular embodiment, a factor of from 100 to 500 has been found for the difference in water volume used between the known drip irrigation systems and that of the present invention.
Sectors of grass are known to be grown substantially in isolation, for example, on golf courses wherein the greens are formed within soil-filled depressions in the ground and continuously or at predetermined intervals fed with water and nutrients. In such an arrangement, the system of the present invention can ideally provide water and nutrients to the grass roots on an on-demand basis, thereby saving both water and nutrients, and also ensuring optimal sustenance of the greens.
The following Tables 1-4 include data on experiments conducted indoors (Table 1) and outdoors (Table 2), and the flow rates for water and nutrient (Table 3) and for watering results in series and for single plants (Table 4).
TABLE 1
Indoor experimental conditions
Growth
Plant
medium
Feed
Comments
Cherry tomatoes
Soil, sand,
Tap water; nutrient
Greenhouse
vermiculite,
and water a
peat,
Rockwool,
Fleximat d
Radishes, lettuce,
Soil b
Dual tubes
Greenhouse
carrots, tomatoes,
beets, onions,
spinach
Parsnips, parsley,
In separate pots
Nutrient feed
Greenhouse in
potatoes
with
deep pots
Beans c , tomatoes,
vermiculite
Nutrient feed
In greenhouse
canola
Rockwool and
FlexiMat
a Two separate feed lines for water and nutrients.
b Beets did not mature, although the leaves were abundant.
c Bean roots appear to crawl all over the planter and throughout the growth media.
d The system was a model for the growth of plants in the International Space Station.
TABLE 2
Outdoor experimental conditions
Plant
Growth medium
Feed
Comments
Zucchini, garlic,
Soil
Water
Garden, good
melons, tomatoes,
results
eggplant, corn a
Grass b
Soil
Water
Visible
improvement
Strawberries
Peat and FlexiMat
Vertical plant
Indoors and
nutrient
outdoors
a Corn, melons did not take and grow.
b Spacing of irrigation tubes of 1. 1.5, and 2 ft (40-50 cm, 10 ft long).
TABLE 3
Test of Rockwool and FlexiMat in series for Astroculture a
Test No.
Flows, side A
Flows, side B
Flow Ratio, W/N
1
W 19
N 4.8
4.2
2
N 20.5
W 70.3
3.4
3
W 76
N 14
5.4
4
N 25.4
W 75.1
3.0
5
W 63
N 31
2.0
6
W 66
N 36
1.8
7
N 27
W 74
2.7
a Planter with two tubes, one for water (W), the other for nutrient solution (N). The reservoirs were interchanged periodically to cancel any membrane effects. Flow rates in mL/hr; experiment time March 18 to July 16.
TABLE 4
Watering results (mL/hr) for various vegetables (carrots, cherry
tomatoes, onions, beets, radishes, spinach) in potted planters
in two series of five (B and C) compared with single irrigated
plant (X) a
Test No.
Time interval (hr)
X
B
C
1
25
5.4
32.4
16.2
2
25
9.7
41.8
41.7
3
24
9.4
39.4
35.6
4
24
16.9
21.4
31.9
5
26
24.2
23.2
36.3
6
23
8.6
48.9
41.9
7
23.5
5.7
51.7
38.3
8
3
21
30.0
12.0
9
24
7.5
33.7
18.9
10
22.5
26
56
30.4
11
20
12.6
42.3
42.7
a Experiment time, February 19 to June 6.
Another aspect of the invention is directed to the making of tubing for use with a “water-on-demand” system. In one method, sheets of a low-porosity substance are coated with the aforementioned polyhydroxystyrene, and formed into cylinders by, for example, thermal, ultrasonic, or impulse means.
Although not intended as a limitation, a possible explanation of the operation of the polyhydroxystyrene polymer ( FIG. 6 ) will now be presented. First, how the polyhdroxystyrene attaches to the membrane: Polyhydroxystyrene has two groups, an hydroxyl (OH), which is hydrophilic and can hydrogen bond with water, and the styrene groups, which include a benzene ring (—C 6 H 4 —) attached to an ethylene group (═CH—CH 2 —), both of which are hydrophobic and can stick to the hydrophobic polyethylene membrane, leaving the hydrophilic (OH) group, which forms a weak hydrogen bond with water.
As discussed above, the polymer can act as a capillary through the membrane. It has been shown that organic impurities in water are 10 5 -10 6 times more likely to stick at the exit end wall of the capillaries, where there is a gas-liquid-solid equilibrium (i.e., air-water-membrane). The organic impurities are in equilibrium along the walls of the capillary, where the equilibrium is only between liquid and solid. Thus the surface of the exit pores become hydrophobic due to the adsorption of the trace organic impurities in water and/or nutrient solution.
When a plant is in need of water, it emits chemicals called exudates that can include a surfactant that removes the adhering organic compounds at the exit wall and liquid from the irrigation tube now is allowed to flow. This has been shown for two different membranes in the prior art, as discussed above with reference to FIGS. 7-8L .
High-purity water is free of organic impurities. Some domestic water supplies are often purified to such an extent that very little organic impurities remain. This would result in pore closure only after a large, and usually unnecessary, volume of water had passed through the membrane. The result would not be suitable because of the time delay between the removal of the organics and their deposition onto the membrane and the closure of the pores. On the other hand, too much organic content in the water could result in a delay in opening the closed pores because of the limited amount of surfactant that is released by the roots.
It has been found that in general the membrane area needed for a plant is best supplied by a tube of diameter equal to about a 1-cm radius, with a thickness of 0.5 mm maximum and pore sizes of from 0.1 to 5 μm, with a preferred average of 0.4 μm, although this is not intended as a limitation, and other porosity values can be used. This segment of the membrane is to be in contact with the roots of the plant. Short segments of membrane tubing can be supplied with water and/or nutrient solution by smaller diameter tubing, but care must be taken to prevent air locks in the line. Tubing of 1-cm ID would not be considered too large. Since the feed lines are exposed to light (sunlight or artificial lighting), it is necessary to use opaque tubing, or the solar active light will result in algae formation that can eventually block the pores. It is believed that the coating of the hydrophobic membrane is primarily to allow the resulting hydrophilic surface to become hydrophobic and to close the pores. Leaving the inner pore uncoated would restrict the flow of water through the membrane.
In the foregoing description, certain terms have been used for brevity, clarity, and understanding, but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such words are used for description purposes herein and are intended to be broadly construed. Moreover, the embodiments of the apparatus illustrated and described herein are by way of example, and the scope of the invention is not limited to the exact details of construction.
Having now described the invention, the construction, the operation and use of preferred embodiments thereof, and the advantageous new and useful results obtained thereby, the new and useful constructions, and reasonable mechanical equivalents thereof obvious to those skilled in the art, are set forth in the appended claims. | A method for efficiently delivering an aqueous solution to plants includes positioning a distal portion of a microporous hydrophobic tubing coated with a hydrophilic polymer adjacent a root system of a plant and channeling an aqueous solution from an inlet to the distal portion through a lumen. The tubing along the distal portion has a porosity adapted for permitting a flow of the aqueous solution therethrough when acted upon by a surfactant root exudate generated by the roots due to water stress. The aqueous solution is held in a reservoir, from which it can be channeled to the hydrophilic device's inlet. A nutrient solution can also be channeled to the plant roots via additional tubing. | 8 |
BACKGROUND OF THE INVENTION
The invention relates to means for rapidly stabilizing acrylic fibers by precisely controlling partial oxidation in an oxidizing atmosphere to a density level at which the fibers will not burn when subjected to an ordinary match flame and are capable of sustaining conventional carbonization temperatures to produce carbon fibers. The process of the invention involves the utilization of selected treatment temperature modes for the fiber as it passes through varying density ranges during oxidative stabilization. Acrylic fibers, as referred to throughout the specification and claims, are acrylonitrile homopolymer fibers and copolymer fibers containing at least about 80 mol % acrylonitrile. These fibers are routinely supplied in the form of tows comprising continuous multifilament bundles conventionally containing about 1,000 to about 160,000 individual fibers.
The thermal stabilization of a bundle of acrylic fibers historically has required a heat treatment of relatively long duration (e.g., elapsed time of at least about 4 hours). A lengthy heating period has normally been required to produce a density level at which an acrylic fiber bundle is non-burning when subjected to an ordinary match flame and will withstand carbonization temperatures, in view of the fact that rapid heating during stabilization to temperatures in the vicinity of the exothermic transition point of a fiber bundle produces "run-away" intermolecular cross-linkage reactions which result in local accumulation of heat. These "hot spots" in the bundle cause uneven heat distribution and result in the formation of a highly viscous liquid substance which, at the temperature of formation, causes fusion (i.e., a bonding) of the individual fibers, and may result in complete fragmentation of the fiber bundle. The fusion temperature is defined as that temperature at which formation of the highly viscous liquid substance is initially observed to form. The extensive time required for acrylic fiber stabilization has been a primary cause of relatively low production rates and associated high manufacturing costs for commercial carbon fiber production.
SUMMARY OF THE INVENTION
The present invention provides a process for rapidly thermally stabilizing a bundle of acrylic fibers in an oxidizing atmosphere, under a tension at least sufficient to prevent significant fiber shrinkage, comprising the steps of: (a) directly exposing the bundle of fibers to a heat treatment temperature in the range of about 2° C. to about 8° C. below a predetermined temperature at which fusion of a segment of the bundle of fibers is observed to occur; (b) immediately decreasing the heat treatment temperature of the bundle of fibers at a predetermined rate wherein the temperature is constantly maintained at about the maximum which the bundle of fibers can tolerate without fusing as the fiber density is simultaneously and progressively increased until a critical density is attained at which the bundle of fibers will tolerate an increase in temperature without fusing; and then (c) immediately increasing the heat treatment temperature of the bundle of fibers at a predetermined rate wherein the temperature is constantly maintained at about the maximum which the bundle of fibers can tolerate without fusing as the fiber density is simultaneously and progressively increased to a level at which the bundle is capable of sustaining carbonization at a temperature of at least about 800° C. in a non-oxidizing atmosphere.
As used herein, the phrase "about the maximum which the bundle of fibers can tolerate without fusing" refers to a temperature in the range of about 2° C. to about 8° C. below the fusion temperature, as hereinbefore defined, is observed to be attained for the fibers of a bundle at a particular density. Additionally, "significant fiber shrinkage" is defined as no more than about 5% shrinkage.
DESCRIPTION OF THE DRAWING
The single drawing is a graphic representation of a time/temperature profile developed according to one aspect of the invention for use in the stabilization of a bundle of acrylic fibers.
DETAILED DESCRIPTION OF THE INVENTION
Generally, the process of the invention initially involves a preliminary determination of the fusion temperature of a segment of an acrylic fiber bundle of the specific type to be treated. This may be accomplished by exposing separate segments of this bundle, in an appropriate oxidizing atmosphere, to individual temperature levels which are gradually elevated, preferably in 1° C. increments near the point where fusion is observed, until a temperature is attained at which a segment is observed to fuse immediately upon exposure to a particular temperature level. A separate segment must be used for each temperature increment to prevent an incorrect fusion point value due to slight stabilization of the fiber bundle resulting from exposure to gradually elevating temperatures.
This determination, and the temperature determinations described below, are carried out under essentially the same conditions (e.g., fiber tension, oxidation atmosphere, bundle physical size and number of filaments comprising the bundle) that will be used in the actual plant scale fiber stabilization.
The acrylic fiber bundle to be stabilized is initially exposed directly to a treatment temperature of about 2° C. to about 8° C. below the fusion temperature determined using the procedure outlined above. Immediately following the exposure of the bundle to a temperature in this range, the treatment temperature is immediately decreased during a first period to prevent gradual fusion of the individual fibers of the bundle. The rate of temperature reduction during this period is determined experimentally by ascertaining the maximum temperatures which the fiber bundle can tolerate as the fiber density is progressively increased and employing this rate of temperature reduction for treating the bundle.
When the fibers have attained a particular density, hereinafter referred to as the critical density, by this treatment, the actual value depending on the characteristics of the particular fiber bundle being stabilized, they are capable of tolerating a progressive increase in temperature in a second treatment period, but this must also be carried out at a predetermined rate to prevent fusion of the fibers. This upheat rate is also determined experimentally and is applied to the fiber bundle until a density is attained which allows conventional carbonization.
Fiber treatment may be accomplished in a batch process using an oven having means for closely controlling the varying treatment temperatures, or a continuous process wherein the fiber bundle is passed through heating means designed to provide the appropriate time/temperature treatment profile for particular grades of acrylic fiber.
The process of the invention typically provides thermal stabilization of an acrylic fiber bundle in about 10 to 30% of the time conventionally required for such treatment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The experiments described hereinbelow are carried out in an oven having an air atmosphere under essentially the same conditions as will be used in plant scale fiber stabilization.
The fusion temperature of a segment of fiber tow composed of 40,000 acrylic fibers having a fiber density of about 1.2 g/cm 3 is determined by supporting the segment between two clips at a tension in the range of about 0.04 to 0.06 grams/denier. The segment is placed in an oven heated to a temperature of 275° C. and observed. No fusion being noted, the sample is removed from the oven, the temperature of the oven is increased 10° C., and a new sample is placed therein. This process is repeated until fusion of a sample is observed immediately upon exposure to a temperature of 335° C. The temperature of the oven is then lowered to 325° C. and the process is again repeated as the temperature is raised in increments of 1° C. until fusion of a segment is immediately observed at 330° C.
Next, a sample of tow identical to that from which the segments of tow were taken for the experiment above is mounted in the same configuration and under the same tension used therefor such that the tow is prevented from sagging and shrinking, and the mounted tow is exposed to a temperature of about 325° C. (5° C. below the tow segment fusion temperature). The temperature is then immediately decreased to 320° C. and held at that selected temperature (T) until fusion is observed, the exact time of 58 seconds required for fusion being recorded.
A second mounted sample of tow is placed in the oven at a temperature of 325° C. and the temperature is immediately decreased to temperature (T) and held for a period of time slightly less (ca. 5 seconds) than the time determined for fusion to occur at that temperature. The temperature of the oven is again decreased to a temperature (T 1 ) of 315° C. and held until fusion is observed, the time to fusion of 1 minute and 47 seconds being recorded.
This process is repeated, starting with a new sample being initially exposed to 325° C. for each trial and following the step-wise time/temperature profile as the temperature is progressively decreased until a temperature point (P) of 271° C. is attained at which the fiber density is at a level where no fusion characteristics are exhibited after exposure of one hour. This temperature point is the one which produces the critical density at which the tow can tolerate a controlled increase in temperature. An elapsed time of exactly 9 minutes was required to reach this density.
A new mounted tow sample is placed in the oven at 325° C. and the time/temperature profile determined above is followed until temperature (P) is reached. The temperature is then immediately increased until fusion is observed at a temperature (X) of 277° C.
A new mounted sample of tow is then placed in the oven at 325° C. and the time/temperature profile previously determined, including the reversal from progressively decreasing to increasing temperature at point (P), is followed until a temperature 2° C. below temperature (X) of 275° C., designated (X 1 ), is attained and is held thereat for 5 seconds. As no fusion is observed, the total elapsed time of 9 minutes and 53 seconds required for this heating period is recorded.
A new mounted sample of tow is then placed in the oven at 325° C. and the predetermined time/temperature profile is followed through the holding period (5 seconds) for temperature (X 1 ). The heat treatment temperature is then immediately increased until fusion is observed at temperature (Y) of 282° C. A new tow sample is placed in the oven at 325° C. and the predetermined time/temperature profile is followed until a temperature 2° C. below temperature (Y) of 280° C., designated (Y 1 ), is attained and is held thereat for 5 seconds. As no fusion is observed, the total elapsed time of 11 minutes and 20 seconds is recorded.
It has previously been determined that a density of at least about 1.35 g/cm 3 is required for this particular tow to sustain carbonization at a temperature of at least about 800° C. in a non-oxidizing atmosphere. Therefore, new mounted tow samples are placed in the oven as required and the temperature is increased in a step-wise manner following the above procedure until this density is attained.
The fiber density at each temperature level may be determined by treating a sample of tow according to the temperature rate profile developed to a particular level, flooding the oven with nitrogen to stop the oxidation reaction, removing the sample from the oven, and measuring the density by means well known in the art.
Using the data obtained in the experiments above, a time/temperature profile graph, shown in the drawing, is constructed. The time/temperature parameters illustrated may be utilized for rapid acrylic fiber stabilization in an oxidizing atmosphere for the particular type of tow used in determining the graph's plot by controlling the heat treatment of the tow in the range of about 2° C. to 8° C. below the indicated temperatures while generally adhering to the indicated time sequence.
A sample of this tow is mounted in the same manner as in the experiments above and placed in an oven with an air atmosphere at a temperature of 325° C. and the time/temperature treatment parameters are regulated to essentially follow the shape of the graph at about 5° C. below the profile line. After a stabilizing cycle of 23 minutes the sample is removed from the oven. The stabilized tow has a fiber density value of 1.360 g/cm 3 and is thus capable of sustaining conventional carbonization at 800° C. in a non-oxidizing atmosphere.
While the invention has been described in detail and with reference to a specific embodiment thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the scope and spirit thereof, and, therefore, the invention is not intended to be limited except as indicated in the appended claims. | An acrylic fiber bundle is rapidly thermally stabilized in an oxidative atmosphere by exposure to a selected temperature profile as the fiber passes through varying density ranges during stabilization. | 3 |
REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Application Ser. No. 62/538,552, filed Oct. 7, 2015.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates to securing a rifle on an upright person by engaging a sling of the rifle at two points, one at the shoulder and one near the waist.
BACKGROUND
[0003] Hunters and other users of rifles frequently walk along rough terrain while hunting or traveling through natural territory. The usual method of supporting a rifle by its sling, with the sling suspended from the shoulder, is an unreliable way of carrying the rifle, since the rifle is easily dislodged should the person stumble or fall.
[0004] There exists a need for a way of securing a rifle supported by its sling for people traversing rough or uneven terrain.
SUMMARY
[0005] The disclosed concepts address the above stated situation by providing retaining apparatus reliably securing the rifle by its sling, while still enabling quick deployment of the rifle. To this end, novel retaining apparatus includes an upper anchorage pinning the sling to a backpack harness strap, and a lower anchorage pinning the rifle stock to a strap near the waist of the user. The upper anchorage provides a hook preventing the sling from slipping off the shoulder of the user. The lower anchorage provides a holster encircling the rifle stock and clamping to a harness strap near the waist.
[0006] The rifle is readily released for use from the upper and lower anchorages.
[0007] It is an object to provide improved elements and arrangements thereof by apparatus for the purposes described which is inexpensive, dependable, and fully effective in accomplishing its intended purposes.
[0008] These and other objects will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Various objects, features, and attendant advantages of the disclosed concepts will become more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
[0010] FIG. 1 is a perspective partial view of a person standing, with a rifle secured by the novel apparatus, according to at least one aspect of the disclosure;
[0011] FIG. 2 is an enlarged perspective detail view of an upper anchorage device used in FIG. 1 ;
[0012] FIG. 3 is an enlarged perspective detail view of a lower anchorage device used in FIG. 1 ;
[0013] FIG. 4 is similar to FIG. 3 , but shows the lower anchorage device partially disassembled to enable engagement or release of the rifle;
[0014] FIG. 5 is a perspective detail view taken from an opposite direction as FIG. 4 ; and
[0015] FIG. 6 is a perspective detail view similar to FIG. 5 , but showing opening of a strap engagement feature.
DETAILED DESCRIPTION
[0016] Referring first to FIG. 1 , according to at least one aspect of the disclosure, there is shown apparatus 100 for securing a rifle 2 supported by a sling 4 of rifle 2 on a user 6 wearing a harness 8 comprising straps 10 . Harness 8 may be that of a backpack (not shown in its entirety) for example. The apparatus 100 may comprise an upper anchorage 102 securing sling 4 at a shoulder strap 10 A ( FIG. 2 ) of harness 8 at a shoulder 12 of user 6 . Referring principally to FIG. 2 , upper anchorage 102 may comprise a foldable loop 104 bearing a fastener 106 , such as hook and loop fastener, snaps, or still others. Foldable loop 104 is configured to encircle shoulder strap 10 A of harness 8 , and to folded upon itself as shown in FIG. 2 and retained folded by fastener 106 . Upper anchorage 102 may also comprise a strap hook 108 ( FIG. 2 ) open towards a neck 14 of user 6 when foldable loop 104 encircles shoulder strap 10 A. Orientation of strap hook 108 assures that when the user is in the standing position illustrated in FIG. 1 , sling 4 will not slip from shoulder 12 of user 6 .
[0017] With sling 4 thus retained at the upper position at shoulder 12 of user 6 , a lower anchorage 110 clamps or pins a stock 14 of rifle 2 near a waist 16 of user 6 . Lower anchorage 110 advantageously prevents rifle 2 from being inclined to the point that it could be aimed at a person (not shown) walking behind user 6 .
[0018] It should be noted at this point that orientational terms such as upper and lower refer to the subject drawing as viewed by an observer. The drawing figures depict their subject matter in orientations of normal use, which could obviously change with changes in body posture and position. Therefore, orientational terms must be understood to provide semantic basis for purposes of description only, and do not imply that their subject matter can be used only in one position.
[0019] Also referring to FIGS. 3-6 , lower anchorage 110 grasps rifle 2 at stock 14 ( FIG. 1 ), and comprises a holster 112 comprising a lateral wall 114 configured to define a pocket 116 partially encircling stock 14 of rifle 2 . Lateral wall 114 includes an open portion 118 and a pocket axis 120 passing through pocket 116 parallel to lateral wall 114 . Open portion 118 of lateral wall 114 is configured to enable stock 14 ( FIG. 1 ) to be moved into and withdrawn from pocket 116 when a longitudinal axis 18 of rifle 3 is parallel to pocket axis 120 .
[0020] A closure 122 releasably secures stock 14 of rifle 2 in pocket 116 . A retainer 124 (see FIG. 5 ) is configured to engage a waist strap 10 B ( FIG. 1 ) of harness 8 . Closure 122 of holster 112 may comprise a flexible strap 128 made for example from a woven fabric. Holster 112 may comprise a holster hook 126 ( FIGS. 3 and 4 ). Flexible strap 128 may comprise a strap loop 130 configured to engage and be releasably retained by holster hook 126 . Strap loop 130 may be elastic, so that it may more readily stretch to slip over and be removed from holster hook 126 . Strap loop 130 may include a pull tab 132 ( FIGS. 3, 4, 5 ) projecting from strap loop 130 to facilitate drawing flexible strap 128 past and into engagement with holster hook 126 .
[0021] Strap hook 108 of upper anchorage 102 is rigid. That is, in use, strap hook 108 is sufficiently rigid as to oppose deflection, compressing, spreading open, etc. Strap hook 108 may be fabricated from one eighth inch thick metals such as steel, aluminum, and brass, or alternatively, hard plastic. Foldable loop 104 of upper anchorage 102 is flexible. Foldable loop 104 may be fabricated from fabric, leather, flexible plastics, stranded metal, and like materials.
[0022] Lateral wall 114 of holster 112 may be rigid, and may be fabricated from one eighth inch thick metals such as steel, aluminum, and brass, or alternatively, hard plastic. Lateral wall 114 of holster 112 may include an outer layer of yielding material. The yielding material may comprises a fabric, leather, and other materials which would avoid abrading rifle 2 .
[0023] Referring specifically to FIG. 6 , apparatus 100 may further comprise an adjustment feature configured to enable flexible strap 128 to be drawn tight against stock 14 of rifle 2 when stock 14 is in holster 112 . This is shown in FIGS. 5 and 6 . The adjustment feature may comprise a cinch 134 maintaining tightness of flexible strap 128 after flexible strap 128 has been drawn tight against stock 14 of rifle 2 .
[0024] Referring to FIGS. 5 and 6 , retainer 124 of lower anchorage 110 may comprise a flap 136 configured to close over and retain waist strap 10 B of harness 8 proximate waist 16 of user 6 (see FIG. 1 ). Cinch 134 of lower anchorage 110 may be located along flexible strap 128 of lower anchorage 110 such that cinch 134 is covered by flap 136 . In an implementation of apparatus 100 illustrated in FIGS. 5 and 6 , snaps 138 engage complementing snaps 140 in a lower flap 142 . Flap 136 and lower flap 142 may be of leather, and may be stitched to a fabric or leather covering of holster 112 .
[0025] In use, upper anchorage 102 is coupled to shoulder strap 10 A of harness 8 , with strap hook 108 opening towards neck 15 of user 6 . Sling 4 of rifle 2 is then placed onto upper anchorage 102 such that strap hook 108 prevents sling 4 from sliding from shoulder 12 (to the left, as shown in FIG. 1 ).
[0026] After lower anchorage 110 has engaged waist strap 10 B by closing flap 136 over lower flap 142 (see FIG. 6 ), snaps 138 are pressed into engagement with complementing snaps 140 of lower flap 142 . FIG. 5 depicts lower anchorage 110 in the closed condition after snaps 138 and complementing snaps 140 are mutually affixed. With waist strap 10 B entrapped between flap 136 and lower flap 142 , stock 14 may be placed in pocket 116 , and flexible strap 128 may be drawn tightly over stock 14 . FIG. 4 shows flexible strap 128 prior to engagement with holster hook 126 . FIG. 3 shows flexible strap 128 secured to holster hook 126 . Rifle 2 will then be pinned at two points to user 6 , using harness 8 . While rifle 2 will still have some mobility relative to user 6 , rifle 2 is now securely retained on the person of user 6 for purposes of walking, hiking, light climbing, and the like.
[0027] While the disclosed concepts have been described in connection with what is considered the most practical and preferred implementation, it is to be understood that the disclosed concepts are not to be limited to the disclosed arrangements, but are intended to cover various arrangements which are included within the spirit and scope of the broadest possible interpretation of the appended claims so as to encompass all modifications and equivalent arrangements which are possible. | Apparatus for retaining a rifle by its sling on a person. An upper anchorage pins the sling to a backpack harness strap, and a lower anchorage pins the rifle stock to a strap near the waist of the user. The upper anchorage provides a hook preventing the sling from slipping off the shoulder of the user. The lower anchorage provides a holster encircling the rifle stock and clamping to a harness strap near the waist. | 5 |
This application is a division of application Ser. No. 681,707, filed Dec. 13, 1984, U.S. Pat. No. 4,654,153.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to spinning preparations and processes for the melt spinning of synthetic fibers.
2. Description of the Related Art
In the melt spinning of synthetic fibers and their further processing into textile or industrial yarns, the multifilament yarns are wound without twisting onto spinning bobbins. The individual capillaries are in the form of bundles of parallel filaments, being held together solely by the more or less clearly pronounced adhesion effect of the spinning preparation. In the subsequent drawing process, the yarns are normally given a protective twist of a few turns per meter. However, this protective twist is not sufficient for many subsequent processing operations. Accordingly, the filaments either have to be twisted or protected by coating with a film of size in a separate process step. Both twisting and also sizing are expensive additional process steps. Accordingly, investigations have long been made to find alternatives for improving the inter-filament cohesion of the yarns to such an extent as to make these process steps superfluous.
The spinning preparations used in the past contain as filament cohesion promoters such additives as sarcosides or polymers of relatively high viscosity, such as polyisobutylene. Depending on the concentration in which they are used, compounds such as these are capable of improving the cohesion-promoting effect of spinning preparations by increasing the adhesion forces between the individual capillaries. However, the cohesion effect obtained in this way is only temporary because the additives in question are washed out again during the first wet process, for example in the dyeing operation. Another disadvantage attending many of these cohesion promoters lies in their inadequate thermal stability. This seriously restricts their use for spinning preparations which are intended for texturing or for industrial yarns which have to be subjected to high-temperature drawing.
DESCRIPTION OF THE INVENTION
The present invention relates to spinning preparations for the melt-spinning of synthetic fibers which contain smoothing agents, emulsifiers, wetting agents, antistatic agents and, optionally, other additives, and which contain from about 1 to about 30% by weight of at least one epoxidized compound having at least 8 carbon atoms. The present invention also relates to a process for obtaining permanent inter-filament cohesion in the melt-spinning of synthetic fibers in which the above spinning preparation is applied to the fibers in a quantity of from about 0.3 to about 2.0% by weight followed by heating to a temperature in the range of from about 150° to about 250° C. The epoxidized compounds having at least 8 carbon atoms referred to above are derived from one or more of the following:
a. A C 8 -C 24 mono- or di-olefinically unsaturated fatty acid. Preferably, from 12 to 18 carbon atoms are present therein.
b. A C 8 -C 24 mono- or di-olefinically unsaturated fatty alcohol. Preferably from 12 to 18 carbon atoms are present therein.
c. A C 1 -C 3 alkyl ester of a C 8 -C 24 mono- or di-olefinically unsaturated fatty acid. Preferably, the fatty acid portion thereof contains from 12 to 18 carbon atoms. The methyl ester is preferred although the ethyl and propyl esters can also be employed.
d. A glyceride of a C 8 -C 24 mono- or di-olefinically unsaturated fatty acid. Preferably, the fatty acid portion contains from 12 to 18 carbon atoms. The glyceride can be a mono-, di- or triglyceride.
e. A C 8 -C 24 mono- or di-olefin, preferably containing from 12 to 18 carbon atoms.
The introduction of one or more epoxide groups is carried out in known manner, for example by reacting the above compounds with hydrogen peroxide in the presence of formic acid. The above compounds are preferably substantially fully epoxidized, although compounds that contain at least one epoxy group and contain remaining unsaturation can also be used herein. Preferred compounds for use herein are the fully epoxidized products of unsaturated C 12 -C 18 fatty acids, unsaturated C 12 -C 18 -fatty alcohols, and C 1 -C 3 esters of unsaturated C 12 -C 18 fatty acids, for example, unsaturated C 12 -C 18 fatty acid methyl esters, or unsaturated C 12 -C 18 fatty acid triglycerides, and C 12 -C 18 -olefins. Specific examples of suitable products are the epoxidation products of oleic acid methyl ester, soya oil fatty acid methyl ester, soya oil, mixtures of unsaturated C 12 -C 18 -fatty alcohols, 1,2-hexadecene and the like.
The spinning preparations of the invention have the following composition:
1. from about 35 to about 60% by weight of one or more smoothing agents,
2. from about 1 to about 30%, preferably about 8 to about 20%, and more preferably from about 5 to about 15% by weight of at least one epoxidized compound of the invention,
3. from about 30 to about 45% by weight of emulsifiers, wetting agents, and antistatic agents, and
4. any balance, water.
The above spinning preparations are applied in the usual way immediately after the melt-spinning process. They are applied in the form of aqueous emulsion, e.g. from about 10 to about 25% by weight aqueous emulsions, or in the form of solutions in organic solvents, for example in white spirit, or even in undiluted form providing the viscosity of the concentrated preparation is suitable for application. The quantity applied amounts to between about 0.3 and about 2.0% by weight, expressed as total active substances (i.e. ingredients other than water). The preparation is applied by means of applicator rolls or by means of metering pumps in conjunction with suitable applicators.
Smoothing agents include mineral oils, fatty acid esters, alkylene oxide adducts, and polymers, and are well known in this art. Suitable emulsifiers, wetting agents and antistatic agents include anionic and nonionic surfactants, such as ethylene oxide adducts with higher fatty alcohols, alkyl phenols or other solids, triethanolamine soaps, alkane sulfonates, phosphoric acid esters and the like. After the spinning preparations have been applied, the treated filaments are heat-treated at temperatures in the range of from about 150° to about 250° C., and preferably at temperatures in the range of from about 150° to about 230° C. This thermal aftertreatment, which is carried out for from about 0.1 to about 5 seconds, is essential to the onset of the cohesion-promoting effect, and can be carried out immediately after application of the spinning preparation of the invention, or even at a later stage in a separate operation. The present spinning preparations show adequate stability for prolonged periods at normal ambient or storage temperatures. The process of the invention is suitable for obtaining a permanent, temperature-resistant and washing-resistant cohesionpromoting effect in the production of textile yarns, industrial yarns or bulked continuous filament yarns from polyamide (PA), polyester (PES) or polyolefin, for example polypropylene (PP). Apart from the heat treatment, no changes need to be made to the standard procedure.
The invention will be illustrated but not limited by the following examples.
The spinning preparations set forth below were applied in the form of 10-25% by weight aqueous emulsions to various fibers immediately after melt spinning. The preparations were applied by applicator rolls in a quantity of from 0.5 to 1.3% by weight, based on anhydrous preparation. After application, thermal fixing was carried out by heating to 150°-230° C. The preparation of Example 7 did not contain an epoxide compound and was used for comparison. The cohesion-promoting effect was tested as follows:
The filament to be tested was clamped vertically into a holder. The filament had a total length of 50 cm. At its lower end, the filament was loaded by a weight of 5.7 g/tex. The filament was cut with sharp scissors at a length of 40 cm. As a result of the sudden relaxation, the free end of the filament splits open into individual capillaries to a greater or lesser extent, depending upon the cohesion-promoting effect of the preparation. The proportion of unsplit filament in the overall length of the filament was evaluated as a percentage, the test value being represented by the average value of 20 individual measurements (literature: R. Buttner, R. Schrot, Textiltechnik 29 (1979) 4, Page 223).
EXAMPLE 1
50% of i-tridecylstearate
10% of soya oil methyl ester epoxide
14% of hardened castor oil+25 EO
11% of coconut oil fatty alcohol+6 EO
9% of oleic acid mono -/diglyceride
6% of petroleum sulfonate, Na-salt
EXAMPLE 2
40% of trimethylol propane tripelargonic acid ester
15% of epoxy stearic acid methyl ester
13% of oleyl alcohol+5 EO
13% of petroleum sulfonate, Na-salt
7% of hardened castor oil+25 EO
9% of triethanolamine oleate
3% of water
EXAMPLE 3
50% of EO/PO-copolymer, MW 1500, EO/PO-ratio 5:7
15% of soya oil methyl ester epoxide
25% of nonyl phenol+10 EO
10% of hardened castor oil+25 EO
EXAMPLE 4
50% of EO/PO-copolymer, MW 2000, EO/PO-ratio 1:1
10% of C 12 -C 18 -epoxy fatty alcohol mixture
20% of nonyl phenol+15 EO
20% of hardened castor oil+25 EO
EXAMPLE 5
50% of hexadecylstearate
10% of soya oil epoxide
10% of oleic acid mono-/diglyceride
10% of C 12 -C 14 fatty alcohol+5 EO
15% of C 12 -C 18 -fatty alcohol+6 EO mono-/diphosphoric acid ester, K-salt
5% of hardened castor oil+25 EO
EXAMPLE 6
50% of EO/PO-copolymer, MW 2000, EO/PO-ratio 1:1
20% of epoxy-1,2-hexadecane
20% of nonyl phenol+6.5 EO
10% of nonyl phenol+15 EO
EXAMPLE 7 (Comparison Example)
45% of trimethylol propane tripelargonic acid ester
20% of oleyl alcohol+5 EO
14% of petroleum sulfonate, Na-salt
7% of hardened castor oil+25 EO
10% of triethanolamine oleate
4% of water
The results of the cohesion tests are set forth in Table 1 below
TABLE 1______________________________________ FixingSpinning Tempera-preparation % Applied Fiber ture (°C.) % Cohesion______________________________________Example 1 0.9 Nylon 6, 180 92 1100 dtex f 210Example 2 1.1 PES, 1250 230 93 dtex f 220Example 3 0.5 PES, 167 160 95 dtex f 34Example 4 1.2 PP, 1200 150 90 dtex f 68Example 5 0.5 Nylon 66, 180 88 44 dtex f 13Example 6 1.3 PP, 2200 150 90 dtex f 204Example 7 1.1 PES, 1250 26(Comparison dtex f 220Example)______________________________________ | A spinning preparation, for the melt spinning of synthetic fibers, containing a smoothing agent, an emulsifier, a wetting agent, an antistatic agent, and an epoxidized compound containing at least 8 carbon atoms to produce a cohesion promoting effect on the fibers. ' | 3 |
TECHNICAL FIELD
[0001] This document relates to various pulley apparatuses and, more particularly, to pulley apparatuses that can be used in block-and-tackle configurations (as well as the associated configurations, methods, kits, etc.).
BACKGROUND
[0002] There are many situations in which relatively heavy objects must be lifted and/or suspended (and/or lowered under control). For example, hunters must often suspend heavy animals (e.g., from a tree) for cleaning purposes; furniture and other heavy objects must be loaded onto trucks; trunks/crates must be moved to attics or garage lofts; portions of smaller vehicles (e.g., ATVs) must be lifted for purposes of changing a tire or pulled out of a stuck situation; and so on. In many instances, even a strong individual is unable to lift the objects in the desired manner.
[0003] The same can hold true when someone wants to introduce an optimum amount of tension in a line of some sort. For example, during the construction of a barbed-wire fence, the wire must be pulled tight to create a viable fence. Pulling the wire tight can be difficult or impossible for even a strong individual.
[0004] One mechanism that can aid in lifting such objects and/or pulling such objects tightly is a block-and-tackle configuration. Block-and-tackles involve arranging one or more pulleys in relation to a fixed object and feeding rope through the pulleys in such a way as to create a mechanical advantage. In this way, by pulling the rope over a longer distance, a greater lifting force can be achieved.
[0005] In many instances, configuring a block-and-tackle can present difficulties. Feeding the rope through the pulley(s) and/or attaching the load to the block-and-tackle can pose challenges that limit the usefulness and/or applicability of block-and-tackles.
SUMMARY
[0006] Embodiments of the present invention provide pulley apparatuses that can be easily incorporated into block-and-tackle configurations. In some embodiments, the pulley can be fixed via its hook and/or via its aperture. In some embodiments, a rope can be easily dropped into place and removed, rather than having to be threaded in. For example, the pulley housing can include a rope channeling structure near the end opposite the aperture, and the rope channeling structure can facilitate introducing the rope into engagement with the wheel and/or removing the rope from engagement with the wheel. In some embodiments, the rope channeling structure can prevent the rope from inadvertently becoming removed from the pulley. In some embodiments, the pulley can be hung by the aperture, the hook, or both. In some embodiments, the hook can be weighted such that it always hangs down (unless otherwise acted upon). In some embodiments, the hook can be oriented at various angles relative to the aperture (e.g., 180 degrees, 90 degrees, etc.). In some embodiments, the wheel's axle and the hook can be integrally formed of the same material. Some such embodiments can result in increased strength, improved performance, and/or reduced manufacturing costs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The following drawings are illustrative of particular embodiments of the present invention and therefore do not limit the scope of the invention. The drawings are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description. Embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements.
[0008] FIG. 1 is an isometric view of a pulley apparatus according to embodiments of the present invention.
[0009] FIG. 2 is an exploded view of the pulley apparatus of FIG. 1 .
[0010] FIG. 3 is a side view of the pulley apparatus of FIG. 1 .
[0011] FIGS. 4A-4D are isometric views of a pulley apparatus like that of FIGS. 1-3 in connection with a rope.
[0012] FIG. 5 is a front view of the pulley apparatus of FIG. 1 , with the hook assembly being rotated relative to the support structure.
[0013] FIGS. 6A-6B are an isometric view and a side view, respectively, of a pulley apparatus according to embodiments of the present invention.
[0014] FIG. 7 is a top view of a block-and-tackle kit according to embodiments of the present invention.
[0015] FIG. 8 is an exploded view of a tie-down tensioning device that can be implemented in embodiments of the present invention.
[0016] FIGS. 9A-9C illustrate a method of creating a block-and-tackle according to embodiments of the present invention.
[0017] FIGS. 10A-10C illustrate a method of creating a block-and-tackle according to embodiments of the present invention.
[0018] FIG. 11 is an isometric view of a block-and-tackle according to embodiments of the present invention.
[0019] FIG. 12 is an isometric view of a block-and-tackle according to embodiments of the present invention.
DETAILED DESCRIPTION
[0020] The following detailed description is illustrative in nature and is not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the following description provides practical illustrations for implementing exemplary embodiments of the present invention. Examples of constructions, materials, dimensions, and manufacturing processes are provided for selected elements, and all other elements employ that which is known to those of ordinary skill in the field of the invention. Those of ordinary skill in the art will recognize that many of the examples provided have suitable alternatives that can be utilized.
[0021] FIGS. 1-3 show a pulley apparatus 10 according to embodiments of the present invention. As shown, the pulley apparatus 10 includes a support structure 15 , a hook assembly 20 , a wheel 25 . Some embodiments can include a clipping mechanism 26 for securing the support structure 15 with the hook assembly 20 . In some embodiments, the pulley apparatus 10 can assist in raising and/or lowering objects by providing a mechanical advantage, as is discussed in greater detail elsewhere herein. The pulley apparatus 10 of FIG. 1 comprises only four parts, which can significantly simplify the manufacturing process and provide for a more consistent final product.
[0022] The support structure 15 of the pulley apparatus 10 can support the other components of the pulley apparatus 10 . In some embodiments, the support structure 15 can include first and second opposed end sections 32 , 34 , along with first and second opposed side members 27 , 30 extending between the first and second end sections 32 , 34 . In many embodiments, the first and second opposed side members 27 , 30 include substantially solid panels. In some embodiments, all of the support structure 15 is integrally formed of the same material. In such embodiments, the support structure 15 can be a strip of sheet metal bent into a desired shape. In many embodiments, the first end section 32 of the support structure defines an aperture 36 . In many embodiments, the portion of the first end section 32 that defines the aperture 36 is generally parallel to the first and second opposed side members 27 , 30 . In some embodiments, the portion of the first end section 32 that defines the aperture 36 is generally perpendicular to the first and second opposed side members 27 , 30 (e.g., with the first end section 32 being twisted go degrees). As is discussed in greater detail elsewhere herein, in some embodiments, the support structure 15 can include a hook assembly anchor 38 .
[0023] FIGS. 4A-4D show a pulley apparatus 410 like that of FIGS. 1-3 in connection with a length of rope 412 to illustrate how the rope 412 can be inserted into the pulley apparatus 410 . The pulley apparatus 410 has a support structure 415 , which has a second end section 434 . As shown, in certain preferred embodiments, the second end section 434 can include a rope channeling structure 440 . The rope channeling structure 440 can assist in inserting rope 412 into the pulley apparatus 410 , as well as inhibiting rope 412 already inserted from being accidentally removed from the pulley apparatus 410 . The rope channeling structure 440 can include a first segment 442 extending from the first side member 427 and a second segment 444 extending from the second side member 430 . The first and second segments 442 , 444 can together define an entrance portion, an exit portion, and a narrower restrictor portion. FIG. 3 shows the entrance portion 316 , the restrictor portion 317 , and the exit portion 318 defined by the pulley apparatus 10 of FIGS. 1-3 . Referring to FIGS. 4A-4D , in some embodiments, the first and second segments 442 , 444 of the rope channeling structure 434 curve toward one another from the respective side members 427 , 430 in defining the exit portion and curve back away from one another in defining the entrance portion. In some such embodiments, the restrictor portion can include a location at which the first segment 442 is nearest the second segment 444 .
[0024] As noted, FIGS. 4A-4D illustrate how a length of rope 412 can be inserted into the pulley apparatus 410 . FIG. 4B shows how the entrance portion can be configured to channel the rope 412 toward the restrictor portion upon entrance into the pulley apparatus 410 . The restrictor portion can be configured to inhibit rope channeled to it from passing therethrough. In some embodiments, the support structure 415 is configured to hingedly flex, with the first support structure end section 432 serving as a hinge and the first and second segments 442 , 444 being configured to be pressed apart. In some such embodiments, the rope 412 can press the first and second segments 442 , 444 apart to pass through the restrictor portion. As shown in FIGS. 4C-4D , the rope 412 can engage the wheel 425 and be moved into an operational position.
[0025] To remove the rope 412 from the pulley apparatus 412 , the process previously discussed can be reversed. The rope 412 can be removed from the operational position and disengaged from the wheel 425 . The exit portion can be configured to channel the rope 412 toward the restrictor portion upon exit from the pulley apparatus 412 . The rope 412 can be pulled through the restrictor portion, thereby removing the rope 412 from the pulley apparatus 412 . The restrictor portion can inhibit the rope 412 from being accidentally removed from the pulley apparatus 412 , which can be beneficial during setup and/or operation of the pulley apparatus 412 . In many embodiments, an operator must intentionally pull the rope 412 through the restrictor portion in order to remove the rope 412 from the pulley apparatus 412 .
[0026] Referring again to FIGS. 1-3 , in some embodiments, the pulley apparatus 10 can include a hook assembly 20 coupled to the support structure 15 . The hook assembly 20 can be configured to hang the pulley apparatus 10 from an object (e.g., a tie-down tensioning device, as is discussed elsewhere herein) and/or to hang an object (e.g., some type of weight) from the pulley apparatus 10 . The hook assembly 20 can include a hook 50 configured to hook the pulley apparatus 10 to the object and/or to hook the object to the pulley apparatus 10 . The hook assembly 20 can include a wheel axle 55 extending between the first and second opposed side members 27 , 30 of the support structure 15 . The hook assembly 20 can include a shaft 60 connected on one end to the pulley hook 50 and on an opposed end to the wheel axle 55 . In some embodiments, all of the hook assembly 20 is integrally formed of the same material (e.g., by bending a metal rod into a desired shape). In many embodiments, the hook 50 of the hook assembly 20 is positioned opposite the first end section 32 of the support structure 15 .
[0027] Referring now to FIG. 5 , in some embodiments, the hook assembly is rotatable relative to the support structure 15 about the axis ( 61 in FIG. 2 ) defined by the wheel axle ( 55 in FIGS. 2-3 ). The hook assembly 20 can be released from the hook assembly anchor 38 of the support structure 15 and rotated to any desired position. In many instances, this rotatability can make assembly of the pulley apparatus 10 significantly easier, with one step being inserting the wheel axle 55 into the first side member 27 , into the central bore 63 of the wheel (discussed further elsewhere herein), and out of the second side member 30 , another step being securing the wheel axle 55 (e.g., with clipping mechanism 26 ) to prevent the hook assembly 20 from disengaging, and a third step being rotating the hook assembly 20 to engage the hook assembly anchor 38 . Assembly in this manner can be considerably easier in terms of alignment of the various components. If the desired position of the hook assembly 20 is 180 degrees opposite from the support structure aperture 36 (which is often the case), the hook assembly 20 can engage the hook assembly anchor 38 , according to some preferred embodiments. The hook assembly anchor 38 (which is often part of the first segment 42 of the rope channeling structure 34 ) of the support structure 15 is configured to align the hook 50 of the hook assembly 20 opposite the aperture 36 of the support structure 15 .
[0028] Referring again to FIGS. 1-3 , the pulley apparatus 10 can include a wheel 25 , which can be positioned between the first and second opposed side members 27 , 30 of the support structure 15 . The wheel 25 can be configured to rotate about the axis 61 defined by the wheel axle 55 of the hook assembly 20 . The wheel can include a central bore 63 interfacing with the wheel axle 55 of the hook assembly 20 . The wheel 25 can include a groove 64 extending around a circumference of the wheel 25 and being configured to receive rope (as is shown in FIGS. 4A-4B ).
[0029] FIGS. 6A-6B show a pulley apparatus 610 according to embodiments of the present invention. In many ways, the pulley apparatus 610 of FIGS. 6A-6B is similar to the pulley apparatus 10 of FIGS. 1-3 and the pulley apparatus 410 of FIGS. 4A-4D . Referring again to FIGS. 6A-6B , the pulley apparatus 610 can include a support structure 615 (such as those discussed elsewhere herein), a hook assembly 620 (such as those discussed elsewhere herein), and two wheels 624 , 625 (such as those discussed elsewhere herein). As shown, both wheels 624 , 625 are positioned between the first and second opposed side members 627 , 630 of the support structure 615 . Both wheels 624 , 625 can be configured to rotate about the axis 661 defined by the wheel axle 655 of the hook assembly 620 . In many embodiments, both wheels 624 , 625 include a central bore that interfaces with the wheel axle 655 of the hook assembly 620 . In many embodiments, both wheels 624 , 625 include a groove 664 , 665 extending around a circumference of the wheel 624 , 625 and being configured to receive rope. Although two wheels 624 , 625 are shown, pulley apparatuses according to embodiments of the present invention can include one wheel, two wheels, three wheels, four wheels, or any suitable number of wheels, depending on the particular application.
[0030] FIG. 7 shows a block-and-tackle kit according to embodiments of the present invention. The kit can include a length of rope 712 , one or more pulley apparatuses 710 (such as those discussed elsewhere herein), a tie-down tensioning device 713 , and a tie-down hook 714 . As is discussed in greater detail elsewhere herein, the tie-down hook 714 can be adapted to hook into a second tie-down aperture 716 . In some embodiments, the kit can include instructions for creating a block-and-tackle out of the rope 712 , the pulley apparatus(es) 710 , the tie-down tensioning device 713 , and the tie-down hook 714 , according to methods discussed elsewhere herein and/or other suitable methods. Although one pulley apparatus is shown, block-and-tackle kits according to embodiments of the present invention can include one pulley apparatus, two pulley apparatuses, three pulley apparatuses, four pulley apparatuses, or any suitable number of pulley apparatuses, depending on the particular application.
[0031] FIG. 8 shows an illustrative tie-down tensioning device 813 (split open to expose the interior) that can be used in block-and-tackles according to embodiments of the present invention. In many embodiments, the tie-down tensioning device 813 can include a housing 809 . The housing 809 can include first and second housing end sections 871 , 872 . The first housing end section 871 can define a first tie-down aperture 817 . In many embodiments, the pulley apparatus's pulley hook ( 50 of FIGS. 1-3 ) can be configured to hook into the first tie-down aperture 817 . The second opposed housing end section 872 can define a second tie-down aperture 816 . In some embodiments, the housing 809 can include both a rope inlet 873 and a rope outlet 874 in the first housing end section 871 . In many embodiments, the housing 809 can include a rope path 876 from the rope inlet 873 to the rope outlet 874 . In some such embodiments, the rope path 876 can pass through the second housing end section 872 around the second tie-down aperture 816 and/or through a clam cleat 877 . Tie-down tensioning devices such as those discussed herein are described in greater detail in U.S. Pat. No. 7,428,769 (titled “Tie Down Tensioning Device” and assigned to Tie Boss LLC, the owner of the present invention), which is hereby incorporated by reference herein in its entirety.
[0032] FIGS. 9A-9C and 10 A- 10 C show methods of creating a block-and-tackle according to embodiments of the present invention. A block-and-tackle can provide a mechanical advantage in lifting and/or lowering objects with a rope. An object can be lifted and/or lowered via the exertion of a force that is less than the weight of the object, provided that the force is applied over a longer distance. In many embodiments of the present invention, an object can be lifted (and/or lowered) by pulling a longer length of rope than would ordinarily be required with a force that is less than the weight of the object. Some methods of creating a block-and-tackle involve providing one or more pulley apparatuses (such as those discussed elsewhere herein) and a tie-down tensioning device (such as those discussed elsewhere herein).
[0033] In some embodiments, methods of creating a block-and-tackle can include feeding a leading end 951 of a rope 912 through the tie-down tensioning device 913 . As is discussed elsewhere herein, in many embodiments, feeding a leading end 951 of a rope 912 through the tie-down tensioning device 913 involves feeding the leading end of the rope into the rope inlet, along the rope path, and out through the rope outlet. Most methods of creating a block-and-tackle further include fixing the tie-down tensioning device 913 to a stationary object (e.g., via tie-down hook 914 ). The tie-down tensioning device 913 (including the clam cleat— 877 in FIG. 8 ) can aid in the pulling of the rope by inhibiting slippage.
[0034] Many methods of creating a block-and-tackle according to embodiments of the present invention involve introducing an intermediate portion 953 of a trailing end 952 of the rope 912 to a first pulley apparatus 910 . As is discussed elsewhere herein, in many embodiments, introducing the intermediate portion 953 of the trailing end 952 of the rope 912 to the first pulley apparatus 910 involves contacting the entrance portion of the rope channeling structure with the rope, pressing the rope past the restrictor portion of the rope channeling structure, and positioning the rope in the first-wheel groove (see FIGS. 3 , 4 A- 4 D and corresponding discussion for additional detail).
[0035] In many embodiments, methods of creating a block-and-tackle can include securing an end portion 954 of the trailing end 952 of the rope 912 . The end portion 954 of the trailing end 952 of the rope 912 can be affixed to a rope hook 990 . FIG. 9C shows how the end portion 954 of the trailing end 952 of the rope 912 can be secured by hooking the rope hook 990 into the first tie-down aperture 917 of the tie-down tensioning device 913 . With the end portion 954 of the trailing end 952 of the rope 912 being secured in the embodiment of FIG. 9C , an object to be lifted can be coupled to the first pulley apparatus 910 (e.g., it can be hooked onto the hook 950 or the first pulley apparatus 910 can be oriented with the hook 950 pointed up (or rotated relative to the support structure) and the object can be hooked into the pulley aperture 936 ). The leading end 951 of the rope 912 can be pulled, which can cause the first pulley apparatus 910 , and the attached object, to move upwardly. Pulling the rope 912 a distance of x will cause the object to move upwardly by a distance of roughly x/2. If the object weighs y pounds, the rope 912 must be pulled with a force of y/2 pounds in order to lift the object.
[0036] The method of creating a block-and-tackle illustrated in FIGS. 10A-10C involves multiple pulley apparatuses 910 , 911 . As shown, the method can include hooking the pulley hook 949 of a second pulley apparatus 911 into the first tie-down aperture 917 of the tie-down tensioning device 913 . In this way, the pulley apparatuses 910 , 911 can be oriented oppositely of one another in an operational block-and-tackle. After introducing the intermediate portion 953 of the trailing end 952 of the rope 912 to the first pulley apparatus 910 (see discussion elsewhere herein), a portion of the trailing end 952 of the rope 912 that is between the intermediate portion 953 and the end portion 954 can be introduced to the second pulley apparatus 911 . For example, as is discussed elsewhere herein, such introduction can involve contacting the entrance portion of the rope channeling structure with the rope, pressing the rope past the restrictor portion of the rope channeling structure, and positioning the rope in the groove (see FIGS. 3 , 4 A- 4 D and corresponding discussion for additional detail).
[0037] As noted, methods of creating a block-and-tackle can include securing an end portion 954 of the trailing end 952 of the rope 912 . FIG. 10C shows how the end portion 954 of the trailing end 952 of the rope 912 can be secured by hooking the rope hook 990 into the pulley aperture 936 of the first pulley apparatus 910 . In some embodiments, the first pulley apparatus 910 can be weighted such that its pulley hook 950 naturally hangs downwardly and its pulley aperture 936 is oriented upwardly, thereby aiding in hooking the rope hook 990 into the pulley aperture 936 of the first pulley apparatus 910 . With the end portion 954 of the trailing end 952 of the rope 912 being secured in the embodiment of FIG. 10C , an object to be lifted can be coupled to the first pulley apparatus 910 (e.g., it can be hooked onto the hook 950 ). The leading end 951 of the rope 912 can be pulled, which can cause the first pulley apparatus 910 , and the attached object, to move upwardly. Pulling the rope 912 a distance of x will cause the object to move upwardly by a distance of roughly x/3. If the object weighs y pounds, the rope 912 must be pulled with a force of y/3 pounds in order to lift the object.
[0038] As shown in FIG. 11 , the first pulley apparatus 1110 can include a second wheel (like the two-wheel pulley discussed in connection with FIGS. 6A-6B ). After the rope 912 has been introduced to the first pulley apparatus 1110 and then the second pulley apparatus 911 (as is discussed elsewhere herein), the rope 912 can be re-introduced to the first pulley apparatus 1110 . Specifically, a portion of the trailing end of the rope 912 that is between the portion that was introduced to the second pulley apparatus 911 and the end portion 954 can be re-introduced to the first pulley apparatus 1110 . The rope 912 can be positioned into contact with the entrance portion of the rope channeling structure, and then pressed past the restrictor portion of the rope channeling structure, and then positioned in the second-wheel groove of the first pulley apparatus 1110 . In such a block-and-tackle configuration, the rope hook 990 affixed to the end portion 954 of the trailing end of the rope 912 can be hooked into the pulley aperture 1137 of the second pulley apparatus 911 to secure the end portion 954 of the trailing end of the rope 912 . The leading end of the rope 912 can be pulled, which can cause the first pulley apparatus 1110 , and an object attached thereto, to move upwardly. Pulling the rope 912 a distance of x will cause the object to move upwardly by a distance of roughly x/4. If the object weighs y pounds, the rope 912 must be pulled with a force of y/4 pounds in order to lift the object.
[0039] As shown in FIG. 12 , the second pulley apparatus 1211 can likewise include a second wheel 1296 (like the two-wheel pulley discussed in connection with FIGS. 6A-6B ). After the rope 912 has been introduced to the first pulley apparatus 1110 and then the second pulley apparatus 1211 and then re-introduced to the first pulley apparatus 1110 (as are discussed elsewhere herein), the rope 912 can be re-introduced to the second pulley apparatus 1211 . Specifically, a portion of the trailing end of the rope 912 that is between the portion that was re-introduced to the first pulley apparatus 1110 and the end portion 954 can be re-introduced to the second pulley apparatus 1211 . The rope 912 can be positioned into contact with the entrance portion of the rope channeling structure, and then pressed past the restrictor portion of the rope channeling structure, and then positioned in the second-wheel groove of the second pulley apparatus 1211 . In such a block-and-tackle configuration, the rope hook 990 affixed to the end portion 954 of the trailing end of the rope 912 can be hooked into the pulley aperture of the first pulley apparatus 1110 to secure the end portion 954 of the trailing end of the rope 912 . The leading end of the rope 912 can be pulled, which can cause the first pulley apparatus 1110 , and an object attached thereto, to move upwardly. Pulling the rope 912 a distance of x will cause the object to move upwardly by a distance of roughly x/5. If the object weighs y pounds, the rope 912 must be pulled with a force of y/5 pounds in order to lift the object.
[0040] Certain block-and-tackle configurations are provided in the drawings, but embodiments of the present invention can include block-and-tackle configurations that are not shown. For example, block-and-tackle configurations according to embodiments of the present invention can include one, two, three, four, or more pulley apparatuses. Pulley apparatuses used in block-and-tackle configurations according to embodiments of the present invention can include one, two, three, four, or more wheels. In some embodiments, all of the pulley apparatuses used in block-and-tackle configurations have the same number of wheels. In some embodiments, one or more of the pulley apparatuses used in a block-and-tackle configuration have a different number of wheels than one or more of the other pulley apparatuses used in the block-and-tackle configuration. The number of pulley apparatuses and the number of wheels per pulley apparatus often depends on factors such as the amount of force a user is likely able/willing to exert, an optimum length of rope to be used, the desired simplicity/complexity of the block-and-tackle configuration, and so on.
[0041] In the foregoing detailed description, the invention has been described with reference to specific embodiments. However, it may be appreciated that various modifications and changes can be made without departing from the scope of the invention as set forth in the appended claims. Thus, some of the features of preferred embodiments described herein are not necessarily included in preferred embodiments of the invention which are intended for alternative uses. | Embodiments of the present invention provide pulley apparatuses that can be easily incorporated into block-and-tackle configurations. In some embodiments, a rope can be easily dropped into place and removed, rather than having to be threaded in. For example, the pulley housing can include a rope channeling structure near the end opposite the aperture, and the rope channeling structure can facilitate introducing the rope into engagement with the wheel and/or removing the rope from engagement with the wheel. In some embodiments, the rope channeling structure can prevent the rope from inadvertently becoming removed from the pulley. Some pulley apparatuses can comprise a minimal number of parts, which can significantly simplify the manufacturing process and provide for a more consistent final product. | 8 |
BACKGROUND AND SUMMARY
[0001] This present invention relates generally to a fastener machine and more particularly to a feeding mechanism for a rivet machine.
[0002] Various feeding and setting machines have been used for rivets. Such traditional machines are disclosed in U.S. Pat. Nos. 6,592,015 entitled “Feeding Heads for Fastening Machines” which issued to Gostylla et al. on Jul. 15, 2003, and U.S. Pat. No. 5,752,305 entitled “Self-Piercing Riveting Method and Apparatus” which issued to Cotterill et al. on May 19, 1998. Both of these patents are incorporated by reference herein.
[0003] Another conventional, self-piercing rivet setting machine employs a right angled, T-shaped intersection between a guide track and feed rail paths. This causes a pneumatically driven rivet to undesirably bounce back or ricochet off of the abutting wall of the feed rail (e.g., the top of the T) thereby either jamming the feeding mechanism or being out of position for the subsequent advancement of a pusher shaft. Furthermore, this conventional device employs two linearly moveable plungers, one of which is in the guide track path (e.g., stem of the T) and the other of which is in the trailing branch of the feed rail path. These plungers are hollow and each have a height generally the same as the width. Each plunger is depressed against a compression spring until the plunger directly contacts against a conical face of a set screw. The quick advancing movement of the rivet past each plunger causes each plunger to downwardly move at about 30 feet per second which prematurely fatigues the spring after a number of cycles. Moreover, the air pressure can disadvantageously push the rivet past the plunger in the feed rail prior to advancement of the pusher shaft.
[0004] In accordance with the present invention, a fastener machine is provided. In another aspect, a rivet machine employs a rivet feeding mechanism. A further aspect includes a guide located at an intersection between a feed track and a feed rail with the guide having an angular offset orientation relative to both in order to deter ricocheting of the rivet back into the feed track when the rivet enters the feed rail. Moreover, an aspect of the present machine employs a rocker arm pivotable adjacent a feed rail with a finger of the rocker arm being moveable through a hole in a channel to selectively limit movement of the rivet in the channel. In another aspect, a biased plunger has: a longitudinally longer aspect ratio relative to its nominal width to deter misalignment or cocking during movement of the plunger, a stop surface abutting a flange of the plunger to deter fatigue of a biasing member, and/or a beveled hole edge to deter tripping of the rivet when the rivet moves past the hole. Yet another aspect of the rivet machine provides at least a return sensor, an advancing sensor, a rivet feed sensor and a controller. A method of using a rivet machine is additionally provided.
[0005] Further advantageous and areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view showing a rivet machine;
[0007] FIG. 2 is a perspective view showing a feeding mechanism employed in the rivet machine;
[0008] FIG. 3 is a fragmentary perspective view, with a cover removed, showing the feeding mechanism;
[0009] FIGS. 4-6 are a series of elevational views, with the cover removed, showing operation of the feeding mechanism;
[0010] FIGS. 7-9 are a series of diagrammatic views showing the operation of a rocker arm employed in the feeding mechanism;
[0011] FIG. 10 is a cross-sectional view, taking along line 10 - 10 of FIG. 4 , showing a plunger assembly employed in the feeding mechanism;
[0012] FIG. 11 is an enlarged cross-sectional view, like that of FIG. 10 , showing the plunger assembly; and
[0013] FIG. 12 is a perspective view showing sensors employed in the feeding mechanism.
DETAILED DESCRIPTION
[0014] Referring to FIG. 1 , a rivet setting machine 21 includes a C-frame 23 which is mounted to an articulated robotic arm 25 for automated movement between various operating positions within an industrial factory. An anvil section 27 of C-frame 23 has a die 29 mounted thereon. A ram assembly 31 is mounted to the opposite end of C-frame 23 and includes an air-over-oil fluid actuated cylinder 33 , a nose piece 35 and a linearly moving ram 37 . Alternately, cylinder 33 can be solely hydraulically, pneumatically, or less preferably, servo-motor actuated. A rivet feeding mechanism 41 is mounted to a generally middle segment of C-frame 23 and is elongated in a direction generally perpendicular to the movement direction of ram 37 .
[0015] A vibratory bowl 43 supplies individualized fasteners, such as a self-piercing rivet 45 , to feeding mechanism 41 via a pneumatically pressurized and flexible hose 47 . When multiple workpiece sheets 49 are inserted between ram 37 and die 29 , ram 37 will thereafter push and set the rivet into the upper surface of the workpieces as they are being compressed against die 29 . Self-piercing rivet 45 is preferably a solid (e.g., not hollow) rivet which punches out a blank or slug from the previously unpunched workpiece areas, whereafter the blanks are withdrawn through an aperture in die 29 . The rivet ends are generally flush with the adjacent outside surfaces of workpieces 49 . One such self-piercing rivet is disclosed in U.S. Pat. No. 4,130,922 entitled “Headless Riveting System” which issued to Koett on Dec. 26, 1978, which is incorporated by reference herein.
[0016] FIGS. 2-6 show further details of feeding mechanism 41 . Feeding mechanism 41 includes a curved guide track 61 within a rigid body 63 , and a linearly elongated channel 65 within a rigid feed rail 67 . A removeable cover 69 is bolted onto body 63 and an oppositely mounting gib 71 . Various bolts 73 and dowl pins 75 secure and align cover 69 to body 63 . Hose 47 is connected to one end of feed track 61 .
[0017] A guide 81 is located at an intersection of feed track 61 and feed channel 65 , but is angularly offset relative to adjacent sections of both. An angle α between the direction of guide 81 and an elongation direction 83 of feed channel 65 is between 110° and 160°, and more preferably about 120°. This offset configuration deters ricochet or bounce back of rivet 45 when it initially enters feed channel 65 and contacts a back wall 85 thereof. A plunger 87 further urges rivet 45 toward an intermediate and temporary holding position (as shown in FIG. 4 ) while also deterring movement of rivet 45 back into feed track 61 .
[0018] Feeding mechanism additionally includes a pusher shaft 91 , a tie rod 93 rotatably pinned to shaft 91 , a piston rod 95 coupled to tie rod 93 , and a pneumatic fluid actuator cylinder 97 which operably advances and retracts pusher shaft 91 . Cylinder 97 and body 63 are affixed to a rigid frame 99 .
[0019] With reference to FIGS. 3 , 8 , 10 and 11 , an elongated hole 101 is positioned in a bottom surface 103 of guide 81 . A nominal section of plunger 87 is moveably positioned within hole 101 such that a rounded or frusto-conical distal end 105 thereof projects beyond bottom surface 103 when the plunger is fully extended. The plunger is preferably a solid part. A laterally enlarged and circular flange 107 is located at a proximal end of plunger 87 . It is noteworthy that a longitudinal distance from the proximal to distal ends are at least two and more preferably at least three times greater than the diameter width of the nominal section of plunger 87 . This aspect ratio helps to align plunger 87 within hole 101 thereby preventing undesired cocking or jamming of the plunger during operation. A compression spring 109 fits within a bore 111 in a retainer block 113 fastened to a bottom of feed rail 67 by bolts 115 and dowl pins 117 . An intermediate countersink 119 is provided between hole 101 and bore 111 such that abuttment surfaces 121 and 123 contact against the facing surfaces of flange 107 to limit the longitudinal movement of plunger 87 . This serves to prevent overcompression and premature fatigue of spring 109 . Feed rail 67 is mounted to body 63 by a spring loaded pin 80 .
[0020] Additionally, a beveled edge 131 is machined at an intersection between hole 101 and bottom surface 103 . Such a bevel annularly extends around the periphery of the intersection and preferably has an angle β of 15° to 30° relative to bottom surface 103 , and more preferably 30°, but may alternately be rounded. This bevel edge deters tripping or jamming of the rivet when it depresses plunger 87 as it rides over hole 101 in response to the feeding pneumatic pressure. Land is present laterally adjacent hole 101 on bottom surface 103 so as to provide supporting ledges for the rivet.
[0021] FIGS. 3 and 7 - 9 , best illustrate a further rivet positioning device of the present feeding mechanism. A rocker arm 161 includes an upwardly projecting finger 163 at a first end and an upwardly projection foot 165 at an opposite end thereof. A fulcrum 167 is positioned in a generally middle section projecting oppositely from finger 163 and foot 165 . Fulcrum 167 has a somewhat triangular side view shape, the rounded apex of which is received within a valley 169 of a podium upstanding from retainer block 113 . A cavity 171 is present between facing surfaces of retainer block 113 and channel 65 of feed rail 67 .
[0022] An elongated slot or hole 181 is accessible by cavity 171 and extends through a bottom surface of channel 65 and laterally bordered by supporting ledges. Thus, when rocker arm 161 is pivoted to a rivet holding position as shown in FIG. 7 , finger 163 protrudes through hole 181 so as to deter undesired advancement of rivet 45 therepast. In this condition, a nominal underside surface 183 of shaft 91 abuts against foot 165 , via hole 185 , to maintain the rocker arm 161 in the position shown in FIG. 7 with finger 163 extending into a blocking position in channel 65 .
[0023] When shaft 91 is advanced to an intermediate position, as shown in FIG. 8 , foot 165 of rocker arm 161 is upwardly rotated into a relief gap 191 in rod 91 such that rivet 45 downwardly depresses finger 163 in a detented manner as rivet 45 passes over hole 181 . An intersecting edge of hole 181 adjacent the bottom surface of channel 65 is beveled like that illustrated in FIG. 11 . Subsequently, FIG. 9 shows rivet 45 advanced to a setting ram-engagement position beyond feed rail 67 and with rocker arm 161 downwardly rotated. Alternately, a pivot pin and/or biasing spring can be used to move the rocker arm, however, such an alternate configuration may not be as cost effective as with the preferred embodiment.
[0024] Pushing shaft 91 is preferably machined from AMPCO 18 bronze. This material prevents magnetization of shaft 91 which would otherwise occur if steel. Magnetization would undesireably prevent the shaft from releasing the rivet. Furthermore, plunger 87 and rocker are machined from 6150 steel which is heat treated, hardened and ground to RC 60-63 and RC 50-54, respectively. The feed rail, retaining block and body are machined from M2 steel, which is heat treated, hardened and ground to RC 60-63.
[0025] Turning now to FIGS. 1 and 12 , multiple sensors are connected to a programmable controller 201 , preferably a computer, including non-transient memory such as RAM, ROM, a hard disc drive, removeable memory or the like. A microprocessor uses this stored software and received data to interface with input and output devices such as a keyboard, display screen, warning lights or the like. Programmed software instructions are stored in the memory for receiving sensor signals and making the necessary calculations and determinations as to whether the rivet machine is operating properly and whether an error signal needs to be output.
[0026] More particularly, a first sensor is a no-rivet proximity switch 203 which detects if no rivet is present when cylinder 97 actuates the pusher shaft. A second sensor is an in-position proximity switch 205 which detects whether the pusher shaft has fully advanced the rivet. A third sensor is a return proximity switch 207 which detects whether the pusher shaft has fully retracted. A rod 209 extending from a back side of the piston and moveable with the pusher shaft, includes a forward/return flag 211 and a missing rivet flag 213 . Flag 211 is sensed by switches 205 and 207 while flag 213 is sensed by switch 203 . Switches 203 , 205 and 207 are preferably photo-electric sensors such as model BGL 20A-001-S49 which can be obtained from Balluff Inc.
[0027] Furthermore, proximity sensors 231 and 233 are positioned adjacent entrance and exit ends of feed tube 47 . The tube sensors are preferably of a ring proximity switch type that are connected to controller 201 and used to determine if a rivet has entered and exited tube 47 . Tube sensors 231 and 233 send appropriate signals to controller 201 which determines if a rivet has been properly fed through the tube, and prevents multiple rivets from being fed during the same feed cycle in the feeding mechanism to prevent rivet jamming therein. Accordingly, controller 201 will send an error message to an output device if a misfeed has occurred.
[0028] The control logic is as follows. Before a rivet is sent to the rivet insertion unit from the bowl feeder, the pusher shaft is in its retracted position which is indicated by the return position photo-electric sensor being activated. Subsequently, when the bowl feeder receives a signal to send a rivet from the controller software, the bowl feeder blows a single rivet through the hose whereby the rivet passes through the first ring sensor which inductively senses the passage of the rivet therethrough and communicates with the software that the bowl feeder actually sent a rivet as so instructed by the software. If no rivet passes through the first ring sensor in a predetermined amount of time, then the controller software will indicate a fault or error that the bowl feeder failed to send a rivet. An operator then must clear this fault before the system will further cycle.
[0029] Next, the rivet will pass the second ring sensor at the opposite end of the tube. When the second ring sensor is activated and sends the appropriate signal to the controller software, then the software will cause a cessation of pneumatic pressure into the hose. But if no rivet passes the second inductive ring sensor within a predetermined period of time, the controller software will indicate a fault that the rivet is stuck in the hose. In this event, the operator must clear the fault before the system will cycle.
[0030] Furthermore, after the second sensor has indicated that the rivet has travelled through the hose and is in the rivet staging area, the controller software sends a signal to feed a rivet to the nose piece in the ram assembly. In this event, the controller software causes the actuator cylinder to advance the pusher shaft. The pusher shaft accordingly advances until the rivet is pushed into the setting ram-engaging position aligned between the ram and die. The rivet advance-return flag activates the advance photo-electric sensor for a predetermined amount of time (preferably 0.1-0.2 seconds) to ensure that it is in the final position. Once the advance photo-electric sensor has been activated, the pusher shaft is then caused to return by reverse actuation of the cylinder. If no rivet is present then the missing rivet flag activates the associated no-rivet photo-electric sensor and the controller software signals that a fault is caused by the rivets being stuck in the feeding track. Action must be taken to clear this fault before the system will continue to cycle. Moreover, if the pusher shaft is activated and no sensor is activated then there is a rivet jam between the pusher shaft and feed rail which must be cleared before cycle resumption.
[0031] While various constructions have been disclosed, other modifications may be made. For example, alternate fasteners can be set by the machine although many of the benefits of the present machine will not be achieved. Furthermore, different types of sensors can alternately be employed but certain advantages may not be realized. Such variations are not to be regarded as a departure from the present invention and all such modifications are intended to fall within the scope of the present invention. | A fastener machine is provided. In another aspect, a rivet machine employs a rivet feeding mechanism. A further aspect includes a guide located at an intersection between a feed track and a feed rail with the guide having an angular offset orientation relative to both in order to deter ricocheting of the rivet back into the feed track when the rivet enters the feed rail. Moreover, an aspect of the present machine employs a rocker arm. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to a method of and apparatus for flushing a cooling system of an automobile engine.
The cooling systems in automobiles are fairly standard and generally comprise a radiator which is linked by hoses to both an engine block and a water pump. A heater is also provided between the pump and the engine block itself. The cooling system, therefore, consists of a number of flow paths through which water or coolant is circulated when the engine is in operation thereby reducing the engine operating temperature and correspondingly reducing the possibility of damage to the engine components themselves. Due to the nature of the automotive cooling system, however, sediment and deposits, such as rust, scale and the like, will build up inside the hoses and various elements over a period of time. This results in inefficient operation of the system, and in extreme cases can even cause the system itself to actually become blocked. To prevent this, it is generally considered advisable in the automotive industry for the cooling system to be flushed at periodic intervals and the water or coolant contained therein to be replaced.
In the prior art, the most common type of cooling system flushing is accomplished by draining the cooling system and then running the engine while fresh water is introduced into the system by means of a hose attached to an opening in the top of the radiator. This method, however, is ineffective in removing the rust and scale which has built up as it provides for only a unidirectional flow. Additional apparatus is known in the prior art for improving this method which consists of the use of a mixer chamber which combines pressurized air and water. This combination provides a more effective scrubbing action inside the cooling system itself than with water alone, but nevertheless does not remove all the rust and scale.
A more efficient method of cleaning the automotive cooling system is known in the prior art which consists of a four-cycle operation using the pressurized air and water combination. This method employs four separate flow-through steps each of which covers a different combination sequence of the individual elements of the cooling system itself. While this results in a much cleaner flushing, the process is complex and requires a number of costly items of equipment. Further, in view of the nature of the number of connections that are involved and the location where they must be made, this method is very difficult to employ. Therefore, while the four-cycle method does provide an effective flushing, it is much more expensive and more difficult to operate. Nevertheless, despite the drawbacks in terms of efficiency, cost and ease of operability, these methods and this apparatus for flushing automobile cooling systems are well-known and widely used.
SUMMARY OF THE INVENTION
The method of and apparatus for flushing an automobile cooling system according to the invention herein is more efficient and easier to operate than the prior art flushing systems. The apparatus of this invention generally comprises four basic parts which are an "X" connector, a flow-through radiator cap, a hose plug and a mixer chamber. When in operation, this apparatus provides a means for a two-cycle flushing according to the method of this invention.
The apparatus of this invention is installed by initially cutting a hose between a heater and a water pump in a standard automobile cooling system. The plug is then inserted into the water pump end of the cut hose. At the same time, the flow-through radiator cap replaces a standard sealing type of radiator cap normally covering a top opening in the automobile radiator. This, in effect, creates a flow path through the entire cooling system from the now cut radiator hose through the heater, to an engine block, back to the water pump and up through the radiator and finally out the flow-through radiator cap.
The "X" connector itself is comprised of a pair of vertical pipes which are interconnected by an independent pair of crossover pipes. A pair of diverter values are provided so that any flow through the "X" connector is either through the vertical pipes or through the crossover pipes. The output of the mixer chamber, which combines pressurized air and water, is attached to one end of a vertical pipe of the "X" connector. The opposite end of this vertical pipe is connected to the open end of the cut heater hose. At the same time, the flow-through radiator cap is connected to one end of the opposite vertical pipe for the "X" connector which directs any flow from the cap to a drain.
The method of this invention is essentially a two-cycle one. When the mixer chamber is turned on, the combination of water and pressurized air flow through the first vertical pipe of the "X" connector and into the cut end of the heater-water pump hose. This combination of water and air circulates through the entire cooling system as previously explained and exits at the flow-through radiator cap where it is directed to the drain. When the draining water becomes clear, the system has been essentially cleaned in the first cycle, and the valves of the "X" connector are turned so that the flow in and out of the "X" connector is through both of the crossover pipes. In the second cycle, the output of the mixer chamber, therefore, enters the cooling system through the flow-through radiator cap. The combination of air and water mixture proceeds through the system in the reverse direction and exits through the cut water pump-heater hose. From there, it is directed through one of the crossover pipes of the "X" connector into the drain. The entire cooling system is cleaned effectively in a two-cycle operation which is easy to accomplish as it requires only simple connections which do not have to be altered or changed for either of the operating cycles. When the cleaning is complete, the end of the plug in the water pump hose is removed and the hose is resealed.
Accordingly, a principal object of the present invention is to provide a method whereby an automobile cooling system can be efficiently cleaned.
Another object of the present invention is to provide an apparatus for the purpose of flushing the automotive cooling system which is inexpensive and can be easily installed.
Other and more specific objects of the invention will be in part obvious and will in part appear from the following description of the preferred embodiments taken together with the drawings.
DRAWINGS
FIG. 1 is a block diagram of the apparatus of this invention attached to an automobile cooling system;
FIG. 2 is an enlarged side view of the flow-through radiator cap of this invention;
FIG. 3 is an enlarged side view of a "T" plug;
FIG. 4 is an enlarged side view of another plug; and
FIG. 5 is an enlarged side view of the "X" connector.
The same reference numbers refer to the same elements throughout the various Figures.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, an automobile cooling system is shown at 10. The cooling system 10 generally comprises four main elements which are a radiator 20, an engine block 30, a water pump 40 and a heater 50. Under operating conditions, the cooling system 10 is sealed and filled with water or coolant which is circulated through the entire system by the water pump 40.
As shown in FIG. 1, the radiator 20 has a top 22 and a bottom 23. A radiator opening 25 is disposed in the top 22. The radiator opening 25 has a lip 27 disposed around it, and when the cooling system is in operation, this radiator opening 25 would be covered with a standard type of sealing radiator cap (not shown) secured to the lip 27. The radiator 20 also has a drain plug 26 located in its bottom 23 which is used to drain the coolant from the cooling system 10. The drain plug 26 would be closed when the cooling system 10 is being flushed in accordance with the method and apparatus of the invention as described herein. The radiator 20 also has a side opening 28 which is disposed near the top 22 and a lower opening 29 which is disposed near the bottom 23. Both the openings 28, 29 are adapted to receive hoses.
The engine block 30 has a first opening 32, a second opening 33 and a third opening 34 all of which are adapted to receive hoses. The first opening 32 is connected by a radiator-engine block hose 36 to the side opening 28 of the radiator 20. A thermostat 37 is disposed at the first opening 32 of the engine block 30, and the thermostat 37 effectively blocks radiator-engine block hose 36 when the cooling system 10 is not actually in operation.
The water pump 40 has a first opening 42, a second opening 43 and a third opening 44 all of which are also adapted to receive hoses. The first opening 42 of the water pump 40 is connected to the lower opening 29 of the radiator 20 by a radiator-water pump hose 46. The second opening 43 of the water pump 40 is similarly connected to the second opening 33 of the engine block 30 by an engine block-water pump hose 48.
As also shown in FIG. 1, the heater 50 is disposed between the engine block 30 and the water pump 40. The heater 50 has a first opening 52 which is connected by a water pump-heater hose 55 to the third opening 44 of the water pump 40. The heater 50 also has a second opening 53 which is similarly connected to the third opening 34 of the engine block 30 by an engine block-heater hose 57. Consequently, the cooling system 10 has a number of flow paths between the four basic elements.
A method for flushing this automobile cooling system 10 according to the invention herein comprises a number of individual steps. Initially, the sealing radiator cap (not shown) is removed from the radiator opening 25 which depressurizes the cooling system 10. A flow-through cap 60, as shown in FIG. 2, is then inserted in the radiator opening 25. The flow-through cap 60 is comprised of a hollow, central cylindrical core 62 having a top 63 adapted to receive a hose and a sealing collar 64 disposed around its bottom. The sealing collar 64 is adapted to be received by the radiator opening 25 of the radiator 20 so that the outside edge of the collar 64 fits against the inside of the radiator opening 25 thereby preventing any fluid from leaving the radiator 20 except through the hollow central core 62 of the flow-through radiator cap 60. A spring 66 is disposed above the sealing collar 64, and the spring 66 supports a cover 68. The cover 68 has a pair of J-shaped flanges 69 disposed on opposite sides and extending downwardly therefrom. When the flow-through cap 60 is in place, the cover 68 is pressed downward against the spring 66 so that the flanges 69 become hooked under the lip 27 of the radiator opening 25 of the radiator 20. This arrangement is similar to the attaching arrangement of the standard sealing type of radiator cap. When this is accomplished, the flow-through cap 60 is secured in place. However, unlike the standard radiator cap, the fluid inside the cooling system 10 can escape through the hollow central core 62.
When the flow-through cap 60 has been installed, a cut 56 is made in the water pump-heater hose 55 at its approximate midpoint, as shown in FIG. 1. A plug 70, as best shown in FIG. 3, is then inserted through the cut 56 into the water pump end of the hose 55. The plug 70 consists of a hollow main tube 72 which is cylindrical and open at both ends. One end of the tube 72 is adapted to receive a removable cap 73. The tube 72 also has a "T" connector 74 mounted on it near its midpoint. The "T" connector 74 is cylindrical and has an internal passageway 76 which extends longitudinally therethrough and internally connects with the hollow interior of the tube 72. A lip 77 surrounds the end of the "T" connector 74 opposite the tube 72. A "T" connector cap 78 is adapted to fit over the lip 77 and when in place, it seals the "T" connector passageway 76.
With the removable cap 73 attached to one end of the main tube 72, the plug 70 is installed in the cooling system 10 so that the capped end of the tube 72 is inserted into the water pump end of the cut water pump-heater hose 55. The opposite end of the tube 72 is then inserted into the heater end of the water pump-heater hose 55, and the plug 70 is secured in place by clamps 79. Because of the tube cap 73, no fluid can flow from the water pump 40 directly to the heater 50 as would occur in normal operation of the cooling system 10. Instead, a fluid path is provided through the passageway 76 of the "T" connector 74 through the tube 72 and into the heater 50.
As shown in FIGS. 1 and 5, an "X" connector 80 is next connected to the cooling system 10. The "X" connector 80 consists of a first vertical pipe 82 having a top opening 83 and a bottom opening 84. The "X" connector 80 also has a similar second vertical pipe 86 mounted parallel to the first vertical pipe 82. The second vertical pipe 86 has a top opening 87 and a bottom opening 88. As best shown in FIG. 5, the end of the first vertical pipe 82 near the bottom opening 84 is internally connected to the upper end of the second vertical pipe 86 near its top opening 87 by a first crossover pipe 91. Similarly, the end of the first vertical pipe 82 near its top opening 83 is internally connected to the lower end of the second vertical pipe 86 near its bottom opening 88 by a second crossover pipe 92. The crossover pipes 91, 92 are independent of each other and do not interconnect. A first diverter valve 94 is located at the junction of the first crossover pipe 91 and the first vertical pipe 82. Depending upon the alignment of the first diverter valve 94, a flow is passed either from the bottom opening 84 straight up through the first vertical pipe 82 and out the top opening 83 or from the bottom opening 84 through the first crossover pipe 91 and out the top opening 87 of the second vertical pipe 86. A second diverter valve 95 is located at the junction of the second crossover pipe 92 and the second vertical pipe 86 and operates in the same manner to either direct a flow through the second vertical pipe 86 or through the second crossover pipe 92.
Referring now to FIG. 1, the "X"0 connector 80 is attached to the automobile cooling system 10 in the following manner. A first flexible hose 98 is connected from the top opening 83 of the first vertical pipe 82 to the "T" connector 74 of the plug 70. The "T" connector cap 78 is not in place at this time and therefore a flow path is created through the first vertical pipe 82, through the first flexible hose 98, through the plug 70 and into the heater 50. At the same time, a second flexible hose 99 is connected to the top opening 87 of the second vertical pipe 86 of the "X" connector 80. The end of this second flexible hose 99 opposite the "X" connector 80 is attached over the top 63 of the central core 62 of the flow-through radiator cap 60 mounted on the radiator 20. A drain hose 97 is then connected from the bottom opening 88 of the second vertical pipe 86 to a drain (not shown). In operation, the method according to the invention herein is essentially a two-cycle process. For the first cycle, the diverter valves 94, 95 are selectively arranged to permit a fluid flow only through the respective vertical pipes 82, 86. Water under pressure is then fed into the bottom opening 84 of the first vertical pipe 82. The water (shown in solid lines) then proceeds through the first vertical pipe 82, out its top opening 83 and into the first flexible hose 98. From there, the water enters the cooling system 10 through the plug 70, and it circulates from the heater 50 through the engine block-heater hose 57 and into the engine block 30 itself. As the thermostat 37 prevents a flow through the radiator-engine block hose 36, the water is directed out of the engine block 30 and through the engine block-water pump hose 48 to the water pump 40. After the water circulates through the water pump 40, it proceeds into the radiator 20 through the radiator-water pump hose 46. The water circulates through the radiator 20 from the bottom to the top and it finally exits through the central core 62 of the flow-through radiator cap 60. The water has essentially been circulated through the entire automobile cooling system 10. The exiting water is directed by the second flexible hose 99 back to the "X" connector 80 where it flows into the top opening 87 of the second vertical pipe 86. It proceeds through the second vertical pipe 86 to its bottom opening 88. From there, the drain hose 97 routes it to the drain. When the water from the drain hose 97 becomes substantially clear, the first cycle is complete.
When the first cycle is finished, the diverter valves 94, 95 are placed in their opposite mode so that they will direct the flow through the respective crossover pipes 91, 92. In this configuration, the pressurized water flows from the bottom opening 84 of the first vertical pipe 82 up through the first crossover pipe 91 and out the top opening 87 of the second vertical pipe 86. Due to the status of the second diverter valve 95, this flow cannot pass down the second vertical pipe 86 to the drain hose 87, and, therefore, the water proceeds through the second flexible hose 99 and into the top of the radiator 20 by means of the flow-through radiator cap 60. The water passes through the automobile cooling system 10 in the opposite direction as before, as shown by the dotted lines in FIG. 1, and it exits through the "T" connector 74 of the plug 70. The first flexible hose 98 directs this water into the top opening 83 of the first vertical pipe 82 where it flows through the second crossover pipe 92, through the second diverter valve 95 and out the bottom opening 88 to the drain hose 97. Because of the status of the first diverter valve 94, the exiting water cannot pass through the first vertical pipe 82 but must proceed through the second crossover pipe 92. When the exiting water becomes clear after the second cycle, the cooling system 10 is completely flushed.
The scrubbing or cleaning action of the water can be enhanced by the use of a mixer chamber 100. The mixer chamber 100 is a well-known device in the prior art and serves to combine the water with a source of pressurized air. The mixer chamber 100 has an output 102 and a pair of inputs 104, 105. An air hose 107 from a pressurized air supply (not shown) is attached to one input 104 of the mixer chamber 100. At the same time, a water hose 108 is attached to the other input 105. The output 102 is then connected to the bottom opening of the first vertical pipe 82 of the "X" connector 80, as shown in FIG. 1. A pair of gauges 110 are provided on the mixer chamber 100 to monitor the respective rates of flow of air and water, and a pair of valves 112 is also provided to control those rates of flow. For convenience, both the mixer chamber 100 and the "X" connector 80 can be held in a single storage compartment 115.
When the flushing is complete, the capped end of the tube 72 of the plug 70 is taken out of the water pump end of the hose 55. The tube cap 73 is removed, and the tube 72 is then reinserted into the hose 55 and again secured in place by the clamps 79. The first flexible hose 98 is then removed from the "T" connector 74 and the "T" connector cap 78 is installed. This effectively reconnects the water pump-heater hose 55. At the same time, because the plug 70 is left in the system, it is readily available for use when the cooling system 10 must be flushed again. The second flexible hose 99 is then removed and the flow-through radiator cap 60 is replaced with a standard radiator cap after the cooling system 10 has been refilled with coolant.
Another type of plug 120 which may be used is shown in FIG. 4. This plug 120 comprises a hollow tube 122 having flanges 123 at each end. A removable cap 125 is inserted into one end of the tube 122 and the opposite end of the tube 122 is placed in the water pump end of the cut water pump-heater hose 55. With this plug 120 installed, the first flexible hose 98 is then connected directly to the heater end of the cut hose 55. When the flushing has been completed, the first flexible hose 98 is removed, and the tube 122 is uncapped. The formerly capped end of the tube 122 is thereupon inserted into the heater end of the cut hose 55, and the plug 120 is secured in place.
It should be obvious that the method of this invention could be in practice in a variety of ways. For example, the water pump-engine block hose might be cut and the water introduced to the engine block end. Other hoses might also be cut, but at least with the arrangement of most cooling systems, the use of other hoses would not permit such a complete flow through, as additional hose and elements might be by-passed. It should also be noted that a different type of flow-through radiator cap might be used or the second flexible hose attached directly to the radiator opening itself. Further, the cleaning fluid used for the flushing may be other than the water or the water and air combination as described herein.
From the foregoing description of the invention and the discussion of the prior art, the numerous advantages and improvements incident to this invention will now be apparent to those skilled in the art.
Accordingly, the above description of the invention is to be construed as illustrative only, rather than limiting. The invention is limited only by the scope of the following claims. | A two-cycle method for flushing an automobile cooling system and apparatus associated therewith. The method comprises cutting a hose between a water pump and a heater of a standard automobile cooling system. A pressurized air and water mixture is then introduced into the heater end of the cut hose, and after circulating through the cooling system, it exits through an opening in the top of a radiator which is normally sealed by a radiator cap. When this exiting water becomes clear, the second cycle is begun. The air and water mixture is introduced into the radiator opening and it circulates through the system in the opposite direction eventually exiting from the heater end of the cut hose. The apparatus of this invention includes a flow-through radiator cap which replaces the standard radiator cap, a plug which seals the water pump end of the cut hose and an "X" connector which by means of a pair of diverter valves directs the flow of the air and water into either the cut hose or the radiator opening. A mixer chamber is also provided which combines the pressurized air and water obtained from separate sources. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to data transfer through a communication system channel, and, more particularly, to signal adjustment for detection of data information from a recording medium.
[0003] 2. Description of the Related Art
[0004] A read channel component is an integrated circuit (IC) of a computer hard disk (HD) drive that encodes, detects, and decodes data, enabling a read/write head to correctly i) write data to the disk drive and ii) read back the data. The disks in an HD drive have a number of tracks, each track consisting of i) user (or “read”) data sectors and ii) control (or “servo”) data sectors embedded between the read sectors. Information stored in the servo sectors is employed to position the head (e.g., a magnetic recording/playback head) over a track so that the information stored in the read sector can be retrieved properly.
[0005] A servo sector typically comprises a servo preamble, an encoded servo address mark (SAM), encoded Gray data, a burst demodulation (demod) field, and a repeatable run-out (RRO) field. The servo preamble allows for timing recovery and gain adjustment of the written servo data. The SAM is an identifier of fixed bit-length that identifies the data as servo data, with the value for this identifier the same for all servo sectors. Gray data represents the track number/cylinder information and provides coarse positioning information for the head. The burst demod field provides fine positioning information for the head. RRO field data provides head positioning information that is i) finer than that provided by Gray data and ii) coarser than that provided by the burst demodulation fields. Specifically, RRO field data is typically employed to compensate for when the head does not follow a circular track around the disk. The read sector comprises a read preamble, a read address mark (RAM), and encoded user data. The read preamble also provides for timing recovery and gain adjustment, and the RAM identifies the read sector user data.
[0006] When the head of a recording system reads data from a sector of an HD, the data is provided as an analog signal (readback signal) that is subsequently level-adjusted, equalized, and sampled for further digital signal processing to detect and decode the sector information. Some older prior-art systems may perform analog rather than digital signal processing of the read signal. For level-adjustment, prior-art read channel components typically employ one or more attenuator stages and a variable gain amplifier (VGA) to adjust the readback signal provided from the head to a desired level before further processing.
[0007] The one or more attenuators provide coarse level-adjustment of the readback signal by attenuation, while the VGA provides fine level-adjustment through variable signal gain. The VGA has a finite range of operation. If the attenuator settings are too high or too low, the VGA may not be able to compensate for the gain error introduced by incorrect attenuator settings and may saturate at the VGA lower or upper gain (or “rail”).
[0008] At the beginning of a read or servo event (i.e., when the read or servo sector is being read), the prior-art read channel component performs a zero gain start (ZGS) to quickly predict the gain error in the readback signal prior to acquisition of the readback signal's gain and timing. Signal timing and gain acquisition over the preamble field is referred to as the “acquire mode” (ACQ mode). Since the preamble pattern (e.g., 2T pattern of 11001100. . . ) is known over a preamble field, prior-art systems employ efficient decision-directed (DD) algorithms for acquisition of gain and timing over this field, and using a substantial number of the preamble bits for this acquisition. The gain adjustment is estimated by a ZGS circuit that is provided entirely to a VGA register (which sets the VGA gain) so that adaptive gain adjustment of the DD algorithm starts from a relatively close starting point (i.e., the DD algorithm starts with an almost correct VGA gain as predicted by the ZGS circuitry).
[0009] After the ZGS, gain of the VGA is determined automatically (within its finite range of operation) by the read channel component using an adaptive signal-processing algorithm. However, prior-art setting of the attenuation is not an adaptive process. HD drive manufacturers determine off-line an appropriate level of attenuation for different sectors of an HD (a time-consuming and cumbersome process), and then program the read channel's attenuation setting for different sectors in firmware. Pre-programming attenuation levels provides for several problems in prior-art systems.
[0010] For example, when a “head switch” occurs (e.g., when a different head in a different disk platter is selected for reading/writing the data), large gain error (e.g., ±12 dB) from the nominal readback signal amplitudes can occur. Also, the VGA operates best within a linear range of operation near the center of its gain range. VGA performance deteriorates due to non-linear effects when the VGA operates near its lower and upper range levels.
[0011] In addition, the ZGS adjustment is dependent on the attenuator setting. For example, for a particular attenuator setting of −12 dB, VGA adjustment range of 0 to 24 dB, and VGA gain setting at the range center (12 dB), a ZGS adjustment of −12 dB adds −12 db to the VGA register which puts the VGA register at its lower limit of 0 dB. Consequently, this ZGS adjustment drives the operation of the VGA to the lower rail. This indicates that the selected attenuation is not adequate, and the incoming signal amplitude is very high.
SUMMARY OF THE INVENTION
[0012] In accordance with one embodiment of the present invention, a level of a readback signal is dynamically adjusted by: (a) detecting an event in the readback signal; (b) generating a zero gain start (ZGS) adjustment value for the event; (c) dividing the ZGS adjustment value into an attenuator portion and a gain portion; and (d) adjusting: i) an attenuation, by at least one attenuator, of the readback signal based on the attenuator portion, and ii) a gain, by a variable gain amplifier (VGA), of the readback based on the gain portion, wherein the gain portion tends to adjust the gain of the VGA within a predefined sub-range.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Other aspects, features, and advantages of the present invention will become more fully apparent from the following detailed description, the appended claims, and the accompanying drawings in which:
[0014] FIG. 1 shows a read channel component operating in accordance with exemplary embodiments of the present invention; and
[0015] FIG. 2 shows an exemplary method of setting attenuation and gain for the AFE of FIG. 1 .
DETAILED DESCRIPTION
[0016] FIG. 1 shows read channel component 100 operating in accordance with exemplary embodiments of the present invention. Read channel component 100 comprises analog front end (AFE) 101 having attenuator (ATT 1 ) 110 , attenuator (ATT 2 ) 111 , variable gain amplifier (VGA) 112 , fixed AFE gain 113 , analog-to-digital converter (ADC) 114 , and VGA register (reg) 115 . Read channel component 100 further comprises zero gain start (ZGS) circuit 102 , adaptive VGA gain loop circuit 103 , detector and decoder 104 , and processor 105 .
[0017] ATT 1 110 and ATT 2 111 attenuate an input readback signal in accordance with corresponding settings. The read back signal is typically coupled to AFE 101 from the preamp of the read/write head assembly by A/C coupling stages (not shown in FIG. 1 ). The readback signal is attenuated first by ATT 1 110 and then by ATT 2 111 . Typically, one of ATT 1 110 and ATT 2 111 is configured to settle faster than the other. For the described embodiment, ATT 1 110 has a longer settling period than ATT 2 111 . Consequently, attenuation of ATT 1 110 is adjusted only at the beginning or at the end of a servo event or a read event. ATT 2 111 settles such that adjustment of the attenuation of ATT 2 111 corrupts few, if any, samples during an event.
[0018] VGA 112 applies gain to the signal from ATT 2 111 to adjust the readback signal to a desired level. Gain of VGA 112 is set by the value of VGA reg 115 . VGA 112 operates substantially linearly in a range of low- to high-gain (upper and lower rails, respectively). Fixed AFE gain 113 represents gain added to the output signal of VGA 112 by other circuit components, such as an equalizer. The signal from fixed AFE gain 113 is quantized into digital samples by ADC 114 .
[0019] ZGS circuit 102 monitors the readback signal. During acquire (ACQ) mode (at the beginning of a read or a servo event), ZGS circuit 102 generates i) attenuation settings for ATT 1 110 and ATT 2 111 and ii) a gain setting for VGA 112 in accordance with an exemplary embodiment of the present invention, as described subsequently. After gain adjustment by ZGS circuit 102 , adaptive VGA gain loop processor 103 implements an algorithm, such as an adaptive, decision-directed (DD) gain control algorithm, to maintain the signal applied to ADC 114 at a desired level by adjusting the gain of VGA 112 . For example, the DD gain control algorithm might operate based on minimizing the least mean square (LMS) error between the actual and desired signal level outputs from ADC 114 .
[0020] Detector and decoder 104 is employed to detect and decode read and servo event data. Operation of elements of read channel component 100 might be coordinated by processor 105 .
[0021] In accordance with exemplary embodiments of the present invention, i) input attenuation level of, for example, ATT 1 110 , ATT 2 111 , and ii) gain of VGA 112 are set during ZGS so as to share the ZGS signal level adjustment (ZGS adjustment) between the attenuator settings and the VGA gain setting. Further adjustment is made for each subsequent servo or read sector event. While attenuation by the fast and slow settling attenuators and the gain by the VGA are shown in the FIGS. in a specific order, the present invention is not so limited. The order of attenuation and gain, as well as the number of attenuators and gain stages, might vary depending on a given implementation.
[0022] As an aid to understanding of the present invention, the exemplary embodiment is described with respect to the following configuration. Attenuation settings for ATT 1 110 correspond to attenuation levels of 0,4,8, and 12 dB, and attenuation settings for ATT 2 111 correspond to attenuation levels 0,2,4,6, and 8 dB. VGA 112 has a linear range of gain of 0 to 24 dB. The gain of fixed AFE gain 113 is 12 dB. ADC 114 provides one LSB change for every 15 mV (millivolts), where an LSB is a quantization level of the ADC. Thus, to achieve about ±20 LSBs at the output terminal of ADC 114 , the input signal to ADC 114 is about 600 mV.
[0023] For example, if the ZGS adjustment for the initially detected read or servo event is - 12 dB, then instead of correcting for the entire −12 dB gain error by adjustment of the VGA register as in the prior art, the exemplary embodiment accounts for only a portion of the ZGS adjustment value (up to the maximum attenuation level supported in the particular attenuator implementation) in the attenuator setting. The remaining portion of the ZGS adjustment is accounted for in adjustment of the gain value of the VGA register. For example, if the maximum attenuation possible is 6 dB, 6 dB of attenuation is selected in the attenuator and −6B is accounted for (12-6=6dB) in the VGA register. Since the VGA gain is not near the rails, the VGA has head-room for adaptation of the VGA gain.
[0024] FIG. 2 shows an exemplary method of setting attenuation and gain in accordance with the present invention. At step 201 , the beginning of a read or servo sector event is detected. At step 202 , a ZGS adjustment value is calculated by, for example, ZGS circuit 102 of FIG. 1 .
[0025] At step 203 , the ZGS adjustment value is divided into an attenuator portion and a gain portion. For the described embodiment herein, the division might be in 2-dB steps since the attenuators settings are in 2-dB increments. For the initial read or servo sector event, the division (ratio of attenuator portion to total ZGS adjustment value and ratio of gain portion to total ZGS adjustment value) might be predetermined offline. Also, the initial setting of the attenuator having the slower settling time (e.g., ATT 1 ) might be predetermined offline. Alternatively, the ratio might be calculated during ACQ mode based on a current setting of the gain register such that the gain portion operates the VGA within a defined sub-range about its center gain, unless the attenuators are at their maximum attenuation settings.
[0026] At step 204 , the attenuation setting of the attenuator having the fastest settling time is adjusted by the attenuator portion, and the VGA gain value (of, e.g., VGA register 115 ) is adjusted by the gain portion. At step 205 , the attenuation and gain settings are retrieved. During processing of the read or servo event, the gain control loop adjusting the gain of the VGA (e.g., adaptive VGA gain loop processor 103 ) further adjusts the gain value of the gain register based on the input level to the ADC. Consequently, step 205 begins a process to adjust the gain and attenuator settings so as to be able to handle subsequent events more effectively.
[0027] At step 206 , a test determines whether the current value of VGA gain is outside of a predefined sub-range about center gain. If the test of step 206 determines that the current value of VGA gain is not outside of a predefined sub-range, then the method returns to step 201 to process the next read or servo event.
[0028] If the test of step 206 determines that the current value of VGA gain is outside of the predefined sub-range, then the method advances to step 207 . At step 207 , the attenuation settings of the slow and fast settling attenuators are examined, and an amount of excess VGA gain is determined. At step 208 , a test determines whether the amount of excess VGA gain can be accounted for by the slow settling attenuator. If the test of step 208 determines that the amount of excess VGA gain can be accounted for by the slow settling attenuator, then, at step 209 , the setting of the slow settling attenuator is adjusted to account for the excess VGA gain and the current value of VGA gain is adjusted to be within the sub-range. From step 209 , the method returns to step 201 .
[0029] If the test of step 208 determines that the amount of excess VGA gain can not be accounted for by the fast settling attenuator, then, at step 210 , a test determines whether the slow attenuator can account for a portion of the excess gain. If the test of step 210 determines that the slow attenuator cannot account for a portion of the excess gain, then the method returns to step 201 . If the test of step 210 determines that the slow attenuator can account for a portion of the excess gain, then the method advances to step 211 .
[0030] At step 211 , only a portion of the attenuation of the slow settling attenuator is adjusted and the remainder is accounted for in the attenuation of the fast settling attenuator. At step 212 , the amount of excess VGA gain is divided into a gain portion and a fast settling attenuator portion. At step 213 , the setting of the fast settling attenuator is adjusted to account for the excess VGA gain and the current value of VGA gain is correspondingly adjusted to be within the sub-range based on the gain portion. From step 213 , the method returns to step 201 .
[0031] The following example illustrates the method of FIG. 2 . The readback signal amplitude might be between 45 mV and 500 mV, with 150 mV as the nominal value. Thus, the gain error has a swing of about ±10.5 dB from the nominal value. Desirably, VGA 112 is operated such that its gain is near the center (12 dB) of its range to achieve ±20 LSBs (for, for example, preamble detection level). Initially, the attenuation of ATT 1 110 ( FIG. 1 ) is set to −12 dB, the attenuation of ATT 2 111 is set as 0 dB, and VGA gain is set to 12 dB. Attenuation of ATT 1 110 and/or ATT 2 111 is desirably set such that, for a nominal output voltage of the readback signal (˜150 mV), the VGA input signal level is about 37.5 mV (providing an ADC output range of ±20 LSBs). The VGA output level is 150 mV because of the initial 12-dB gain setting.
[0032] Re-distribution of the attenuation and gain between VGA 112 , ATT 1 110 , and ATT 2 111 for a read or servo event occurs as follows. The ZGS adjustment value is calculated, which ZGS adjustment value varies between ±12dB (i.e., correct up to ±12 dB of gain error). For example, if the ZGS adjustment value is −4.5 dB, then the ZGS adjustment is split between ATT 2 111 (in steps of 2 dB) and the gain value for VGA 112 . An additional 4 dB of attenuation is added to ATT 2 111 and −0.5 dB gain is added to the gain value of VGA 112 . Consequently, the gain range of VGA 112 is −11.5 dB to +12.5 dB.
[0033] The gain control loop implemented by adaptive VGA gain loop circuit 103 adaptively sets the gain of VGA 112 during the ACQ mode. Upon the end of ACQ mode, VGA gain is examined to see if some of the offset from its center (excess VGA gain) can be accounted for in ATT 1 110 and ATT 2 111 for the next read or servo event. For example, on top of −4 dB in ATT 2 111 and −0.5 dB in VGA 112 after ZGS adjustment, if the VGA settles −3 dB from its center, another −2 db can be accounted for in ATT 2 111 (for a total of −6dB). After adjusting the attenuation of ATT 2 111 , the gain of VGA 112 is at −1 dB off of its range center. Adjustments to attenuation of ATT 2 111 can be made up to a maximum of 8 dB attenuation.
[0034] Alternatively, for a non-zero setting of ATT 2 111 , if the gain of VGA 112 settles on the positive side from its center, part of the gain can be accounted for (in 2 dB steps) in the attenuation of ATT 2 111 by decreasing the attenuation up to a minimum of 0 dB.
[0035] Table 1 summarizes settings of ATT 1 , ATT 2 , and VGA for different gain error scenarios for a prior-art system having two attenuators and for the above example under different gain error scenarios and for two events.
TABLE 1 Gain Example, 1 st Event Example, 2 nd Event Error From Prior Art ATT2 VGA ATT2 VGA 150 mV ATT1 ATT2 VGA ATT1 (after ZGS) (after ACQ) ATT1 (after ZPS) (after ACQ) +12 −12 0 0 −12 −8 8 −12 −8 8 +10 −12 0 2 −12 −8 10 −12 −8 10 +8 −12 0 4 −12 −8 12 −12 −8 12 +6 −12 0 6 −12 −6 12 −12 −6 12 +4 −12 0 8 −12 −4 12 −12 −4 12 +2 −12 0 10 −12 −2 12 −12 −2 12 0 −12 0 12 −12 0 12 −12 0 12 −2 −12 0 14 −12 0 14 −12 0 14 −4 −12 0 16 −12 0 16 −8 0 12 −6 −12 0 18 −12 0 18 −8 0 14 −8 −12 0 20 −12 0 20 −4 0 12 −10 −12 0 22 −12 0 22 −4 0 14 −12 −12 0 24 −12 0 24 0 0 12
[0036] A read channel of a recording system operating in accordance with one or more embodiments of the present invention may exhibit the following advantages. Auto-adjustment of attenuation and gain in a read- channel component eliminates the off-line process of attenuation-level selection for proper VGA operation. In addition, auto-adjustment of attenuation and gain tends to operate the VGA within the center of its linear operating range, discouraging operation at or near the VGA rails, and allows for large variations in differing readback signal levels from different heads.
[0037] The present invention can be embodied in the form of methods and apparatuses for practicing those methods. The present invention can also be embodied in the form of program code embodied in tangible media, such as floppy diskettes, CD-ROMs, hard drives, or any other machine-readable storage medium, wherein, when the program code is loaded into and executed by a machine, such as a computer, the machine becomes an apparatus for practicing the invention. The present invention can also be embodied in the form of program code, for example, whether stored in a storage medium, loaded into and/or executed by a machine, or transmitted over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein, when the program code is loaded into and executed by a machine, such as a computer, the machine becomes an apparatus for practicing the invention. When implemented on a general-purpose processor, the program code segments combine with the processor to provide a unique device that operates analogously to specific logic circuits.
[0038] It will be further understood that various changes in the details, materials, and arrangements of the parts which have been described and illustrated in order to explain the nature of this invention may be made by those skilled in the art without departing from the principle and scope of the invention as expressed in the following claims. | A recording system, such as a magnetic or optical recording system, sets input attenuation level setting and variable gain amplifier (VGA) operating region during zero gain start (ZGS) by sharing the ZGS adjustment between attenuator settings and VGS gain setting. Further adjustment is made to attenuator settings and VGS gain setting for each subsequent servo or read sector event. The input attenuation level setting and variable gain amplifier (VGA) operating region are set so as to minimize effects of gain error due to incorrect attenuator setting, and subsequently operate the VGA near the center of its range where the non-linear effects are minimal. | 6 |
BACKGROUND OF THE INVENTION
[0001] The present invention concerns a method for rendering a three dimensional scene.
[0002] The process of producing three dimensional (3D) computer generated images for short or feature animation movies involves a step called lighting. The lighting phase consists of defining a lighting scenario that is aimed to illuminate a 3D representation of a scene made of 3D geometries with material properties that describe how the geometry of a given scene reacts to light. The lighter is the person responsible for defining this lighting scenario. The lighter work consists of an iterative process of changing parameters to a lighting scenario in order to achieve the artistic goal of generating a beautiful image. At each step of modification of a parameter, the lighter needs to see the result of the modification on the final image to evaluate the effect of such modification.
[0003] Lighting complex 3D images requires processing of very complex 3D geometries with very sophisticated representations to obtain the desired “artistic” result. Lighting a 3D scene correctly requires a great amount of time and manual labor due to the complex interactions of the various materials in the 3D scene, the amount of reflectivity of the materials and the position of one or more light sources.
[0004] One of the bottlenecks for processing large 3D scenes is the amount of complex geometric calculations that must be performed. The current algorithms used for rendering complex images usually require computer processing times ranging from several minutes for a simple 3D image to many hours. Advantageously, computing power cost less and less. Disadvantageously, the skilled labor to create the 3D images costs more and more.
[0005] The current standard process to light a 3D scene is that a few parameters of the 3D scene (such as, for example, light, texture, and material properties) are changed and then the work is rendered by one or more computers. However, the rendering process can take minutes or many hours before the results of the changes are able to be reviewed.
[0006] Further, if the 3D scene is not correct, the process must be repeated.
[0007] Known techniques to improve the time needed for rendering includes using dedicated hardware components as described in document U.S. Pat. No. 7,427,986.
[0008] Alternatively, document U.S. Pat. No. 7,532,212 describes a method aiming at a limitation of the amount of data to be loaded in memory.
[0009] The purpose of the present invention is to further improve the lighting productivity and artistic control when producing 3D computer generated images without the disadvantages of the known methods.
SUMMARY OF THE INVENTION
[0010] The present invention concerns a method for rendering or interactive lighting of a tridimensional scene in order to obtain a twodimensional image of said scene comprising the steps of performing a shading process taking into account a set of shader and material properties of the 3D objects of the scene wherein the shading process produces a shader framebuffer used to store information records related to shaders and/or material properties of the tridimensional scene in a format where said information records can be accessed in relation with a an image position in the twodimensional image.
[0011] The present invention overcomes limitations of the prior art by providing a method to improve the lighting productivity and artistic control when producing 3D computer generated images.
[0012] The geometry fragments are represented by an array of value that depends only of the size of the final image independently from the initial geometry complexity using a deep file approach. The framebuffer file approach is applied to a re-lighting application to make it more efficient than other existing interactive lighting solutions.
[0013] According to one embodiment of the invention, the method according to the invention comprises the steps of performing a rasterization process in order to produce a geometry frame buffer; Performing a visibility process of the tridimensional scene with regards to a set of lights defined in the scene in order to produce a shadow map; and wherein the geometry framebuffer, shading framebuffers are split into buckets corresponding to portions of the twodimensional image.
[0014] Indeed, the use of a geometry framebuffer can be very cumbersome when dealing with complex geometries. For a given complex 3D image, the size of the resulting geometry framebuffer file can be around 100 Gb, and cannot be generated and/or loaded all at once by one process. So in order to be able to generated and access data of that size, the geometry framebuffer file is split into a collection of smaller files which can be independently generated, loaded and discarded on demand by a client process.
[0015] According to one aspect of the invention, buckets are stored on persistent storage, and loaded in live memory when the corresponding image portion is to be processed.
[0016] The disk storage (hard drive) is used instead of the live memory (RAM) to cache the result of the computation of each process or sub process. The reason for this is that the RAM is limited in size, and is temporary memory limited to the life of one process. Using disk storage gives access to virtually unlimited and cheap memory resources for static caching of the information and ensures avoiding multiple computations of the same data.
[0017] Interactivity in the lighting process is improved by computing once for all, all the geometry fragments visible from a given point of view and put the result to disk.
[0018] According to another aspect of the invention, the rasterization, visibility and/or shading process are divided into subprocesses. According to a further aspect, the visibility process is performed independently for each light source.
[0019] According to another aspect of the invention, shader information is stored in a shading tree structure comprising a plurality of nodes and wherein the shader framebuffer is conceived for storing the results of the evaluation of a node from the shading tree structure.
[0020] Caching of results of shading nodes calculation limit re-evaluation needs on modifications. Indeed for each fragment of the geometry framebuffer is mapped with the result of the evaluation of the corresponding fragment in a given shader and generates a custom framebuffer for this shader only to cache its evaluation state.
[0021] According to another aspect of the invention, only sub-regions of the image are processed while in the shading process.
[0022] Such mechanism can be called the “region of interest” of the rendered image. It is constituted of a sub-portion of the full image to limit the computation of the image to the specified region. This method is using only the appropriate precomputed buckets from the cached geometry, shadow and shader framebuffers, allowing optimal rendering of the portion of the image loading only a minimal amount of data.
[0023] According to another aspect of the invention, the geometry framebuffer comprises additional information for interactive control of the scene file or for non rendering related use, such as additional scene description information to be used to navigate through the components of the scene from a final rendered image view.
[0024] According to a further aspect of the invention, geometry frame buffer is adapted for dynamic extension.
[0025] According to a further aspect of the invention, the shader framebuffer is suitable for storing of additional information for use by the shaders.
[0026] These types of data can be of any kind, and not just geometric information. Each shader in the shader tree can then use this to store specialized precomputing data that can help it speed up its final computation.
[0027] The present invention also concerns a system for implementing a method as mentioned above, comprising a central processing unit but also a computer program product implementing said method and a storage medium comprising source code or executable code of a computer program implementing said method.
[0028] Methods and devices that implement the embodiments of the various features of the invention will now be described with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is a schematic view of an hardware architecture used in connection with the method according to the present invention.
[0030] FIG. 2 is a schematic view of a rendering architecture.
[0031] FIG. 3 is a schematic view of a rendering architecture including the caching structure used in the invention.
[0032] FIG. 4 is a schematic diagram of a method according to the invention.
[0033] FIG. 5 is a schematic diagram illustrating the caching and reusing of the result of a shader evaluation.
DETAILED DESCRIPTION
[0034] The drawings and the associated descriptions are provided to illustrate embodiments of the invention and not to limit the scope of the invention. Reference in the specification to “one embodiment” or “an embodiment” is intended to indicate that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least an embodiment of the invention. The appearances of the phrase “in one embodiment” or “an embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
[0035] Throughout the drawings, reference numbers are re-used to indicate correspondence between referenced elements.
[0036] The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor, but does not limit the variations available.
[0037] As used in this disclosure, except where the context requires otherwise, the term “comprise” and variations of the term, such as “comprising”, “comprises” and “comprised” are not intended to exclude other additives, components, integers or steps.
[0038] In the following description, specific details are given to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific detail. Well-known methods and techniques may not be shown in detail in order not to obscure the embodiments.
[0039] Also, it is noted that the embodiments may be described as a process that is depicted as a flowchart, a flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be rearranged. A process is terminated when its operations are completed. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination corresponds to a return of the function to the calling function or the main function.
[0040] Moreover, a storage may represent one or more devices for storing data, including read-only memory (ROM), random access memory (RAM), magnetic disk storage mediums, optical storage mediums, flash memory devices and/or other machine readable mediums for storing information. The term “machine readable medium” includes, but is not limited to portable or fixed storage devices, optical storage devices, wireless channels and various other mediums capable of storing, containing or carrying instruction(s) and/or data.
[0041] Furthermore, embodiments may be implemented by hardware, software, firmware, middleware, microcode, or a combination thereof. When implemented in software, firmware, middleware or microcode, the program code or code segments to perform the necessary tasks may be stored in a machine-readable medium such as a storage medium or other storage(s). A processor may perform the necessary tasks. A code segment may represent a procedure, a function, a subprogram, a program, a routine, a subroutine, a module, a software package, a class, or a combination of instructions, data structures, or program statements. A code segment may be coupled to another code segment or a hardware circuit by passing and/or receiving information, data, arguments, parameters, or memory contents. Information, arguments, parameters, data, etc. may be passed, forwarded, or transmitted through a suitable means including memory sharing, message passing, token passing, network transmission, etc.
[0042] The term “data element” refers to any quantum of data packaged as a single item. The term “data unit” refers to a collection of data elements and/or data units that comprise a logical section. The term “storage database” includes any mechanism that provides (i.e., stores and/or transmits) information in a form readable by a machine (e.g., a computer). For example, a machine-readable medium includes read only memory (ROM); random access memory (RAM); magnetic disk storage media; optical storage media; flash memory devices; electrical, optical, acoustical or other form of propagated signals (e.g., carrier waves, infrared signals, digital signals, etc.); etc.
[0043] In general, the terms “data” and “data item” as used herein refer to sequences of bits. Thus a data item may be the contents of a file, a portion of a file, a page in memory, an object in an object-oriented program, a digital message, a digital scanned image, a part of a video or audio signal, or any other entity which can be represented by a sequence of bits. The term “data processing” herein refers to the processing of data items, and is sometimes dependent on the type of data item being processed. For example, a data processor for a digital image may differ from a data processor for an audio signal.
[0044] In the following description, certain terminology is used to describe certain features of one or more embodiments of the invention.
[0045] The term “bucket” refers to a data unit that is stored with an associated key for rapid access to the quantum of data. Such as, for example, a bucket can consist of a block of memory that is subdivided into a predetermined number of smaller blocks of uniform size, each of which is an allocatable unit of memory. The terms “stream,” “streamed,” and “streaming” refers to the transfer of data at a steady high-speed rate sufficient to ensure that enough data is being continuously received without any noticeable time lag.
[0046] The term “shading” refers to the effects of illumination upon visible (front facing) surfaces. When a 3D scene is rendered, the shading is combined with the reflected light, atmosphere, and camera information to compute the final appearance of the inside and outside surface colors for a 3D scene.
[0047] The term “UV mapping” refers to a 3D modeling process of making a 2D image representing a 3D model. The UV map transforms the 3D object onto an image known as a texture.
[0048] The term “noise” refers to pseudo random, unwanted, variations in brightness or color information inducted into an image. Image noise is most apparent in image regions with low signal level, such as shadow regions.
[0049] The term “sampling techniques” refer to a statistical practice that uses measured individual data points to statistically infer, or predict, other non-observed data points based on the observed data points.
[0050] As described in FIG. 1 : the method according to the invention may be implemented using a standard computer architecture 5 comprising a Central Processing Unit or CPU 1 composed of one or many cores, accessing data through a BUS 4 and storing data either temporarily in a Random Access Memory unit 2 or permanently on a file system 3 .
[0051] A system according to the invention was tested on two different types of computers: A HP xw6600 graphic workstation (2 Intel Xeon CPU quad core 2.84 Ghz, 8 Gb RAM DDR2, 160 Gb 10,000 rpm hard drives), and a HP Elitelook 8730w laptop computer (1 Intel Core 2 extreme CPU 2.53 Ghz, 8 Gb RAM DDR2, 320 Go 7,200 rpm hard drive).
[0052] Referring to FIG. 2 , a rendering architecture 10 is a system taking a lighting scenario of a 3D Scene as input 11 and generating a final image as output 12 . The rendering architecture 10 comprises three main units performing three distinct processes.
[0053] First process is a rasterisation process 13 , wherein the geometry complexity of the 3D Scene is converted into camera space depending of the resolution of the final image.
[0054] Second process is a visibility process 14 , wherein the geometry complexity of the 3D Scene is processed from the point of view of the lights, in order to determine the corresponding shadows.
[0055] Third Process is a shading process 15 , wherein the final color of a given pixel is determined by evaluating how the materials applied to the geometry visible from this pixel reacts to light.
[0056] Each process can be divided into sub-processes as described below.
[0057] The rasterisation process 13 is applied to a rectangular area representing the final image 16 . This process can be split into sub processes by dividing the computation of the geometry complexity in image space into sub images named buckets 17 .
[0058] A bucket is a portion of a framebuffer, a fragment is the atomic entity in the framebuffer or bucket. A fragment would correspond to a pixel if there is no antialiasing for example.
[0059] The visibility process 14 can be independently applied to each light 18 of a lighting scenario 11 of a 3D scene.
[0060] The shading process 15 can be applied independently for each pixel and for each object of the lighting scenario used to described a material property 19 . Considering a material architecture using a graph of connected material operators commonly called shaders to represent the properties of each material, each shader 20 may be computed independently from the other.
[0061] Now referring to FIG. 3 , the caches or storage entities used in the above described rendering architecture 10 are identified.
[0062] A geometry framebuffer cache 22 resulting from the rasterisation process 13 in image space 16 , a shadow map cache 23 resulting from the visibility process 14 for each light 18 of the lighting scenario of the 3D Scene, a generic shader framebuffer cache 24 used to cache the state of any shader 20 and material property 19 of the shading process 15 , with the option for some shaders to generate more specialized cache 25 on a case per case basis.
[0063] Referring now to FIG. 4 , there is shown a diagram of the steps of a method for lighting a 3D scene that decreases the rendering time experienced by a user when lighting complex 3D scenes when any 3D parameters are changed and providing interactive feedback according to one embodiment of the present invention.
[0064] The method comprises a step of storing complex geometric calculations into a geometry framebuffer file 22 on disk.
[0065] This file will be generated by storing the result of a rasterization process 13 for an already defined camera 30 .
[0066] When performing the shading 15 in the interactive re-lighting session 32 , a selection of the subregion 33 of the image or portion of the scene to be shaded or reshaded is performed corresponding to a change in a portion of the scene 35 .
[0067] Depending on the subregion being shaded 33 , only the required data will be streamed 34 in memory and then discarded, using the bucket 17 representation of the geometry framebuffer File 22 . In more detail, according to an example, a single bucket of the selected portion of the 3D scene is loaded into a memory. Then, the shading of the selected portion of the 3D scene is performed. Once this shading is performed, the memory is cleared. Then, the next bucket of data of the selected portion of the 3D scene is processed. The steps of loading and clearing are repeated until the shading is applied to the portion of the 3D scene to be manipulated
[0068] This approach avoids loading the whole geometry framebuffer file in memory.
[0069] The evaluation state 36 of each shader 20 is cached under a geometry framebuffer file representation 24 in order to re-shade only the modified shaders and their dependencies, and reloading the prior shader state from disk on next update.
[0070] Turning now to FIG. 5 , the process of shader evaluation results caching and reusing is described in more detail.
[0071] A shader 20 is an object used to compute the properties of a given material associated to a given geometry in a 3D scene. When lighting a 3 d scene, the final rendered image is computed from the point of view of a camera 30 .
[0072] The camera 30 is defining the projection 40 used to transform 3D geometries 42 into image space or geometry framebuffer 22 , this geometry framebuffer describing for each sub-pixel all the geometry fragments visible under the given sub-pixel. Each sub pixel is identified by pixel coordinates x, y and subpixel coordinates sx, sy.
[0073] As described previously, when rasterising the 3D scene, the framebuffer is split 43 into logical buckets 17 , each bucket representing a set of fragments of the image.
[0074] During the shading process 15 , when shading the fragments under a subpixel 44 of a given bucket 17 , the material 19 associated to that fragment will be evaluated 45 , triggering the evaluation of a shader s 3 20 , itself trigerring the evaluation of another shader s 2 20 and storing the final result of this evaluation (usually under the form of an array of 4 double precision values for red/green/blue/alpha channels) into a file structure following the same organisation as the geometry framebuffer, that is, one cache file per bucket 46 , 47 and one value per fragment. Note that each shader will perform the same task of storing the result of its own evaluation into its own shader cache file.
[0075] Now when modifying one of the input parameters 48 of the shader s 3 , looking at the dependencies, the final material m 1 19 will need to be recomputed and the cache for shader s 3 47 will be invalidated, but shader s 2 not depending on this modification will not be affected and will keep its cache 46 clean for future evaluation.
[0076] Then, when reshading the image 22 after modification of s 3 's parameter 48 , the shading of the fragments under a given sub pixel 44 will trigger again the evaluation of Material ml 19 itself trigerring the evaluation of shader s 3 20 , which cache is invalid, itself trigerring evaluation of shader s 2 20 , which evaluation will be skipped since the cache is valid and the resulting value will directly be read from the shader cache file for the given fragment.
[0077] The geometry framebuffer file approach can be used to store the result of any node of the shading tree instead of just the leaf node currently represented by the Camera. Therefore, any node can use its cache to skip its re-evaluation when a parameter it does not depend on is changed in the shading tree. This way, only the shading nodes after the changed node in the shading tree need to be recomputed. The prior node computations in the shading tree are already stored and do not need to be changed, unlike the current related art that would recalculate the entire shading tree. Because a typical 3D scene contains thousands of shading nodes, re-computing only a dozen nodes while storing the remaining node can increase the interactive rendering speed by a factor of up to 100 times.
[0078] The method further comprises steps for using the shading tree node caching to improve rendering quality.
[0079] The present method also improves the quality of the 3D scene rendering. For example, currently most of the shadows in a 3D scene are computed through sampling techniques. These sampling techniques create noise. To diminish the noise a common approach is to increase the number of samplings, therefore the computation time. Since the shadowing information is cached in the geometry framebuffer file the “virtual” cached image can be filtered to diminish noise without the computing time usually required to do so.
[0080] In another embodiment, the geometry framebuffer file can be dynamically extended, that is, other types of information, such as, for example, the results of a computation or an index to external information, not just the complex geometric calculations, regarding the 3D scene can be stored. For example, a color per pixel, a parametric UV mapping, a texture UV mapping, index to the name of a character, a computation time, or an index to the most intense light among other types of information that can be stored in the storage.
[0081] In another embodiment, the geometry framebuffer file approach can be used to provide specialized user interface displays for the user that is customized for maximum efficiency. For example, the specialized user interface display can provide interactive geometry, materials, lights or name of animators who worked on the character, and the version of the animation for the character, among other information, can be displayed and selected from the specialized user interface display. Additionally, any relevant information to the workflow can also be presented in a more efficient specialized user interface display increasing the productivity of the user and reducing the resources necessary to produce a completed 3D scene.
[0082] As can be seen on FIG. 4 , storage of extra information may be provided for interactive control of the 3D scene like selection 37 of scene component from the rendered image window 38 or leveraging from storing generic information 39 on a per pixel basis in the geometry framebuffer file to reference production pipeline data.
[0083] For this purpose, geometry framebuffer file index information (meta-data) can be stored for a rendered 3D character or a 3D scene that can include production information. For example, after a 3D character or the 3D scene is completely rendered, meta-data information relevant to the character, such as, for example, version, rendering time, who worked on it, name of the character, can be stored and indexed for retrieval during the production process. This provides the capability for a user to select the 3D character or the 3D scene at any point in the production process and interactively access and display the information related to the 3D character or 3D scene.
[0084] Each computation step can be automatically triggered by the rendering engine as it usually is or manually activated/deactivated by the user. Indeed, the user can decide whether or not to recompute the geometry framebuffer, the shadow maps, the shaders. Additional to this the user can explicitly deactivate the evaluation of a given shader or freeze it and force it to use the cache of the previous computation. The goal is to avoid expensive computation that the user could assume to be useless.
[0085] For example, in the case of a scene with reflection, the reflection of the scene will be performed by a ray-trace light. The reflection computation can be very slow since it might need to process the whole scene geometry. This raytraced light can be freezed to speed up the final image computation while modyfing other lighting parameters of the scene. Even if the final image is not the correct one since the modifications can affect the reflection, these differences might not necessarily matter to the artist in a given context.
[0086] In conclusion, the decision on what is important to artisticly judge if an image is correct depends on subjective human parameters that the software cannot smartly guess. We are proposing a system where the artist can tailor the lighting process to adapt it to its own methodology and ensure maximum flexibility when performing its artistic task.
[0087] Although the present invention has been described with a degree of particularity, it is understood that the present disclosure has been made by way of example. As various changes could be made in the above description without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be illustrative and not used in a limiting sense. | The present invention concerns a method for rendering or interactive lighting of a tridimensional scene ( 35 ) in order to obtain a twodimensional image ( 12 ) of said scene comprising the steps of performing a shading process ( 15 ) taking into account a set of shader and material properties of the 3 D objects of the scene wherein the shading process produces a shader frame-buffer ( 24 ) used to store information records related to shaders ( 20 ) and/or material properties ( 19 ) of the tridimensional scene ( 35 ) in a format where said information records can be accessed in relation with a an image position (x, y, sx, sy) in the twodimensional image ( 12 ). | 6 |
TECHNICAL FIELD
[0001] This invention relates to the art of micro-electromechanical systems (MEMS) devices and methods of their making, and more particularly, to arrays of tiltable micro mirrors, e.g., small mirrors, which can reflect light.
BACKGROUND OF THE INVENTION
[0002] One solution for all-optical switching employs two MEMS devices each containing an array of tiltable micro mirrors, e.g., small mirrors, which can reflect light, which herein refers to any radiation in the wavelength of interest, whether or not in the visible spectrum. An optical path is established for light supplied from an input source, e.g., an optical fiber, to an output, e.g., an output fiber, by steering the light using a first micro mirror on the first optical MEMS device, the first micro mirror being associated with the input fiber, onto a second micro mirror on the second optical MEMS device which is associated with the output fiber. The second micro mirror then steers the light into the output fiber. Each fiber connected to the system is considered a port of the system, the input fibers being the input ports and the output fibers being the output ports.
[0003] There are various prior art methods of making such an array of tiltable micro mirrors. Typically the array is made in two parts. The first part includes the electrodes which control the tilt of the micro mirrors and some type of spacer which holds the second part offset from the electrodes. The second part includes the micro mirrors and their springs and any other supporting structure.
[0004] The spacers of one prior art mirror array are made from polyimide, which is photo-patternable type of plastic that is deposited on the substrate. Disadvantageously, such spacers are a) not flat at the top, b) are relatively soft, e.g., compared to silicon, c) must be hard baked at high temperatures, and d) the height of the resulting spacers is not uniform from device to device even when the same processing is employed.
[0005] In another prior art arrangement, the micro mirrors are manufactured from a silicon on insulator (SOI) wafer and then portions of the back of the wafer are etched to allow the mirror to move freely. The unetched portions serve as the spacers and keep the micro mirrors elevated with respect to the electrodes which are on a second wafer. See for example U.S. Pat. No. 6,201,631, which is incorporated by reference as if fully set forth herein. However, such micro mirrors are relatively fragile, and the height of the spacers is dictated by the thickness of the wafer on which the micro mirrors were formed, which is typically greater than 200 μm.
[0006] Yet another prior art method creates micro mirrors as suspended structures by depositing a thick sacrificial layer on a substrate, with appropriate patterning to make holes therethrough via etching. Then, a material to form the micro mirrors is conformally deposited on top of the sacrificial layer. The layer for the micro mirrors is patterned, and the micro mirrors are formed. A portion of the conformally deposited mirror material is then etched away to allow access to the sacrificial layer. Finally, the sacrificial layer is removed via etching. This process suffers from the fact that it takes a long time to grow the thick sacrificial layer, and the height of the suspended micro mirrors is typically limited by thickness of the sacrificial layer, so the height is often limited to no more than 5 μm.
[0007] A process similar to that used for making accelerometers as taught in “ISAAC:integrated silicon automotive accelerometer” by Leland ‘Chip’ Spangler and Christopher J. Kemp, published in Sensors and Actuators A 54 (1996), pages 523-529, which is incorporated by reference as if fully set forth herein, is unsuitable for making arrays of micro mirrors. This is because when using that process it is too hard to control the final thickness of the membrane that would be used for the mirror and other delicate structures, such as springs, which would also be formed from the same membrane.
SUMMARY OF THE INVENTION
[0008] I have recognized that MEMS devices with an arbitrary gap between the two chips in a flip-chip arrangement can easily be achieved, in accordance with the principles of the invention, by etching into a first substrate to form mesas which act as the spacers and between which, or even on which, any required circuit elements are formed, e.g., after the mesas are formed. Thereafter, points of a layer at a first surface of the second substrate within which MEMS structures are made are bonded to the mesas of the first substrate. The second substrate is then removed, leaving the structures bonded to the mesas.
[0009] In accordance with an aspect of the invention, the mesas may be formed by placing a hard mask, such as silicon oxide, which defines the desired pattern of mesas on the first substrate, and then etching the unmasked portion of the substrate using an anisotropic etchant, such as a mixture of potassium hydroxide (KOH) with isopropanol (IPA). In accordance with another aspect of the invention, since KOH and IPA are incompatible with complementary metal oxide semiconductor (CMOS) type processes, in lieu of using KOH and IPA, tetramethyl ammonium hydroxide (TMAH) mixed with a surfactant, e.g., nonylphenol ethoxy ether or other equivalent compounds, which is compatible with CMOS processing, can be used.
[0010] In one embodiment of the invention, micro mirrors with an arbitrary gap between the micro mirrors and their respective electrodes can easily be achieved by etching into a first substrate to form mesas which act as spacers between which, or even on which, the electrodes are formed after the mesas are formed. Thereafter, the micro mirrors and their supporting structure, which are made on the surface of a second substrate, are bonded to the mesas of the first substrate. The second substrate is then removed, leaving the micro mirror array bonded to the mesas. The inventive method enables the mesa tops be flat to enable a good bond with the mirror supporting structure. The inventive method also enables the space between the mesas be flat, so that electrodes deposited in the space are flat and have a uniform distance to their respective mirror in its neutral position.
[0011] In accordance with an aspect of the invention, various ones of the mesas may be of different sizes. In accordance with another aspect of the invention, various ones of the mesas may be used to implement functionality other than the supporting function of spacing. For example, a) a mesa with a hole in it may be used to seat a ball lens, b) a mesa with V-grooves may be used to seat optical fibers, c) long narrow mesas placed between micro mirrors may function as windbreakers, d) a mesa with a pattern etched into its top, e.g., a fiducial mark, can be used for alignment purposes, and e) the like.
[0012] In accordance with another embodiment of the invention, vias may be made through the mesas or through any of the substrate to facilitate the making of electrical connections. In accordance with another aspect of the invention, mesas of different heights can be made by removing the mask which was covering any mesa for which it is desirable that it have less height at a point during the etching process and then resuming etching.
BRIEF DESCRIPTION OF THE DRAWING
[0013] In the drawing:
[0014] [0014]FIG. 1 shows a cross-section of substrate with hard mask forming thereon a pattern of locations at which the mesas will be formed, in accordance with the principles of the invention;
[0015] [0015]FIG. 2 shows a cross-section of the substrate of FIG. 1 after it has been etched with a wet anisotropic etch;
[0016] [0016]FIG. 3 shows a cross-section of the substrate of FIG. 2 after the hard mask is removed;
[0017] [0017]FIG. 4 shows the substrate as it appears in FIG. 3 and also a second substrate which is facing upside down with respect to the first substrate;
[0018] [0018]FIG. 5 shows a three-dimensional view of a portion of FIG. 4 in which the part of the micro-electromechanical system that is going to move is a paddle;
[0019] [0019]FIG. 6 shows the two substrates of FIG. 4 bonded to each other before removal of the sacrificial layer and the “handle wafer”;
[0020] [0020]FIG. 7 shows removal of the sacrificial layer;
[0021] [0021]FIG. 8 shows removal of the “handle wafer”;
[0022] [0022]FIG. 9 shows a mesa in which is seated a ball lens, in accordance with an aspect of the invention;
[0023] [0023]FIG. 10 shows a mesa with V-grooves in respective ones of which are seated optical fibers, in accordance with an aspect of the invention;
[0024] [0024]FIG. 11 shows micro mirrors between which have been formed long narrow mesas to function as windbreakers, in accordance with an aspect of the invention;
[0025] [0025]FIG. 12 shows a mesa into which has been etched a pattern which may be used as a fiducial mark for alignment purposes, in accordance with an aspect of the invention;
[0026] [0026]FIG. 13 shows crossed intersecting mesas which can function as a fiducial mark, in accordance with an aspect of the invention;
[0027] [0027]FIG. 14 shows another embodiment of the invention which employs vias; and
[0028] [0028]FIG. 15 shows mesas of different heights, in accordance with aspect of the invention.
DETAILED DESCRIPTION
[0029] The following merely illustrates the principles of the invention. It will thus be appreciated that those skilled in the art will be able to devise various arrangements which, although not explicitly described or shown herein, embody the principles of the invention and are included within its spirit and scope. Furthermore, all examples and conditional language recited herein are principally intended expressly to be only for pedagogical purposes to aid the reader in understanding the principles of the invention and the concepts contributed by the inventor(s) to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. Moreover, all statements herein reciting principles, aspects, and embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure.
[0030] In the claims hereof any element expressed as a means for performing a specified function is intended to encompass any way of performing that function including, for example, a) a combination of circuit elements which performs that function or b) software in any form, including, therefore, firmware, microcode or the like, combined with appropriate circuitry for executing that software to perform the function. The invention as defined by such claims resides in the fact that the functionalities provided by the various recited means are combined and brought together in the manner which the claims call for. Applicant thus regards any means which can provide those functionalities as equivalent as those shown herein.
[0031] Unless otherwise explicitly specified herein, the drawings are not drawn to scale.
[0032] Additionally, unless otherwise explicitly specified herein, any lens shown and/or described herein is actually an optical system having the particular specified properties of that lens. Such an optical system may be implemented by a single lens element but is not necessarily limited thereto. Similarly, where a mirror is shown and/or described what is actually being shown and/or described is an optical system with the specified properties of such a mirror, which may be implemented by a single mirror element but is not necessarily limited to a single mirror element. This is because, as is well known in the art, various optical systems may provide the same functionality of a single lens element or mirror but in a superior way, e.g., with less distortion. Furthermore, as is well known in the art, the functionality of a curved mirror may be realized via a combination of lenses and micro mirrors and vice versa. Moreover, any arrangement of optical components that are performing a specified function, e.g., an imaging system, gratings, coated elements, and prisms, may be replaced by any other arrangement of optical components that perform the same specified function. Thus, unless otherwise explicitly specified here, all optical elements or systems that are capable of providing specific function within an overall embodiment disclosed herein are equivalent to one another for purposes of the present disclosure.
[0033] The term micro-electromechanical systems (MEMS) device as used herein is intended to mean an entire MEMS device or any portion thereof. Thus, if a portion of a MEMS device is inoperative, or if a portion of a MEMS device is occluded, such a MEMS device is nonetheless considered to be a MEMS device for purposes of the present disclosure.
[0034] In the description, identically numbered components within different ones of the FIGS. refer to the same components.
[0035] [0035]FIG. 1 shows a cross-section of substrate 101 , typically <100>silicon, with hard mask 103 , e.g., silicon nitride or silicon oxide (SiO 2 ), forming thereon a pattern of locations at which the silicon will not be etched and consequently at which mesas will be formed, in accordance with the principles of the invention. FIG. 2 shows a cross-section after substrate 101 has been etched with a wet anisotropic etch, e.g., using, in accordance with aspects of the invention, a mixture of potassium hydroxide (KOH) with isopropanol (IPA) or tetramethyl ammonium hydroxide (TMAH) mixed with a surfactant, e.g., nonylphenol ethoxy ether or other equivalent compounds, which is compatible with CMOS processing, as the etchant. As a result of the etching process, mesas 105 are formed, each of which still has hard mask 103 on its upper surface. It is advantageous if the mesa tops are flat, to enable a good bond portion of the second substrate to be bonded thereto, e.g., the mirror support springs. It is also advantageous that the space between the mesas be flat so that any circuit elements, e.g., electrodes, which are deposited in the space are flat. For micro mirrors it is desirable to have a uniform distance between the micro mirrors in their neutral position and their respective electrodes below them. Use of the aforementioned etchants yields mesas of adequate and uniform height while leaving the spaces in between appropriately flat.
[0036] [0036]FIG. 3 shows a cross-section of substrate 101 after hard mask 103 is removed via an etching step, e.g., using hydrofluoric acid as the etchant if silicon oxide was used as the hard mask. Also shown in FIG. 3 are circuit elements, e.g., electrodes, 107 formed in the valleys between mesas 105 . Note that the valleys are the open spaces that were formed as a result of the etching of substrate 101 to form mesas 105 . Circuit elements such as electrodes 107 may be formed using essentially conventional techniques for forming such circuit elements on flat substrates. However, due to the topography of the substrate given the presence of mesas 105 , when applying photoresist to pattern the electrodes, the photoresist is conformally coated on the wafer, e.g., using a spray coater, onto substrate 101 to form the required conformal coating. Alternatively, the photoresist could be electroplated to form a conformal coating. Other well known techniques for depositing circuit elements on non-flat substrate may be employed to deposit circuit elements on the surfaces of the mesas themselves as well.
[0037] Note that for micro mirrors, in addition to electrodes, there is also formed the wiring that is necessary to provide control signals to the electrodes. However, such wiring is not shown in FIG. 3 due to the difficulty of showing such wires. Those of ordinary skill in the art will readily know how to form such wiring, which uses the same techniques as the making of the electrodes. Furthermore, various other active and passive circuit elements may also be formed on substrate 101 .
[0038] [0038]FIG. 4 shows substrate 101 as it appears in FIG. 3 and also a second substrate 401 which is facing upside down with respect to substrate 101 , but is not yet bonded thereto. Thus, on the “upper” surface of substrate 401 , which is facing downward toward substrate 101 because it has been “flipped”, is a) sacrificial layer 403 , e.g., a deposited layer of silicon dioxide, which will be removed to release those parts which are to move and b) mechanical layer 405 , e.g., silicon deposited on sacrificial layer 403 , from which is formed those parts of the micro-electromechanical system that is going to move, e.g., the micro mirrors. Mechanical layer 405 could be made of, at least in part, or be coated with, a reflecting material, such as a metal or a reflective dielectric stack. Also shown in FIG. 4 is optional bonding agent 407 , e.g., solder, glass, or any other appropriate agent, which will help bond mechanical layer 405 to mesas 105 of substrate 101 . FIG. 5 shows a three-dimensional view of a portion of FIG. 4 in which the part of the micro-electromechanical system that is going to move is a paddle formed in mechanical layer 405 .
[0039] [0039]FIG. 6 shows substrate 101 bonded to substrate 401 before removal of sacrificial layer 403 and unnecessary portion 601 of substrate 401 , which is referred to as the “handle wafer”.
[0040] In one embodiment of the invention, sacrificial layer 403 is removed, e.g., via etching, which causes handle wafer 601 to become detached from the remaining structure thereby enabling the moveable parts of mechanical layer 405 to move. This is shown in FIG. 7. In another embodiment of the invention, the handle wafer is first removed via etching. This is shown in FIG. 8. Sacrificial layer 403 is then removed, also via etching, which allows the moveable parts to move. Typically, one etchant is employed to remove the handle wafer and a different etchant is employed to remove the sacrificial layer. A sacrificial layer need not be employed if it is possible to control the etching such that it stops when it reaches mechanical layer 405 .
[0041] Advantageously, if mechanical layer 405 is not already reflective, well controlled metalization of the moving parts may now be achieved at the surface where the sacrificial layer formerly had been, e.g., using a shadow mask to prevent the metal from coating other parts. Alternatively, the moving part may have been fabricated so as to already have metalization or another reflective material which is exposed upon removal of the sacrificial layer. Further alternatively, a hole or cavity, e.g., the size of the moving parts and at the location of the moving parts, may be drilled through the handle wafer and sacrificial layer through to the moving part layer so that metalization of the moving parts may be achieved through the cavity.
[0042] Further advantageously, high density arrays of circular micro mirrors may be formed since the mesas which hold the micro mirrors up are below the micro mirrors, and so the mesas can be located off center from the rows formed by the micro mirrors, i.e., in those gaps formed at the point where three or more neighboring micro mirrors meet if there are two complete adjacent rows or columns of micro mirrors meeting.
[0043] In accordance with an aspect of the invention, various ones of the mesas may be different sizes. In accordance with another aspect of the invention, various ones of the mesas may be used to implement functionality other than the supporting function of spacing. FIG. 9 shows mesa 905 made in accordance with the principles of the invention in which is seated ball lens 919 , in accordance with an aspect of the invention. FIG. 10 shows mesa 1005 with V-grooves 1021 in respective ones of which are seated optical fibers 1023 in accordance with an aspect of the invention. FIG. 11 shows micro mirrors 1127 between which have been formed long narrow mesas 1125 to function as windbreakers in accordance with an aspect of the invention. This windbreaking function is useful since when one of micro mirrors 1127 is moved it may generate a wind which could affect the positioning of adjacent ones of micro mirrors 127 . The windbreaking mesa blocks the wind and prevents the position of the adjacent micro mirror from being disturbed. FIG. 12 shows mesa 1205 into which has been etched pattern 1229 , which may be used as a fiducial mark for alignment purposes.
[0044] Note that although the mesas have been shown herein as substantially square in shape, this is for clarity and pedagogical purposes only. In practice, the mesas may have any shape. Thus, FIG. 13 shows crossed intersecting mesas 1305 which can function as a fiducial mark, in accordance with an aspect of the invention.
[0045] [0045]FIG. 14 shows, in accordance with another embodiment of the invention, via 1431 connecting electrode 1433 through the mesa 105 and substrate 1435 to connection point 1437 as well as via 1439 connecting electrode 1441 though substrate 1435 to connection point 1443 .
[0046] [0046]FIG. 15 shows, in accordance with aspect of the invention, mesas of different heights which are made by removing the mask which was covering any mesa to have less height at a point during the etching process and then resuming etching. Thus, mesas 105 are used as spacers while mesa 1550 is used for another function, such as those described hereinabove. | An arbitrary gap between the two chips of a MEMS device arranged in a flip-chip arrangement is achieved by etching into a first substrate to form mesas which act as spacers between which, or even on which, any required circuit elements are formed. Points of a layer at a first surface of the second substrate within which MEMS structures are made are bonded to the mesas of the first substrate. The second substrate is then removed, leaving the structures bonded to the mesas. The mesas may be formed by placing a hard mask, such as silicon oxide, which defines the desired pattern of mesas on the first substrate, and then etching the unmasked portion of the substrate using a mixture of potassium hydroxide (KOH) with isopropanol (IPA) or, tetramethyl ammonium hydroxide (TMAH) mixed with a surfactant, e.g., nonylphenol ethoxy ether or other equivalent compounds. | 1 |
TECHNICAL FIELD
The invention relates to a radio frequency induction heating device, and more particularly to a radio frequency induction heater capable of heat treating or annealing one or more narrow bands of a metallic work piece.
BACKGROUND ART
The radio frequency induction heating device of the Present invention has many and varied applications. For example, it could be used to heat treat a narrow portion of a machine tool, such as a cutter or the like, to harden that portion of the tool.
Co-pending application Ser. No. 06/439,909, filed Nov. 8, 1982 in the names of Jerry W. Schoen and Russel L. Young, and entitled LOCAL ANNEALING TREATMENT FOR CUBE-ON-EDGE GRAIN ORIENTED SILICON STEEL, teaches a local annealing treatment for both regular and high-permeability cube-on-edge grain electrical steels to improve the core loss thereof. According to this co-pending application, at some point in the routing of such electrical steels, after at least one stage of cold rolling and before the final high temperature anneal during which secondary grain growth occurs, the electrical steel is subjected to local annealing across its rolling direction, resulting in bands of enlarged primary grains. The bands of enlarged primary grains regulate the growth of the secondary cube-on-edge grains in the intermediate unannealed areas of the electrical steel strip during the final high temperature anneal. The enlarged primary grains of the annealed bands are, themselves, ultimately consumed by the secondary grains resulting in a cube-on-edge grain oriented electrical steel with smaller secondary grains and reduced core loss.
Co-pending application Ser. No. 06/439,884, filed Nov. 8, 1982 in the names of Jerry W. Schoen and Russel L. Young, and entitled LOCAL HEAT TREATMENT OF ELECTRICAL STEEL, discloses a process for improving the core loss of magnetic material of the type having a plurality of magnetic domains of such size that refinement thereof would produce significant core loss improvement. The magnetic material (such as cube-on-edge regular grain oriented silicon steel strip, cube-on-edge high-permeability grain oriented silicon steel strip and cube-on-face silicon steel strip) is subjected to a local heat treatment to produce parallel bands of heat treated regions extending substantially transverse the rolling direction of the magnetic material, with regions of untreated areas therebetween. The heat treatment alters the microstructure within the locally heat treated bands or regions, thereby regulating the size of the magnetic domains. The local heat treatment step is followed by an anneal resulting in improved core loss of the magnetic material. In an exemplary application to regular grain oriented silicon steel or high-permeability grain oriented silicon steel, the finished and finally annealed electrical steel, having a mill glass, an applied insulative coating, or both thereon, is subjected to local heat treatment wherein the heat treated bands are brought to a temperature above about 800° C. in less than 0.5 seconds (and preferably in less than 0.15 seconds). The locally heat treated strip is then annealed at a temperature of from 800° C. to about 1150° C. for a time of less than two hours. The improved core loss is permanent and is achieved without damage to the mill glass or applied insulative coating.
The radio frequency induction heater of the present invention can be used in the practice of the teachings of both of the above mentioned co-pending applications and their teachings are incorporated herein by reference. While the induction heater of the present invention can be used to perform any appropriate heat treatment or annealing step, for purposes of an exemplary showing it will be described in its application to locally annealing a silicon steel strip during the routing thereof as taught in the first mentioned co-pending application and in its application as a device to locally heat treat fully developed cube-on-edge or cube-on-face silicon steels, as taught in the second of the above mentioned co-pending applications. Therefore, when used herein and in the claims, terms such as "locally heating" should be construed broadly enough to cover both a local anneal and a local heat treatment.
The radio frequency induction heating device of the present invention is especially suitable for local annealing or heat treating in high speed commercial applications, owing to the nature of the high frequency currents, the high power output available and the electrical efficiency. The induction heater is simple in construction, having a lower first cost than many other heating systems. It is more energy efficient, potentially safer and easier to maintain than other heating systems, such as laser systems or the like.
DISCLOSURE OF THE INVENTION
According to the invention, there is provided a radio frequency induction heater for locally heating a metallic work piece. The induction heater comprises a conductor, or conductors, surrounded by a core of magnetic material. The core of magnetic material has a narrow slot formed therein and extending longitudinally thereof, so as to serve as the inductor core air gap. The conductor is connected across a source of radio frequency current.
In use, the induction heater is located adjacent the metallic work piece with the inductor core air gap very near (and preferably in contact with) that portion of the metallic work piece to be heated. When a radio frequency current is caused to pass through the conductor, the gap concentrates the flux entering the work piece. This induces voltages in the work piece resulting in eddy currents which flow in the work piece along and parallel to the gap. As a consequence, rapid local heating of a narrow band of the work piece occurs.
The radio frequency current may range from about 10 kHz to about 27 MHz. It will be understood by one skilled in the art that the minimum frequency is determined by the work piece thickness, while the maximum frequency is determined by the degree of eddy current penetration of the work piece required. Both the conductor and the core may have any appropriate cross sectional configuration. The conductor, the core, or both may be fluid cooled, as will be described hereinafter. The core is made of magnetic material and should be so constructed as to limit eddy currents therein. Thus, the core could be laminated of electromagnetic silicon steel or, preferably, could be made of a high resistivity magnetic material, such as ferrite.
When it is desired to produce a plurality of spaced, substantially parallel annealed or heat treated bands across an electrical steel strip (as is the case in the above mentioned co-pending applications), the induction heater is so located as to extend across the strip, and the strip is moved in the rolling direction. The individual annealed or heat treated bands are the result of pulsing the radio frequency current fed to the induction heater. It would also be within the scope of the present invention to produce the parallel spaced annealed bands in the strip by continuously passing the alternating current through the conductor and rotating the ferrite core. Under these circumstances, the core could have more than one gap. As yet another alternative, a plurality of induction heaters could be located in the peripheral portion of a roll, being evenly spaced about the roll with the inductor core air gap of each induction heater being located at the peripheral surface of the roll. As the electrical steel strip is drawn along the roll and the roll is rotated, each induction heater would be energized when its inductor core air gap is adjacent or in contact with the strip.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of one embodiment of the induction heater of the present invention.
FIG. 2 is a fragmentary perspective view of another embodiment of the induction heater of the present invention.
FIG. 3 is a fragmentary perspective view of an induction heater of the present invention in its application to the provision of parallel spaced annealed or heat treated bands on a strip of electrical steel.
FIG. 4 is a fragmentary end elevational view of the structure of FIG. 3.
FIG. 5 is a semi-diagrammatic end elevational view of a roll carrying a plurality of induction heaters of the present invention to provide parallel spaced annealed or heat treated bands on a strip of electrical steel passing thereunder.
DETAILED DESCRIPTION OF THE INVENTION
Reference is first made to FIG. 1 wherein an embodiment of the induction heater of the present invention is generally indicated at 1. The induction heater 1 comprises a conductor 2 and a surrounding, elongated core 3. The conductor 2 may be of any appropriate current conducting material, such as copper, aluminum or the like. The core 3 is formed of a plurality of electrically insulated laminations made of an appropriate magnetic material such as electromagnetic silicon iron. The thickness of the laminations is exaggerated in FIG. 1 for purposes of clarity. By fabricating the core 3 of relatively thin laminations, eddy currents in the longitudinal directions of core 3 are greatly minimized relative to those induced in the work piece. The core 3 has a longitudinal slot 4 which constitutes the inductor core air gap which will be discussed in greater detail hereinafter. In such a structure, the conductor should be electrically insulated from the laminations by any appropriate means, such as an air gap as shown in FIG. 1, to assure that there is no direct current path to the work piece to be heated.
In FIG. 2, a second embodiment of the induction heater of the present invention is generally indicated at 5. This embodiment also comprises a conductor 6 and a longitudinally extending, surrounding core 7. Again, the conductor 6 can be of any appropriate current conducting material, such as copper or aluminum. In this instance, however, the core 7 is made of a ferrite material. By its very nature (i.e. high volume resistivity), ferrite material will minimize eddy currents in the longitudinal directions of core 7. The core 7 is also provided with a longitudinal slot 8 constituting the inductor core air gap. In this embodiment, the conductor is preferably electrically insulated by appropriate means from the core although some ferrite materials may have sufficient resistance to make this unnecessary.
The cores 3 and 7 may have any cross sectional configuration, such as circular, oval, rectangular, square, and the like. The same is true of conductors 2 and 6. To demonstrate this, core 3 is illustrated as having a rectangular cross sectional configuration while core 7 is shown as having a circular cross section. Similarly, conductor 2 is illustrated as having a square cross section while conductor 6 is shown having a circular cross section.
In the embodiments of FIGS. 1 and 2, the conductors 2 and 6 are each connected across a source of radio frequency current (not shown). The radio frequency current may range from about 10 kHz to about 27 MHz.
The ferrite core 7, characterized by a high volume resistivity and a moderately high permeability, is preferred over the laminated core 3. In some instances, when the current value is high, it is desirable to cool the conductor, the core, or both, to prevent excessive heating or melting. To this end, the conductor, the core, or both, may be fabricated in such a way that water or other cooling fluid may be circulated therethrough. To illustrate this, conductor 6, for example, is shown as being tubular in FIG. 2. The core could be cooled by air jets or other appropriate means.
The operation of the embodiments of FIGS. 1 and 2 is substantially identical for both. Thus, a description of the operation of the embodiment of FIG. 2 can be considered to be a description of the operation of the embodiment of FIG. 1 as well.
When a radio frequency current is passed through conductor 6, magnetic flux will be induced in core 7. Air gap 8, however, constitutes an interruption of the magnetic circuit of core 7. The flux tends to jump gap 8 and, in so doing, tends to flair outwardly of the core 7 at gap 8. As a result, air gap 8 tends to concentrate the flux along a finite path. When a metallic work piece is located adjacent (and preferably in contact with) gap 8, some of the flux at the gap will enter the metallic work piece inducing eddy currents therein. Adjacent the gap, these eddy currents flow alternately in both directions parallel to gap 8. Local annealing or heat treating occurs in the work piece due to these induced eddy currents therein and the electrical resistivity of the work piece.
The shape and length of the locally annealed or heat treated region of the work piece is influenced by the high frequency induction heater design, including the width of gap 8 in core 7, the proximity of the work piece to gap 8, in addition to the current magnitude and frequency and the treatment time. For example, the closer the work piece is to gap 8, the more efficient the heating operation is. For this reason, it is preferred that the work piece actually contacts core 7 at gap 8. Gap size determines the width of the magnetic field penetration of the work piece and thus the width of the heated region of the work piece. The narrower the gap, the less will be the width of the heated region of the work piece. Conversely, the wider the gap, the greater will be the width of the heated region of the work piece. Similarly, the greater the treatment time, the greater the width and depth of the heated region of the work piece. The shorter the treatment time, the narrower and shallower will be the heated region of the work piece. The depth of the heated region is also determined by the frequency.
For purposes of an exemplary showing, FIGS. 3 and 4 illustrate the application of an induction heater of the present invention to the practice of the inventions taught in the above identified co-pending applications. In FIGS. 3 and 4, the induction heater of the present invention is generally indicated at 9 and comprises a conductor 10 and core 11 of ferrite material. The core 11 has an inductor core air gap 12 formed therein. The induction heater 9 differs from induction heater 5 of FIG. 2 only in that the conductor 10 (which again may be of copper, aluminum or the like) is shown as a solid conductor, rather than as a tubular conductor as in FIG. 2. FIGS. 3 and 4 also illustrate a strip of electrical steel 13 having a rolling direction indicated by arrow RD. The electrical steel strip 13 is being drawn over the induction heater 9 in the rolling direction and in contact with core 11 at air gap 12.
In the practice of the teachings of the first mentioned co-pending application, the electrical steel strip 13 comprises a regular grain oriented silicon steel or a high-permeability grain oriented silicon steel prior to the final high temperature anneal during which the cube-on-edge orientation is achieved by secondary grain growth. The teachings of the first mentioned co-pending application are based on the discovery that if at some point in the routing of such electrical steels, after at least one stage of cold rolling and before the final high temperature anneal during which secondary grain growth occurs, the electrical steel is subjected to local annealing across its rolling direction, the parallel locally annealed bands of the steel strip will have enlarged primary grains. If the primary grains in the annealed bands are at least 30% and preferably at least 50% larger than the primary grain size in the unannealed areas between the annealed bands, the bands of enlarged primary grains will regulate the growth of the secondary cube-on-edge grains in the intermediate unannealed areas of the electrical steel strip during the final high temperature anneal. The enlarged primary grains of the annealed bands are, themselves, ultimately consumed by the secondary grains, resulting in a cube-on-edge grain oriented electrical steel with smaller secondary grains and reduced core loss. In FIG. 3, the annealed bands are indicated by broken lines at 14. The intermediate unannealed areas are indicated at 15. The annealed bands have a length in the rolling direction (RD) indicated as (x). The unannealed areas have a length in the rolling direction (RD) indicated as (X). The length (x) of the annealed bands 14 should be from about 0.5 mm to about 2.5 mm, while the length (X) of the unannealed regions 15 should be at least 3 mm.
The narrow, parallel, annealed bands 14 are produced by causing the strip 13 to move in the direction of arrow RD. The individual annealed bands are the result of pulsing the radio frequency current fed to conductor 10. The same result, with the required spacing (X) between the annealed bands 14 could be achieved by maintaining the radio frequency current in conductor 10 constant while rotating core 11 at an appropriate rate. Under these circumstances, the core 11 could be provided with more than one gap 12.
It has been found that the desired parameters taught in the first mentioned co-pending application can be achieved using an air gap 12 of from about 0.076 to about 2.5 mm in width. Current frequencies of from about 10 kHz to about 27 MHz can also be used. To maintain strip flatness, the strip must be maintained under pressure in excess of 2.5 MPa during the local annealing step. This can be accomplished by maintaining pressure on strip 13 between core 12 and a supporting surface (not shown) located above the strip.
As indicated above, FIGS. 3 and 4 can also be used to illustrate the practice of the teachings of the second mentioned co-pending application above. The teachings of the second mentioned co-pending application are based on the discovery that the core loss of cube-on-edge regular grain oriented silicon steel strip, cube-on-edge high-permeability grain oriented silicon steel strip, or cube-on-face silicon strip can be improved if the strip, characterized by a plurality of magnetic domains and fully developed magnetic characteristics, is subjected to a local heat treatment to produce parallel bands of heat treated regions extending substantially transverse the rolling direction RD of the strip with regions of untreated areas therebetween. The heat treatment alters the microstructure within the locally heat treated bands, thereby regulating the size of the magnetic domains. The local heat treatment step is followed by an anneal resulting in improved core loss of the magnetic material.
Thus, strip 13 in FIGS. 3 and 4 may be considered to represent one of the above listed electrical steels characterized by a plurality of magnetic domains and having fully developed magnetic characteristics. The bands 14 in this instance represent heat treated bands with untreated areas 15 therebetween.
In the practice of the second mentioned co-pending application, the length (x) of bands 14 should be less than 1.5 mm and preferably less than 0.5 mm. The length (X) of the untreated regions in the rolling direction RD should be at least 2 mm. Treatment times range from about 0.26 seconds to about 0.15 seconds or less. Current oscillating frequencies of from about 10 kHz to about 27 MHz can be used with success. The heat treated bands 14 are brought to a temperature above about 800° C. Again, the gap 12 should have a width of at least about 0.076 mm.
The heat treated bands 14 are produced in any of the ways described above with respect to the first mentioned co-pending application and, again, to maintain strip flatness, the strip should be maintained under a pressure in excess of 2.5 MPa during the heat treatment, as described with respect to the first mentioned co-pending application. The length (X) of the untreated regions in the rolling direction RD should be at least 2 mm.
FIG. 5 illustrates another embodiment of the present invention by which the teachings of either of the above mentioned co-pending applications can be practiced, producing in a strip 13 of electrical steel a plurality of annealed or heat treated bands 14 separated by untreated regions 15. In this embodiment, a roll 16 is provided. The roll 16 may be made of any non-magnetic, electrically non-conductive material. Near its peripheral edge, the roll 16 has a plurality of heating elements 9 mounted or embedded therein. The heating elements 9 are shown to be identical to the heating element 9 of FIGS. 3 and 4. They could, of course, be identical to heating elements 1 and 5 of FIGS. 1 and 2. Each heating element comprises a conductor 10 and a ferrite core 11 having an inductor core air gap 12 therein. The air gap of each induction heater 9 lies at the periphery of roll 16 and extends longitudinally of the roll. The induction heaters 9 are evenly spaced about roll 16 by a distance equivalent to the desired length (X) of the untreated spaces 15. The roll 16 is preferably powered to rotate in the direction of arrow A so as to be synchronized with the line speed of strip 13. When each of the induction heaters 9 achieve the position indicated at 9a in FIG. 5, a radio frequency current will be pulsed through its conductor 10 to produce an annealed or heat treated band 14.
Modifications may be made in the invention without departing from the spirit of it. | A radio frequency induction heater for locally heating a metallic work piece. The induction heater comprises an elongated conductor surrounded by a core of magnetic material having a narrow slot formed therein serving as the inductor core air gap. The conductor is connected across a source of radio frequency current. The induction heater is located adjacent the metallic work piece with the inductor core air gap very near (and preferably in contact with) that portion of the metallic work piece to be heated. When the radio frequency current is caused to pass through the conductor, the gap concentrates the flux entering the work piece, inducing voltages in the work piece resulting in eddy currents which flow in the work piece along and parallel to the gap. This, in turn, results in the rapid local heating of a narrow band of the work piece. | 2 |
RELATED APPLICATIONS
[0001] This is a continuation of International Patent Application No. PCT/CA2004/001586 filed Aug. 31, 2004, which claims benefit of Canadian Patent Application No. 2,449,194 filed on Nov. 12, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention generally relates to a service line distribution base suited for supporting utility poles of the type used to support overhead lines in power transmission and in external lighting, such as street, highway and traffic lighting.
[0004] 2. Description of the Prior Art
[0005] Utility poles, such as traffic lights, street lights and those used to support power transmission lines are typically mounted on a concrete base or foundation partly buried in the soil. Threaded rods extend vertically upwardly from the exposed top surface of the concrete base for engagement in corresponding holes or slots defined in a mounting flange provided at the bottom end of the utility pole. Nuts are threadably engaged on the threaded rods for securing the pole on the concrete base.
[0006] A wire conduit is typically embedded in the concrete base for allowing buried wires to be connected to above-ground equipment, such as lighting fixtures mounted at the top of the utility pole. The number of wire conduits that can be embedded in the concrete base is significantly limited by the structural weakening of the concrete base each time a new conduit is added. Heretofore, the number of wire conduits extending upwardly through a concrete base of a utility pole has been generally limited to four conduits at most. It would be possible to incorporate more wire conduits in the concrete base by increasing the size thereof but this solution is not suitable in that it would result in oversized mass of concrete about the base of each pole. In addition of being unaesthetic, it would significantly increase the cost associated with the installation of the poles.
[0007] With the ever increasing complexity of the power transmission and telecommunication network, there is a need for a new service line distribution base that could accommodate a greater number of wire conduits in a confine space while still offering proper support for utility poles and the like.
SUMMARY OF THE INVENTION
[0008] It is therefore an aim of the present invention to provide a new base adapted to accommodate a greater number of wire conduits while still providing proper support for anchoring a utility pole in the ground.
[0009] It is also an aim of the present invention to provide an underground base comprising a ground anchoring member having an upstanding cruciform portion.
[0010] Therefore, in accordance with a general aspect of the present invention, there is provided a utility pole base comprising a ground anchor having an upstanding cruciform portion adapted to extend into the ground, an above-ground portion defining an internal chamber adapted to house electric wires, said above-ground portion being adapted to support a utility pole.
[0011] In accordance with a further general aspect of the present invention, there is provided a utility pole comprising an underground anchor, said underground anchor having an upstaging portion of cruciform cross-section, a cabinet extending axially from said underground anchor and defining an internal chamber for housing distribution equipment, said internal chamber having a bottom opening for receiving wires projecting upwardly from the underground anchor, and a pole segment extending axially upwardly from said cabinet.
[0012] In accordance with a still further general aspect of the present invention, there is provided an underground base for supporting a service line receiving member, comprising an anchor member having an upstanding portion of cruciform cross-section adapted to be buried into the ground, said anchor member having a top end portion adapted to project out of the ground, said top end portion being provided with mounting points for allowing a service line receiving member to be mounted on top of said anchor member, said mounting points being distributed on an imaginary perimeter bounding an axially open space for allowing buried wire conduits to extend into the service line receiving member once mounted onto the anchor member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Having thus generally described the nature of the invention, reference will now be made to the accompanying drawings, showing by way of illustration a preferred embodiment thereof, and in which:
[0014] FIG. 1 is a side elevation view of a utility pole mounted to a service line distribution base in accordance with a preferred embodiment of the present invention; and
[0015] FIG. 2 is a side elevation view of the service line distribution base;
[0016] FIG. 3 is a partly exploded isometric view of the service line distribution base;
[0017] FIG. 4 is a side elevation view of a ground anchoring portion of the service line distribution base shown in FIG. 3 once installed in the ground with the wire conduits extending upwardly through the anchoring portion;
[0018] FIG. 5 is a top plan view of the anchoring portion installed in the ground;
[0019] FIG. 6 is a partially exploded perspective view of the ground anchoring portion of the service distribution base;
[0020] FIG. 7 is a partially exploded perspective view of a distribution cabinet forming part of the service line distribution base; and
[0021] FIG. 8 is an exploded perspective view of the core components of the distribution cabinet shown in FIG. 7 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] FIG. 1 shows one possible utilization of a preferred embodiment of a service line distribution base 10 anchored in the ground for supporting a utility pole 12 . In the illustrated example, the utility pole 12 is provided in the form of a lamp post including a hollow pole member 14 having a lighting fixture 16 attached at an upper end thereof. It is understood that other type of structures or equipment could be mounted on the service line distribution base 10 . For instance, a medium voltage network pole, a traffic light, a bollard fixture or even a decorative cap.
[0023] As will be seen hereafter, the service line distribution base 10 advantageously provides for partial or complete burial of service lines 18 , including power transmission lines and telecommunication lines, such as telephone lines and cable television lines. The base 10 also advantageously provides for the integration of a distribution system at the bottom of a utility pole, which distribution system can be used by power and telecommunication utilities to connect subscribers to the utility lines concealed in the pole and in the ground.
[0024] As shown in FIGS. 2 and 3 , the base 10 generally comprises a ground anchoring member 18 and a distribution cabinet 20 . The anchoring member 18 is buried in the ground and the distribution cabinet 20 is bolted on top on the anchoring member 18 at ground level. Alternatively, the cabinet 20 could be an integral extension of the anchoring member 18 .
[0025] As shown in FIG. 6 , the ground anchoring member 18 is cruciform and includes a main metal plate 22 on opposed sides of which are symmetrically arranged a pair of identical metal plates 24 . The metal plates 24 are welded to opposed sides of the main plate 22 and extend in a same central normal plane relative to the main plate 22 . Each plate 24 corresponds to a half-plate section of the main plate 22 . Notches or cutouts 26 are defined in the distal side edges of the plates 22 and 24 . The cutouts 26 provides for easy placement of the wire conduits 28 , as shown in FIGS. 4 and 5 . The cutouts 26 also-greatly contribute to increase the number of wire conduits that can be incorporated into the base 10 by allowing the same to have a smaller angle of insertion. A central oblong slot 30 is also defined in the main plate 22 for allowing wire conduits 28 to pass from one side of the cruciform anchoring member 18 to the other, as shown in FIGS. 4 and 5 . Likewise, half-slot sections are defined in the confronting side edges of the plates 24 to form a second central oblong slots 32 ( FIG. 6 ) intersecting the first oblong slot 30 centrally in a plane perpendicular to the main plate 22 . Holes 34 are defined in the upper half portion of the plates for allowing the wire conduits to be attached to the ground anchoring member with attachment straps (not shown), such as wires, cables, filaments and the like.
[0026] As shown in FIG. 6 , a flat horizontal strengthening member 36 preferably extends diagonally between the bottom ends of each pair of adjacent segment of the cruciform anchoring member 18 .
[0027] Mounting plates 38 are welded on the top end edges of each plate 22 , 24 at respective terminal distal ends thereof. Each plate 38 defines a central hole 40 for allowing the cabinet 20 to be secured in position on top of the anchoring member 18 by means of bolts and nuts, as shown in FIG. 3 .
[0028] A collar 42 is provided at the top end of the cruciform anchor 18 about the plates 22 and 24 . The collar 42 provides additional strength at the top end of the anchoring member 18 where the external forces exerted on the anchoring member 18 are the more important. Also, it confines the space through which the wire conduits project upwardly out of the ground. The collar 42 is preferably provided in the form of two half segments 42 and 42 b welded to the distal side edges of the plates 22 an 24 .
[0029] As shown in FIG. 6 , small notches 46 are defined along the proximal longitudinal side edges of the plates 24 in order to reduce the amount of welding that need to be made. Welding full height without notches is also contemplated.
[0030] Longitudinally extending flat plates (not shown) could be welded centrally all along the distal longitudinal side edges of the plates 22 and 24 to further increase the strength of the anchoring member 18 . Each wall segment of the cruciform anchoring member 18 would then have a T-shape.
[0031] Now referring to FIGS. 7 and 8 , the construction of the cabinet 20 will be described. As shown in FIG. 8 , the core of the cabinet 20 comprises a central metal plate 48 having opposed central longitudinally extending top and bottom slits 50 and 52 . Top and bottom cross plates 54 and 56 ( FIG. 7 ) are respectively mounted in the top and bottom slits 50 and 52 . A hook or handle 58 is provided on the top edge of the top cross plate 54 for allowing the cabinet 20 to be lift once assembled. A generally circular top cover 60 is welded on top of the central plate 48 and the top cross plate 54 . The cover 60 defines a central circular hole 62 through which the handle 58 extends. The central hole 62 provides for electric wiring in the utility pole 12 ( FIG. 1 ) to extend into cabinet 20 . Four indentations 64 are uniformly distributed in the circumference of the cover 60 for receiving the top end of four corresponding longitudinally extending legs 66 , 68 , 70 and 72 . The legs 66 , 68 , 70 and 72 are substantially coextensive with the central plate 48 . Legs 66 and 68 are welded to oppose longitudinal side edges of the central plate 48 and in respective indentation in the cover 60 . Legs 70 and 72 are welded to the end edges of the top and bottom cross plates 54 and 56 and in respective indentations 64 in the cover 60 . Each leg 66 , 68 , 70 and 72 has a horizontally extending foot portion 74 defining a hole 76 for allowing the cabinet 20 to be bolted to the mounting plates 38 of the anchoring member 18 (see FIG. 3 ).
[0032] Indentations 78 are preferably defined in the side edges of the central plate 48 to minimize the amount of welding that has to be done to secure the legs 66 and 68 to the plate 48 .
[0033] The opposed faces of the mounting plate 48 are used to mount distribution equipment, such as power bars, electrical connections, junction boxes, etc. . . .
[0034] According to a further embodiment of the cabinet, the central plate 48 can be omitted. Only form reinforced legs would be used.
[0035] Radial slots 80 are defined in the cover 60 to provide for the bolting of various structures on top of the cabinet 20 .
[0036] As shown in FIGS. 3 and 7 , two half-cover shields 82 are securely mounted on top of the cover 60 . Cutouts 84 are provided in the half-cover shields 82 to provide access to the central hole 62 and the radial slots 80 . Leg covering members 86 are provided for covering the legs 66 and 68 . Four access doors 88 are hingedly mounted between the legs 66 , 68 , 70 and 72 . Each door 88 is provided with its respective locking mechanism 90 so that only authorized person can have access to the interior of the cabinet 20 . Semi circular bandings 92 are mounted to the bottom of portion of the legs 66 , 68 , 70 and 80 below the doors 88 in order to completely close the cabinet 20 .
[0037] As shown in FIG. 3 , the assembly of the cabinet 20 is completed by installing semi-circular bumpers 94 at the base of the cabinet 20 once the same has been bolted to the anchoring member 18 .
[0038] As shown in FIG. 4 , the service line distribution base 10 is installed by first lowering the anchor member 18 in an excavated hole of about 1.8 m(6 ft) deep and 1.8 m (6 ft) in diameter with a compacted aggregate bottom 98 (90% MP) to 1.68 m (66 in.) below the predicted finished grade level. The top of the anchoring member 18 exceeds the finished grade predicted level by about 65 mm (2.5 in.). The next step consists of backfilling the hole using successive layers of compacted aggregate 100 from bottom, up to the beginning of the notches 26 at 500 mm (18 in.). It is recommended to verify that the anchoring member 18 is plumb (straight) while compacting. It is also recommended to backfill with well distributed aggregates of crushed stones 0-20 mm (0-¾ in.)compacted at 90%. A grounding rod (not shown) with a grounding cable (not shown) is then installed. Thereafter, the wire conduits 28 are installed for the various networks to be incorporated. The wire conduits 28 are preferably attached to the anchor member 18 with attachment straps (not shown) extending through the holes 34 in the anchor member 18 . Thereafter, the excavated hole is full with flowable concrete 102 up to between 125 to 150 mm (5 to 6 in.) below the finished grade. If the quantity of wire conduits exceeds 12 , it is recommended to reduce the size of aggregate in concrete to from 20 mm (¾ in.) to 12 mm (½ in.) to ensure a good penetration of the flowable concrete in the middle of the structure. Once the flowable concrete has solidified, finish landscaping to grade level. The distribution cabinet 20 is then bolted on top of the ground anchoring member 18 . Finally, the utility pole 12 is bolted on top of the cabinet 20 . The resulting structure is then ready for cabling and installation of distribution equipment by utilities. | A service line distribution base ( 10 ) comprises a ground anchor ( 18 ) having an upstanding cruciform portion adapted to extend into the ground. A cabinet ( 20 ) suited to support a utility pole ( 14 ) extends upwardly from the ground anchor ( 18 ). The cabinet ( 20 ) defines and internal space for receiving buried wire conduits ( 28 ) incorporated to the cruciform ground anchor ( 18 ). The cruciform shape of the ground anchor ( 18 ) advantageously permits to incorporate a greater number of wire conduits ( 28 ) into the base of a utility pole as compared to conventional concrete bases. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a join operation processing system suitable for performing a join operation on a relational database usable in a distributed database management system.
2. Description of the Prior Art
A distributed database management system consists of general local database management systems, each called sites, interconnected with each other by various networks. These sites have memories, each memory including databases distributed and stored therein. A join operation on the relational databases distributed to a multiple sites is needed to be performed at one site by transferring all relational tuples related to the join operation from the other sites to the above one site.
The above method however must also transfer any tuple which is considered not to be involved in a relation as the final result of the join operation. Accordingly, the amount of data transmitted among sites determines the rate of the join operation and the cost of the operation.
A method is known for solving such a problem, which is disclosed in "Using Semi-Joins to Solve Relational Queries" Journal of the Association for Computing Machinery, Vol. 28, No. 1, January 1981, pp 25 to 40. According to this method, the amount of data transferred from a certain site to another site, when relation transmission between the above sites is required to perform a join operation, can be reduced by transferring only attribute values associated with the join operation, thereby performing a semi-join process for the join operation wherein a relation comprising only tuples finally involved in the relation which is considered to be yielded as the result of the join operation is prepared, and transferring the relation as a result of the above semi-join process.
FIG. 1 illustrates a prior art join operation processing system and FIG. 2 likewise illustrates a relation to be processed in the join operation processing system of FIG. 1. In FIG. 2, RX is called a relation name, while A1, A2 and A3 each called an attribute name. In addition, a, b and c or the like are named attribute values of an attribute A1, and A, B, C or the like named attributed values of A2. Moreover, for data types of the respective attributes, A1 represents an English small letter, A2 an English capital letter, and A3 a numeral. A row, for example, such as (a A1) and (b B2), etc., is named a tuple.
Operation of a prior art join operation processing system will be described with reference to FIG. 1. Considering, for example, a join operation processing wherein a relation 3 (named R) managed by a site 1 and a relation 4 (named P) managed by a site 2 are subjected to the join operation under conditions that values of attributes A2 and B1 are equal to each other, and thereafter the resultant relation is transferred to a computer 5 connected with the site 1.
First, a request from an application program 6 of the computer 5 to a distributed data base management system 7, namely, a request for performing a join operation between the relations R and P of a distributed database 18 is transmitted via a database management system access manager 8.
Then, the processing request is analyzed by a processing request analyzer 9a and transferred to a process determining means 10a. The process determining means 10a determines the process in conformity with the analyzed result and informs a database manager 11a of the determined process. The database manager 11a executes a prescribed join operation in conformity with the execution process. In addition, the database manager 11a also has a function to inform, if processing at another site is needed, a database manager of the another site of a necessary process through an intersite communication controller 14a.
The process will further be described in detail. First, as a semi-join process, a project operation is executed on the relation R by the database manager 11a whereby a relation 12 (named R') comprising only the attribute A2 is prepared as an intermediate result. The relation 12 is stored in a local database 13a managed by the site 1.
The database manager 11a transfers a process to be performed by the database manager 11b in the site 2 as well as the relation 12 to the database manager 11b via the intersite communication controllers 14a and 14b and a communication network 15.
The database manager 11b subjects the transmitted relation 12 and a relation 4 (named P) stored in the database 13b managed by itself to a join operation in conformity with the transmitted process, and obtains a relation 16 (named P') as an intermediate result, and stores it in the database 13b. The database manager 11b transfers the relation 16 to a database 13a managed by the site 1. The database manager 11a performs a join operation on the relations 16 and 3 and transfers the resultant relation 17 to the computer 5.
For the join operation processing system, it is assumed that the transfer capability of a communication network for connecting the respective sites of the distributed data base management system to each other is relatively low, and thus, the amount of communication among the respective sites is reduced.
Namely, a semi-join process at each site imposes a burden on the database management system in the situation as described below.
(1) Throughput in each site is low.
(2) Queries from many users are concentrated to any particular site.
(3) Any relation to be processed is large in its capacity and thus an intermediate process yielded by the semi-join process must also require a large capacity.
SUMMARY OF THE INVENTION
It is an object of the present invention to prevent a process speed from deterioration due to a semi-join process in the join operation processing system.
Another object of the present invention is to provide a join operation system operable as a pipe line process for thereby improving a process speed of a join operation in a distributed database management system.
To achieve the above objects, a method of operating a join operation processing system according to the present invention in a distributed database management system having multiple sites each including memories, multiple distributed databases each being stored in each of said memories, computers each connected to said sites via a network for employing said distributed databases, comprises the steps of:
(a) analyzing a processing request from an application program running in the computer for thereby determining whether the request is one for defining relations or one for processing a join operation;
(b) allowing the computer to transmit, in case of the request to define the relations in conformity with the result of the analysis, the request to define the relations to each site, and, in case of the request to process the join operation, allowing the computer to transmit a request to read information to define relations to each site;
(c) allowing each of the sites to analyze the request from the computer for thereby determining whether the request is the request to define the relations or the request to read the relation definition, and if the request is the relation definition request, then store the defined information in the memory, and, if the request is the read request, then read the defined information previously stored in the memory and transfer the read defined information to the computer;
(d) allowing the computer to determine, upon receiving the relation definitions from each of the sites, an execution process to perform the join operation therefor in conformity with the join operation request and to thereby transmit a local processing request to a predetermined site,
(e) allowing each of the sites receiving the local processing request to perform a local join operation on the relation managed by the site itself, and to transmit, if there is any processing to be performed by any site on and after the next site, a local processing request for the next site to perform local processing and the result of the local join operation to the next site, while returning, if there is no processing to be done on and after the next site, the result of the join operation process effected in the site itself to the computer.
The above and other objects, features and advantages of the present invention will become more apparent from the following description when taken in conjunction with the accompanying drawings in which a preferred embodiment of the present invention is shown by way of illustrative example.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1, consisting of FIGS. 1A and 1B, is a block diagram illustrating operation of a prior art distributed database management system,
FIG. 2 is an exemplary view of a relation for illustrating the structure of the relation for use in a join operation processing,
FIG. 3, consisting of FIGS. 3A and 3B, is a block diagram illustrating a preferred embodiment of a join operation system according to the present invention,
FIG. 4 is a fragmentary block diagram illustrating another embodiment of the join operation system according to the present invention,
FIG. 5, consisting of FIGS. 5A and 5B, is a flowchart illustrating operations, in the embodiment of the present invention shown in FIG. 3, of a processing request analysis and execution means 39, a process determination and management means 31, and a database management system access manager 38 in the computer 27, and
FIG. 6, consisting of FIGS. 6A and 6B, is a flowchart illustrating operations, in the embodiment of the present invention shown in FIG. 3, of respective sites 21, 22.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 3 illustrating an embodiment of the present invention with two sites, operation of the join operation processing system will be described.
As shown in the figure, a distributed database management system (hereinafter abbreviated as DDBMS) 24 is constituted by database management systems (hereinafter abbreviated as DBMS) of sites 21 and 22 interconnected with each other through a communication network 23. Furthermore, a distributed database 26 is constituted by local databases 25a and 25b managed by the respective sites described above.
The database at each site stores therein a relation definition for each of the stored relations. The relation definitions are unique to a relation, for example, such as a relation name, each attribute name, a data type of each attribute, length of each attribute value, an INDEX name, and the number of all records, etc.
In FIG. 3, definition 32 is a definition for a relation 29 while definition 33 is one for a relation 30.
A computer 27, by making use of the DDBMS 24, is interconnected with the two sites via the network 23, and includes a first processing request analysis and execution means 39, a process determination and management means 31 and a DBMS access manager 38.
Each of the sites has communication controllers 34a and 34b, processing request analysis and execution means 35a and 35b, and database managers 36a and 36b.
Referring to FIGS. 3, 5 and 6, the processing to define a relation and a flow of the processing of a join operation in respective sites 21 and 22 will be described.
(A) Processing to define a relation
A-(a) First, a request to define a certain relation is issued from an application program (hereinafter, abbreviated as AP) 28 to a first processing request analysis and execution means 39 which is in a wait state for a processing request (FIG. 5: Step 500).
A-(b) The first processing request analysis and execution means 39 analyzes the processing request from the AP 28 (FIG. 1: step 501). Assume that the processing request is a request to define a relation.
A-(c) The definition request for the relation is transmitted to the site (FIG. 5: Step 502). Assume that the definition request is transmitted to the first processing request analysis and execution means 39--DBMS access manager 38--site 21.
A-(d) The processing request is received by the first communication control means 34a in the wait state for the processing request, and delivered to a second processing request analysis and execution means 35a (FIG. 6: Step 600).
A-(e) The second processing request analysis and execution means 35a analyzes the processing request (FIG. 6: Step 601). The processing request is decided to be the definition request for a relation.
A-(f) The relation definition request is delivered to the first database manager 36a by the second processing request analysis and execution means 35a, and the first database manager 36a defines the relation (FIG. 6: Step 602).
A-(g) The computer 27 is informed of the processing state (FIG. 6: Step 603). Namely, the relation is defined by the first database manager 36a, and a fact that the definition information is stored in the database 25a is returned to the computer 27 in the order of the first database manager 36a--second processing request analysis and execution means 35a--first communication execution control means--computer 27. Thereafter, the site 21 returns again to a wait state (FIG. 6: Step 600).
A-(h) The processing status from the site 21 is received by the DBMS access manager 38 which is in a wait state for the processing information (FIG. 5: Step 503).
A-(i) The processing information from the site 21 is returned from the DBMS access manager 38 to the application program 28 via the first processing request analysis and execution means 39 (FIG. 5: Step 504). Thereafter, the first processing request analysis and execution means 39 returns again to the wait state for the processing request (FIG. 5: Step 500).
The processing from A-(a) to A-(i) described above are executed at each site according to the decision of the first processing request analysis and execution means 39 prior to the request for the join operation from the application program 28.
(B) A flow of a join operation in the computer 27.
B-(a) The first processing request analysis and execution means 39 is in a wait state for any processing request. Issued a join operation request from the application program 28, it is received by the processing request analysis and execution means 39 (FIG. 5: Step 500).
In the present example, the requested join operation is supposed to be a request "the relation 29 (named R) and the relation 30 (named P) are joined each other under the condition that the values of the attributes A2 and B1 are equal to each other, and the result is returned to the computer 27."
B-(b) The processing request is analyzed by the first processing request analysis and execution means 39 (FIG. 5: Step 501). The processing request is determined to be one for the join operation, and is delivered to the process determination and management means 31.
B-(c) A request to read the relation definition is transmitted from the process determination and control means 31 to each site via the DBMS access manager 38 (FIG. 5: Step 505). It is assumed in the present example that a read request for definition 32 related to the relation R29 is, for the first time, transmitted to the site 21, and a read request for definition 33 related to the relation P30 is transmitted to the site 22 for the second time.
B-(d) The processing status and the relation definition from each site are received by the DBMS access manager 38 which is in a wait state for information to be returned from each site (FIG. 5: Step 506).
In the present example, the DBMS access manager 38 receives the definition 32 for the first time and the definition 33 for the second time from the assumption of the B-(c).
B-(e) The information returned from each site is delivered to the process determination and management means 31. The process determination and management means 31 decides whether all definitions needed to determine the process are read from each site or not (FIG. 5: Step 507). If all the definitions are already read, then the processing advances to the next process (FIG. 5: Step 508), while if there remains any definition to be read, then the control returns to the above process of B-(c) (FIG. 5: Step 505).
B-(f) The process determination and management means 31 determines the process for the join operation (FIG. 5: Step 508).
The process in the present example comprises:
(1) issuing a processing request to the site 21,
(2) allowing the site 21 to retrieve the relation R29 and to transmit to the site 22 the retrieved result and a request of processing by the site 22, and
(3) allowing the site 22 to perform a join operation on the retrieved result transmitted from the site 21 and the relation P30 in conformity with the processing request transmitted from the site 21, and to deliver the result to the computer 45.
B-(g) The processing request is transmitted to the site 21 in conformity with the process determined in B-(f) (FIG. 5: Step 509). The processing request is transferred in the order of the process determination and management means 31--DBMS access manager 38--site 21. The DBMS access manager 38 waits for information to be returned from the site 22.
B-(h) The DBMS access manager 38 receives the processing status and the result of the processing from the site 22, and supplies them to the process determination and management means 31 (FIG. 5: Step 510).
In the present example, according to conditions in E-(e) and E-(h) described later, each site keeps on processing. As the result of the join operation, tuples (a A1) and (b A1) are obtained for the first time, and tuples (c B2) and (d B2) are obtained next. For the third time, all the sites have completed the processing, and as the result of the join operation, a null set is received by the computer 27. Finally, the application program 28 of the computer 27 has a relation 37 (named Re).
B-(i) The process determination and management means 31 returns the processing status and processing result described above to the AP 28 (FIG. 5: Step 511). This is conducted via the first processing request analysis and execution means 39.
B-(j) The process determination and management means 31 determines whether or not the processing at each site is already completed (FIG. 5: Step 512). With the completion, the control returns to the wait state of Step 500, and otherwise returns to the processing of B-(h) described above (FIG. 5: Step 510).
(C) Processing to read relation definition at site 21.
C-(a) The first communication controller 34a is in a wait status for a processing request. Transmitted the processing request from the computer 27, the communication controller 34a receives it and transfers it to the second processing request analysis and execution means 35a (FIG. 6: Step 600).
C-(b) The second processing request and analysis execution means 35a analyzes the processed request (FIG. 6: Step 601). In the present example, the processing request is that for definition on the relation R29.
C-(c) The read request for the relation definition is transferred by the second processing request analysis and execution means 35a to the first database manager 36a, which means 36a reads the definition 32 on the relation R29 (FIG. 6: Step 604).
C-(d) The processing status and the relation definition 32 are returned to the computer 27 (FIG. 6: Step 605). Namely, the first database manager 36a reads the definition 32 on the relation R, and the definition 32 and completion of the read operation are returned to the computer 27 in the order of the first database manager 36a--second processing request analysis and execution means 35a--first communication controller 34a--computer 27. Thereafter, the site 21 again returns to a wait state (FIG. 6: Step 600).
(D) Join operation in site 21.
D-(a) A processing request is transmitted from the computer 27 in the wait state of the first communication controller 34a for the processing request, and the processing request is received by the first communication controller 34a and transferred to the second processing request analysis and execution means 35a (FIG. 6: Step 600).
D-(b) The second processing request analysis and execution means 35a analyzes the processing request (FIG. 6: Step 601). The processing request is determined to be a request for join operation (that is retrieval on the relation R29 and transmission of the result to the site 22).
D-(c) The second processing request analysis and execution means 35a requests "retrieval" to the first database manager 36a, which means 36a then retrieves the relation R29 and returns the result to the second processing request analysis and execution means 35a (FIG. 6: Step 606).
Since in the present example, retrieval is performed in conformity with values of the attribute A2,
tuples (aA), (bA) are retrieved for the first time,
tuples (cB), (dB) retrieved for the second time, and
tuples (eC), (fC) retrieved for the third time.
D-(d) The second processing request analysis and execution means 35a determines whether or not all of the retrieval processing is completed (FIG. 6: Step 607). If the retrieval processing has not been completed, the operation goes forward to the next processing of D-(e) (FIG. 6: Step 608). If the retrieval processing has been completed, it further goes forward with the processing of D-(g) described later (FIG. 6: Step 609).
In the present example, the operation advances to Step 608 based on the conditions described in D-(c) after the first and second retrieval processings, and to Step 609 for the third time.
D-(e) The second processing request analysis and execution means 35a informs the site 22 of the processing state, i.e., a fact that the processing in the site 21 is running, and the retrieved result via the first communication controller 34a. The second processing request analysis and execution means 35a also transmits a request for processing to be done in the site 22 (FIG. 6: Step 608).
The site 20 starts its operation by receiving the processing request described above.
D-(f) The second processing request analysis and execution means 35a determines whether or not the site 21 is a site executing the first join operation (FIG. 6: Step 610).
The site 21 is determined to be the site executing the first join operation, and the operation returns to D-(c).
D-(g) The second processing request analysis and execution means 35a transmits the processing status, i.e., a fact that the processing at the site 21 has been completed, and the retrieved result to the site 22 via the first communication controller 34a. Then, a request to process at the site 22 is also transmitted (FIG. 6: Step 609). When both the transmissions have been completed, the site 21 again returns to a wait state (FIG. 6: Step 600).
(E) Join operation at the site 22.
E-(a) The second communication execution and control means 34b is in a wait state for a processing request. After receiving the processing request from the site 21 described in D-(e) by the second communication controller 34b, the processing request is transferred to the third processing request analysis and execution means 35b (FIG. 6: Step 600).
E-(b) The third processing request analysis and execution means 35b analyzes the transferred processing request (FIG. 6: Step 601). The processing request is determined to be a request for operation to be conducted by the site 22, i.e., execution of a joint operation between the tuple transferred from the site 21 and the relation P30 managed by the site 22 itself and transmission of the join operation result to the computer 27.
E-(c) The third processing request analysis and execution means 35b transfers the analyzed result to the second database manager 36b. The second database manager 36b effects a join operation between the tuple transmitted from the site 21 and the relation P30 in conformity with the above analyzed result (FIG. 6: Step 606).
In the present example, a join operation is performed between the relation P30 and the tuples (a A) and (b A) for the first time, the tuples (c B) and (d B) for the second time, and the tuples (e C) and (f C) for the third time.
The result is tuples (a A1) and (b A1) for the first processing, tuples (c B2) and (d B2) for the second time, and a null set for the third time.
E-(d) The third processing request analysis and execution means 35b determines, based on the processing status transferred from the site 21 (the processing in the site 21 is in running or not), whether or not all of the processings in the site 22 has been completed.
If the processing has not been completed, the operation advances to processing of E-(e) described later (FIG. 6: Step 608), and if the processing has been completed, the operation advances to E-(h) described later (FIG. 6: Step 609).
In the present example, the operation advances to Step 608 in the first and second decisions and to Step 609 in the third decision based on the conditions of D-(d).
E-(e) The third processing request analysis and execution means 35b transmits the processing status, i.e., a fact that the processing in the site 22 is running, and the join operation result in the site 22 to the computer 27 via the second communication controller 34b (FIG. 6: Step 608).
In the present example, the join operation result transmitted to the computer 27 is, based on E-(c), tuples (a A1) and (b A1) for the first time and tuples (c B2) and (d B2) for the second time.
E-(f) The third processing request analysis and execution means 35b determines whether or not the site 22 is a site in which the first join operation was performed (FIG. 6: Step 610).
The site 22 is determined to not be the site in which the first join operation was performed, and the processing advances to E-(g) (FIG. 6: Step 611).
E-(g) The second communication controller 34b receives the next processing request from the site 21, which is supplied to the processing request analysis and execution means 35b (FIG. 6: Step 611). The processing returns to Step 606 of E-(c).
E-(h) The third processing request analysis and execution means 35b transmits the processing status, i.e., completion of the processing in the site 22, and the result of the join operation in the site 22 to the computer 27 via the second communication controller 34b (FIG. 6: Step 609). Thereafter, the site 22 again returns to a wait status (FIG. 6: Step 600).
The last operation result is a null set based on E-(c).
As described above, in the join operation processing, the processings from B-(g) to B-(j), from D-(a) to D-(g), and from E-(a) to E-(h) constitute pipe line processing in the order of the computer 27--site 21--site 22--computer 27. Accordingly, according to the present invention, the number of data transmissions between the sites can be reduced as compared with prior art cases, and a burden brought about by the semi-join process can be reduced and thus the join operation processing in the distributed database management system can be achieved at a higher speed.
In FIG. 4 illustrating a fragmentary block diagram of another embodiment according to the present invention, a distributed database management system 42 comprises multiple sites 40-1, 40-2, . . . , 40-n, and a network 41 for interconnecting them, and processes a distributed database 44 comprising local databases 48-1, 48-2, . . . , 48-n managed by each site.
The interiors of a computer 45 and a site 40-n are, although partly shown in FIG. 4, the same in their arrangements as those of the computer 27 for the site 21 or the site 22 of FIG. 3.
A join operation processing request on relations 43-a, 43-2, presented to the site 40-1 in conformity with a process is determined by a process determination management means 47 in the computer 45. Then, the site 40-1 processes a relation 32-1 (named R(1)) managed by itself in conformity with the contents of the above processing request, and transmits the processed result and processing requests on and after the next sites to the next site 40-2.
As the site 40-2 receives the result processed at the site 40-1 from the site 40-1 in conformity with the processing request from the site 40-1, it performs any operation on a relation 43-2 (named R(2)) managed by itself and the above result and transmits the yielded result and a processing request on and after the next site to the next site. The above processing is successively operated, and the final result is stored in a database 48-n managed by the site 40-n. The site 40-n returns the final result to the computer 45.
These processings from that in the site 40-1 to that in the site 40-n, and the transmission from the site 40-n to the computer 45 establishes pipe line processing, which can effect join operation processing at a higher speed as in the embodiment described with reference to FIG. 3.
Although certain preferred embodiments have been shown and described, it should be understood that many changes and modification may be made therein without departing from the scope of the appended claims. | A join operation processing system and a method of operating the system is usable in a distributed database management system including multiple local database management systems, computers employing distributed databases stored in the local database management systems, and a communication network for connecting said local database management systems and the computers. The join operation processing system can perform a join operation on a relational database. Each of the computers instructs prior computer to performing the join operation, and the database management system, managing relations associated with the join operation to read definitions so as to define said relations, reads the read definitions to thereby determine a process to process the join operation, and issues a request to the prescribed database management system to perform join operation processing based on the determination. Each database management system transfers a local processing result and a local processing request among the database management systems and performs the join operation processing in a pipe line processing sequence. | 8 |
RELATED U.S. APPLICATION DATA
[0001] This application is a continuation of U.S. patent application Ser. No. 11/505,445, filed Aug. 17, 2006, which is a continuation of U.S. patent application Ser. No. 10/612,016, filed Jul. 3, 2003, now U.S. Pat. No. 7,109,157, which, in turn, is a continuation-in-part of U.S. patent application Ser. No. 10/373,787, filed Feb. 27, 2003, now U.S. Pat. No. 6,946,435, which claims benefit of U.S. Provisional Application No. 60/423,978, filed Nov. 6, 2002, all of which are incorporated herein by reference in their entireties.
TECHNICAL FIELD OF THE INVENTION
[0002] This invention relates to products, methods and kits useful for removing stains, such as menstrual fluid or underarm perspiration stains, from clothes and other soft fabric articles. This invention also relates to methods for reducing the damaging effect of hypochlorite-containing solution on cotton and other soft fabrics.
BACKGROUND OF THE INVENTION
[0003] Menstrual fluid, a composition of blood and endometrial cells, is difficult to remove from cotton panties once it has stained the fabric. Regular bleach is one of the leading household products used for the purpose of cleaning white cotton panties of menstrual fluid stain. Ultra Clorox® Regular Bleach is a designated trademark of the Clorox® Company. A typical, undiluted regular bleach solution contains about 6 wt % of sodium hypochlorite and less than 0.2 wt % of sodium hydroxide. The pH of the undiluted Clorox® Regular Bleach solution is around 11.4. Like other chlorine-releasing bleaches, Clorox® Regular Bleach, even diluted, will disintegrate the fabric. Moreover, even after lengthy soaking, a dark residue stain may still remain on the cotton fabric, even with scrubbing. Vigorous scrubbing accelerates deterioration of the bleach-weakened cotton fibers which, again, leads to damaged panties, and expense and frustration. Some household products, such as hydrogen peroxide, produce free oxygen to dislodge menstrual fluid discharge from cotton fabric but this process may be effective only when the discharge is fresh and minimal fluid penetration of the fabric has occurred.
[0004] Perspiration stain in the underarm areas of white cotton fabric shirts and blouses is also difficult to remove, even for professionals in the garment laundry and cleaner business. Often the stain is not completely removed.
[0005] There is a clamor among women around the world for a process that they can use to remove fresh, set-in or old menstrual fluid or perspiration stain from white cotton fabric, a process that can be used easily, rapidly, with little or no scrubbing, and with no damage to the cotton fabric.
SUMMARY OF THE INVENTION
[0006] One object of the present invention is to provide cleaning products and methods for reducing the damaging effect of hypochlorite-containing solutions on soft fabrics. The fabrics can be made of cotton, cotton/polyester, or other materials. The fabrics may be, for example, in white.
[0007] In accordance with one aspect of the present invention, the method comprises the steps of modifying a hypochlorite-containing solution by adding an alkali metal hydroxide to the solution, such that the weight concentration ratio of the hypochlorite salt over the alkali metal hydroxide in the modified solution is less than 12.5:1, where the modified solution can then be used in contacting a stain on a soft fabric article for at least one minute to remove the stain. In certain cases, the contact with the stain can last for at least 5, 10, 15, 30, 60 minutes or longer before the stain is cleaned, necessitating an appropriate weight concentration ratio in order to maintain a reduced damaging effect.
[0008] The stain can be any type of hard-to-remove stains, such as fresh, set-in or old menstrual fluid or underarm perspiration stains. Other examples of hard-to-remove stains include, but are not limited to, those caused by wine, grass, urine, feces, and certain types of ink.
[0009] In a preferred embodiment, the alkali metal hydroxide is sodium hydroxide, and the hypochlorite salt is sodium hypochlorite. The weight concentration ratio of sodium hypochlorite over sodium hydroxide in the modified solution can be less than 10:1, 5:1, and about 3:1 to 1:1. A sodium hypochlorite/sodium hydroxide ratio also can be less than 1:1.
[0010] In one embodiment, the modified solution includes at least 0.2, 0.3, 0.5, 1, 2, 3 or higher weight percent of sodium hydroxide. For instance, the weight percentage of sodium hydroxide can range from about 0.5% to about 3%.
[0011] In another embodiment, the modified solution includes about 2.5 weight percent of sodium hypochlorite and 0.5 to 1.25 weight percent of sodium hydroxide. In yet another embodiment, the modified solution includes about 6 weight percent of sodium hypochlorite and 1.2 to 3 weight percent of sodium hydroxide.
[0012] In accordance with another aspect of the present invention, the method for reducing the damaging effect of a hypochlorite salt-containing solution comprises the steps of modifying the solution by adding an alkali metal hydroxide to the solution, such that the pH of the modified solution is at least 11.8, where the modified solution can then be used in contacting a stain on a soft fabric article for at least one minute to remove the stain. The fabric article may be, for example, in white.
[0013] The pH of the modified solution can be at least 12, 12.5 or 13. In one embodiment, the pH of the modified solution is about 13.
[0014] In a preferred embodiment, the alkali metal hydroxide is sodium hydroxide, and the hypochlorite salt is sodium hypochlorite. The weight percentage of sodium hypochlorite in the modified solution can be at least 0.5%, 1%, 2%, 3%, 4%, 5%, 6% or more.
[0015] In one embodiment, the modified solution is a modified form of Ultra Clorox® Bleach Regular. Ultra Clorox® Bleach Regular typically contains about 6 weight percent of sodium hypochlorite and less than 0.2 weight percent of sodium hydroxide. To make the modified solution with reduced damaging effect, an additional amount of sodium hydroxide is added.
[0016] Another object of the present invention is to provide products, methods and kits useful for removing hard-to-remove stains from soft fabric articles. The soft fabric articles can be, for example, panties, shirts, blouses, pants, jeans, trousers or other soft fabric articles. The removal preferably is accomplished with little or no scrubbing of the fabrics.
[0017] In one embodiment, the metallic salt of hypochlorous acid is sodium hypochlorite, and the alkali metal hydroxide is sodium hydroxide. The cleaning composition can include, for example, at least 0.3 weight percent of sodium hydroxide. Preferably, the cleaning composition contains about 0.5 to about 3 weight percent of sodium hydroxide. In one embodiment, the weight concentration ratio of sodium hypochlorite over sodium hydroxide is preferably about 2:1.
[0018] The stain to be removed can be menstrual fluid or underarm perspiration stain. For the weight concentration ratio of sodium hypochlorite over sodium hydroxide of about 2:1, the contact between the cleaning composition and the stain can last at least five, fifteen, thirty minutes, or longer, with no damage to the soft fabric article.
[0019] In accordance with another aspect of the present invention, the method includes the steps of providing a cleaning composition which contains an effective amount of a metallic salt of hypochlorous acid and has a pH of at least 11.8, where the cleaning composition can then be used in contacting a stain on a soft fabric article for at least one minute. The metallic salt of hypochlorous acid preferably is sodium hypochlorite.
[0020] In accordance with yet another aspect of the present invention, a kit is provided that is useful for removing stains from clothes or other soft fabrics. The kit includes a cleaning composition which contains an effective amount of a metallic salt of hypochlorous acid and at least 0.2 weight percent of an alkali metal hydroxide. The kit also has an instruction indicating that the cleaning composition contained therein can be used for removing stains from soft fabric articles. In another embodiment, the kit includes a spray bottle capable of spraying the cleaning composition onto the soft fabric article.
[0021] In accordance with yet another aspect of the present invention, the kit includes a cleaning composition which contains an effective amount of a metallic salt of hypochlorous acid and which has a pH of at least 11.8. The kit also has an instruction for removing stains from soft fabric articles employing the cleaning composition. The metallic salt of hypochlorous acid preferably is sodium hypochlorite. In one embodiment, the cleaning composition includes 0.5-3 weight percent of sodium hydroxide.
[0022] In one embodiment, the cleaning composition contains at least 0.3 weight percent of sodium hydroxide. In another embodiment, the cleaning composition contains about 0.5 to about 3 weight percent of sodium hydroxide. The pH of the cleaning composition can be, for example, at least 12, 12.5, or 13. The cleaning composition can contact with the stain on the soft fabric article for at least five, fifteen, thirty minutes, or longer, with no damage to the fabric article.
[0023] In accordance with yet another aspect of the present invention, a kit is provided that is useful for removing stains from clothes or other soft fabrics. The kit includes a cleaning composition which contains an effective amount of a metallic salt of hypochlorous acid and at least 0.2 weight percent of an alkali metal hydroxide. The kit also has an instruction indicating that the cleaning composition contained therein can be used for removing stains from soft fabric articles.
[0024] The metallic salt of hypochlorous acid preferably is sodium hypochlorite, and the alkali metal hydroxide preferably is sodium hydroxide. In one embodiment, the cleaning composition comprises about 0.5 to about 3 weight percent of sodium hydroxide. In one embodiment, the weight concentration ratio of sodium hypochlorite over sodium hydroxide is about 2:1. In another embodiment, a kit includes a spray bottle capable of spraying the cleaning composition onto the soft fabric article.
[0025] Other features, objects, and advantages of the present invention are apparent in the detailed description that follows. It should be understood, however, that the detailed description, while indicating preferred embodiments of the present invention; is given by way of illustration only, not limitation. Various changes and modifications within the scope of the invention will become apparent to those skilled in the art from the detailed description.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The present invention is based on a bleach cleaning composition which contains a metallic salt of hypochlorous acid and an alkali metal hydroxide for removing hard-to-remove stains from clothes and other soft fabric articles. In addition, appropriate amounts of alkali metal hydroxide added to a hypochlorite solution retard the damaging effect of the hypochlorite solution on soft fabric (such as cotton fabric). The metallic salt of hypochlorous acid preferably is sodium hypochlorite. The alkali metal hydroxide preferably is sodium hydroxide. Other hypochlorous salts and/or alkali metal hydroxides can also be used in the present invention.
[0027] The concentration of sodium hypochlorite in the bleach cleaning composition of the present invention preferably is at least 0.5% by weight, based on the total weight of the cleaning composition. For instance, the concentration of sodium hypochlorite can be at least 0.5, 1, 2, 3, 4, 5, 6, 7 or 8% by weight. In one embodiment, the concentration of sodium hypochlorite ranges from 0.5 to 10% by weight. In another embodiment, the concentration of sodium hypochlorite is about 0.5 to 5% by weight. In yet another embodiment, the concentration of sodium hypochlorite is about 1 to 2.5% by weight. In still another embodiment, the concentration of sodium hypochlorite is about 1.5 to 2% by weight.
[0028] The concentration of sodium hydroxide in the bleach cleaning composition preferably is at least 0.2% by weight, based on the total weight of the cleaning composition. For instance, the concentration of sodium hydroxide can be at least about 0.3, 0.4, 0.5, 1, 1.5, 2, 2.5, 3, 4 or 5% by weight. In one embodiment, the concentration of sodium hydroxide ranges from about 0.5 to about 3% by weight. In another embodiment, the concentration of sodium hydroxide ranges from about 1 to 2% by weight. Without limiting the present invention to any particular mechanism, Applicant has found that an appropriate amount of alkali metal hydroxide (such as sodium hydroxide) significantly increases the compatibility of sodium hypochlorite with soft fabric, such as cotton fabric, thereby preventing sodium hypochlorite from damaging the fabric.
[0029] The weight concentration ratio of sodium hypochlorite over sodium hydroxide may vary substantially without affecting the stain-removing power of the cleaning composition. However, the fabric damaging effect of hypochlorite varies with the weight concentration ratio for a given concentration of hypochlorite. Preferably, the weight concentration ratio of sodium hypochlorite over sodium hydroxide is less than 12.5:1. In one embodiment, the weight concentration ratio of sodium hypochlorite over sodium hydroxide can range from about 5:1 to about 1:5. In another embodiment, the weight concentration ratio of sodium hypochlorite over sodium hydroxide is about 3:1 to about 1:1. Ideally, the ratio is about 2:1 for minimum damaging effect.
[0030] In one embodiment, the bleach cleaning composition includes about 6 weight percent of sodium hypochlorite and 1.2 to 3 weight percent of sodium hydroxide. In another embodiment, the cleaning composition includes about 2.5 weight percent of sodium hypochlorite and 0.5 to 1.25 weight percent of sodium hydroxide. In both embodiments, the concentration ratio varies from 5:1 to 2:1. Hence, in both embodiments, the range of concentration ratios is the same and, likewise, the degree of fabric damage effect can be expected to follow suit, ranging to the same minimum. However, in the two embodiments, the pH values are different. It is noted that the concentration ratio is dependent on both the hypochlorite and the hydroxide, whereas the pH is dependent on only the hydroxide. The cleaning composition of the present invention can be a form of regular Clorox® Bleach modified with additional sodium hydroxide.
[0031] The pH of the cleaning composition preferably is at least about 11.8. For instance, the pH of the cleaning composition can be at least 12, 12.5 or 13. In one embodiment, the pH of the cleaning composition is about 13.
[0032] Other ingredients or additives can be added in the bleach cleaning composition. These ingredients or additives include, for example, chelating agents, phosphorous-containing salts, surfactants, or abrasive agents. These ingredients or additives, however, are not necessary for the stain-removing function of the cleaning composition. In one embodiment, the cleaning composition is free of chelating agents, phosphorous-containing salts, surfactants, and abrasive agents.
[0033] The bleach cleaning composition of the present invention can be stored in a container, such as a spray bottle, prior to use. Preferably, the container has an instruction indicating that the enclosed cleaning composition can be used for removing menstrual fluid, perspiration, and other such difficult stains from soft fabric articles and to do so with fabric protection.
[0034] Sodium hypochlorite and sodium hydroxide can be separately stored prior to use. For instance, they can be stored in two separate compartments of a container. The first compartment encloses a sodium hypochlorite solution. The second compartment encloses a concentrated sodium hydroxide solution. The two solutions are mixed together upon use. An exemplary device suitable for this purpose is illustrated in U.S. Pat. No. 6,398,077, which is incorporated herein by reference.
[0035] Soft fabric articles suitable for the present invention can be made of a variety of materials, such as cotton or cotton/polyester. The fabric articles preferably are in white or colorfast fabrics. Examples of soft fabric articles suitable for the present invention include, but are not limited to, panties, shirts, blouses, pants, jeans, trousers, and other wear and bed products.
[0036] The stains to be removed can be menstrual fluid stains or underarm perspiration stains. Other hard-to-remove stains, such as wine, grass, urine, feces, or ink stains, can also be removed using the present invention. The contact between the bleach cleaning solution and the stain may last for at least one minute before the stain is removed. In one embodiment, the contact between the cleaning solution and the stain lasts for at least 5, 10, 15, 30, 60 or more minutes before the stain is removed.
[0037] In accordance with one aspect of the present invention, the soft fabric article that is to be de-stained is first soaked in cold water until the stain areas are thoroughly saturated with water. The fabric article can be swirled around in the water to dislodge as much stain as possible. For articles heavily soiled with stains, the water may be changed to repeat the soaking and swirling step
[0038] The fabric article is then squeezed to remove excess water. White cotton articles heavily stained with menstrual fluid may be tinted slightly pink after this step. The stained areas are arranged for maximal exposure in preparation for the spray with the cleaning composition.
[0039] The cleaning composition can be sprayed on the stain areas, or the entire article if necessary. After spraying, the stain areas can be compressed and confined into a small container to saturate and soak the stain areas or the entire article in the cleaner.
[0040] The stained areas are soaked with the cleaning composition until the stain has been removed. This may require about one to five minutes for removing fresh menstrual fluid stain, and about thirty minutes or more for removing old underarm perspiration stain. The fabric article can be subsequently inspected for any remaining stain. If necessary, spot spray can be applied again to remove the remaining stain.
[0041] After all stain has been removed, the fabric article is thoroughly rinsed in cold water before being put through the detergent wash/rinse and dry cycle, particularly if the fabric article is combined with non-colorfast clothing in the wash. Also, this assures that all sodium hydroxide has been removed from the fabric article before it is worn next to the skin. According to the present invention, menstrual fluid stains or underarm perspiration stains may be removed from a soft fabric article with little or no scrubbing of the article.
[0042] After the stain is removed, the fabric article preferably is not soaked with the cleaning composition any longer than necessary.
[0043] It should be understood that the above-described embodiments and the following examples are given by way of illustration, not limitation. Various changes and modifications within the scope of the present invention will become apparent to those skilled in the art from the present description.
EXAMPLES
Example I
Comparison of Clorox® Bleach to a Cleaning Composition Comprising 2.4 wt % Sodium Hypochlorite and 1.25% Sodium Hydroxide
[0044] Two similar patches (approximately 2.5×2.5 cm 2 ) of 100% cotton fabric were cut from the crotch of a new panty. The first patch was immersed in a diluted Clorox® Bleach solution. The diluted Clorox® Bleach solution contained about 2.4 wt % sodium hypochlorite. After six hours of soaking, the first patch showed signs of shredding. After ten hours of soaking, the first patch shredded completely. In comparison, the second patch was immersed in a solution which contains about 2.4 wt % sodium hypochlorite and 1.25 wt % sodium hydroxide. After ten hours of soaking, no effect of shredding was observed.
Example II
The Damage Effects of Hypochlorite Solutions to Cotton Patches and the Reduction Thereof
[0045] Cotton patches which were resistant to hand-tearing were soaked in different bleach solutions until damages have begun to occur as evidenced by weakening of the fabric such that it can be torn by hands with moderate forces. For each bleach solution to be tested, multiple cotton patches were used. Each patch was inserted into a vial containing the bleaching solution. The patch was removed periodically from the vial to determine the extent of damage by manually administering a tearing action. T c (D) was the cumulative time of soaking before the patch became hand-tearable.
[0046] The bleach solutions were modified from Ultra Clorox® Bleach which contains about 6% NaOCl and less than 0.2% NaOH. Additional NaOH in dry form was added to Ultra Clorox® Bleach to increase the concentration of NaOH. As Table 1 shows, Ultra Clorox® Bleach damages cotton fabrics in an accumulated time of approximately one hour. Decreasing the ratio of NaOCl/NaOH progressively increases the accumulated times for which the bleach solution is cotton-safe. This Example indicates that NaOH, added to Ultra Clorox® Bleach, can abate the damage of cotton fabrics; thereby rendering the bleach solution cotton-safe.
[0000]
TABLE 1
Comparison of the Damage Effects of
Bleaching Solutions
NaOCl/NaOH
NaOH
(weight
(weight
percentage
T c (D)
Cleaning Solution
percentage)
ratio)
(hours)
Ultra Clorox Beach
0-0.2
over 30:1
1
Solution #1
0.4-0.6
12:1
4
Solution #2
1.0-1.2
5.5:1
6
Solution #3
2.0-2.2
3:1
6
Solution #4
3.0-3.2
2:1
9.5
Solution #5
4.0-4.2
1.5:1
9.5
Solution #6
6.0-6.2
1:1
9.5
[0047] The foregoing description of the present invention provides illustration and description, but is not intended to be exhaustive or to limit the invention to the precise one disclosed. Modifications and variations are possible consistent with the above teachings or may be acquired from practice of the invention. Thus, it is noted that the scope of the invention is defined by the claims and their equivalents. | Household-strength bleach contains just two essential components, hypochlorite and hydroxide, and the hypochlorite is well-known to damage soft fabrics. In this invention is discovered a third component, the concentration ratio which is the concentration of hypochlorite over the concentration of hydroxide in the bleach solution. Although considered impossible, hypochlorite bleach can be made fabric gentle by elegantly balancing the concentrations of hypochlorite and hydroxide, requiring no ingredients commonly added to mitigate the damaging effect of hypochlorite. It's all in the ratio (or the reciprocal). By adding hydroxide to a solution of given hypochlorite salt concentration, the bleach fabric protection progressively improves for ratio values below 12.5:1, reaching maximum protection at a ratio value about 2:1. By comparison, the ratio value is >30:1 for fabric-damaging common regular bleach. Regular hypochlorite bleach that eats up cotton can be converted to cotton-gentle hypochlorite bleach having the same cleaning properties. | 3 |
CLAIM OF PRIORITY
This application claims priority under 35 U.S.C. 119(e)(1) to U.S. Provisional Application No. 61/287,289 filed Dec. 17, 2009.
TECHNICAL FIELD OF THE INVENTION
The technical field of this invention is time stamping for emulation and debug of electronic systems.
BACKGROUND OF THE INVENTION
Advanced wafer lithography and surface-mount packaging technology are integrating increasingly complex functions at both the silicon and printed circuit board level of electronic design. Diminished physical access to circuits for test and emulation is an unfortunate consequence of denser designs and shrinking interconnect pitch. Designed-in testability is needed so the finished product is both controllable and observable during test and debug. Any manufacturing defect is preferably detectable during final test before a product is shipped. This basic necessity is difficult to achieve for complex designs without taking testability into account in the logic design phase so automatic test equipment can test the product.
In addition to testing for functionality and for manufacturing defects, application software development requires a similar level of simulation, observability and controllability in the system or sub-system design phase. The emulation phase of design should ensure that a system of one or more ICs (integrated circuits) functions correctly in the end equipment or application when linked with the system software. With the increasing use of ICs in the automotive industry, telecommunications, defense systems, and life support systems, thorough testing and extensive real-time debug becomes a critical need.
Functional testing, where the designer generates test vectors to ensure conformance to specification, still remains a widely used test methodology. For very large systems this method proves inadequate in providing a high level of detectable fault coverage. Automatically generated test patterns are desirable for full testability, and controllability and observability. These are key goals that span the full hierarchy of test from the system level to the transistor level.
Another problem in large designs is the long time and substantial expense involved in design for test. It would be desirable to have testability circuitry, system and methods that are consistent with a concept of design-for-reusability. In this way, subsequent devices and systems can have a low marginal design cost for testability, simulation and emulation by reusing the testability, simulation and emulation circuitry, systems and methods that are implemented in an initial device. Without a proactive testability, simulation and emulation plan, a large amount of subsequent design time would be expended on test pattern creation and upgrading.
Even if a significant investment were made to design a module to be reusable and to fully create and grade its test patterns, subsequent use of a module may bury it in application specific logic. This would make its access difficult or impossible. Consequently, it is desirable to avoid this pitfall.
The advances of IC design are accompanied by decreased internal visibility and control, reduced fault coverage and reduced ability to toggle states, more test development and verification problems, increased complexity of design simulation and continually increasing cost of CAD (computer aided design) tools. In the board design the side effects include decreased register visibility and control, complicated debug and simulation in design verification, loss of conventional emulation due to loss of physical access by packaging many circuits in one package, increased routing complexity on the board, increased costs of design tools, mixed-mode packaging, and design for produceability. In application development, some side effects are decreased visibility of states, high speed emulation difficulties, scaled time simulation, increased debugging complexity, and increased costs of emulators. Production side effects involve decreased visibility and control, complications in test vectors and models, increased test complexity, mixed-mode packaging, continually increasing costs of automatic test equipment and tighter tolerances.
Emulation technology utilizing scan based emulation and multiprocessing debug was introduced more than 10 years ago. In 1988, the change from conventional in circuit emulation to scan based emulation was motivated by design cycle time pressures and newly available space for on-chip emulation. Design cycle time pressure was created by three factors. Higher integration levels, such as increased use of on-chip memory, demand more design time. Increasing clock rates mean that emulation support logic causes increased electrical intrusiveness. More sophisticated packaging causes emulator connectivity issues. Today these same factors, with new twists, are challenging the ability of a scan based emulator to deliver the system debug facilities needed by today's complex, higher clock rate, highly integrated designs. The resulting systems are smaller, faster, and cheaper. They have higher performance and footprints that are increasingly dense. Each of these positive system trends adversely affects the observation of system activity, the key enabler for rapid system development. The effect is called “vanishing visibility.”
FIG. 1 illustrates the trend in visibility and control over time and greater system integration in accordance with the prior art. Application developers prefer the optimum visibility level illustrated in FIG. 1 . This optimum visibility level provides visibility and control of all relevant system activity. The steady progression of integration levels and increases in clock rates steadily decrease the actual visibility and control available over time. These forces create a visibility and control gap, the difference between the optimum visibility and control level and the actual level available. Over time, this gap will widen. Application development tool vendors are striving to minimize the gap growth rate. Development tools software and associated hardware components must do more with less resources and in different ways. Tackling this ease of use challenge is amplified by these forces.
With today's highly integrated System-On-a-Chip (SOC) technology, the visibility and control gap has widened dramatically over time. Traditional debug options such as logic analyzers and partitioned prototype systems are unable to keep pace with the integration levels and ever increasing clock rates of today's systems. As integration levels increase, system buses connecting numerous subsystem components move on chip, denying traditional logic analyzers access to these buses. With limited or no significant bus visibility, tools like logic analyzers cannot be used to view system activity or provide the trigger mechanisms needed to control the system under development. A loss of control accompanies this loss in visibility, as it is difficult to control things that are not accessible.
To combat this trend, system designers have worked to keep these buses exposed. Thus the system components were built in a way that enabled the construction of prototyping systems with exposed buses. This approach is also under siege from the ever-increasing march of system clock rates. As the central processing unit (CPU) clock rates increase, chip to chip interface speeds are not keeping pace. Developers find that a partitioned system's performance does not keep pace with its integrated counterpart, due to interface wait states added to compensate for lagging chip to chip communication rates. At some point, this performance degradation reaches intolerable levels and the partitioned prototype system is no longer a viable debug option. In the current era production devices must serve as the platform for application development.
Increasing CPU clock rates are also limiting availability of other simple visibility mechanisms. Since the CPU clock rates can exceed the maximum I/O state rates, visibility ports exporting information in native form can no longer keep up with the CPU. On-chip subsystems are also operated at clock rates that are slower than the CPU clock rate. This approach may be used to simplify system design and reduce power consumption. These developments mean simple visibility ports can no longer be counted on to deliver a clear view of CPU activity. As visibility and control diminish, the development tools used to develop the application become less productive. The tools also appear harder to use due to the increasing tool complexity required to maintain visibility and control. The visibility, control, and ease of use issues created by systems-on-a-chip tend to lengthen product development cycles.
Even as the integration trends present developers with a tough debug environment, they also present hope that new approaches to debug problems will emerge. The increased densities and clock rates that create development cycle time pressures also create opportunities to solve them. On-chip, debug facilities are more affordable than ever before. As high speed, high performance chips are increasingly dominated by very large memory structures, the system cost associated with the random logic accompanying the CPU and memory subsystems is dropping as a percentage of total system cost. The incremental cost of several thousand gates is at an all time low. Circuits of this size may in some cases be tucked into a corner of today's chip designs. The incremental cost per pin in today's high density packages has also dropped. This makes it easy to allocate more pins for debug. The combination of affordable gates and pins enables the deployment of new, on-chip emulation facilities needed to address the challenges created by systems-on-a-chip.
When production devices also serve as the application debug platform, they must provide sufficient debug capabilities to support time to market objectives. Since the debugging requirements vary with different applications, it is highly desirable to be able to adjust the on-chip debug facilities to balance time to market and cost needs. Since these on-chip capabilities affect the chip's recurring cost, the scalability of any solution is of primary importance. “Pay only for what you need” should be the guiding principle for on-chip tools deployment. In this new paradigm, the system architect may also specify the on-chip debug facilities along with the remainder of functionality, balancing chip cost constraints and the debug needs of the product development team.
FIG. 2 illustrates a prior art emulator system 100 including four emulator components. These four components are: a debugger application program 110 ; a host computer 120 ; an emulation controller 130 ; and on-chip debug facilities 140 . FIG. 2 illustrates the connections of these components. Host computer 120 is connected to an emulation controller 130 external to host 120 . Emulation controller 130 is also connected to target system 140 . The user preferably controls the target application on target system 140 through debugger application program 110 .
Host computer 120 is generally a personal computer. Host computer 120 provides access the debug capabilities through emulator controller 130 . Debugger application program 110 presents the debug capabilities in a user-friendly form via host computer 120 . The debug resources are allocated by debug application program 110 on an as needed basis, relieving the user of this burden. Source level debug utilizes the debug resources, hiding their complexity from the user. Debugger application program 110 together with the on-chip trace and triggering facilities provide a means to select, record, and display chip activity of interest. Trace displays are automatically correlated to the source code that generated the trace log. The emulator provides both the debug control and trace recording function.
The debug facilities are preferably programmed using standard emulator debug accesses through a JTAG or similar serial debug interface. Since pins are at a premium, the preferred embodiment of the invention provides for the sharing of the debug pin pool by trace, trigger, and other debug functions with a small increment in silicon cost. Fixed pin formats may also be supported. When the pin sharing option is deployed, the debug pin utilization is determined at the beginning of each debug session before target system 140 is directed to run the application program. This maximizes the trace export bandwidth. Trace bandwidth is maximized by allocating the maximum number of pins to trace.
The debug capability and building blocks within a system may vary. Debugger application program 100 therefore establishes the configuration at runtime. This approach requires the hardware blocks to meet a set of constraints dealing with configuration and register organization. Other components provide a hardware search capability designed to locate the blocks and other peripherals in the system memory map. Debugger application program 110 uses a search facility to locate the resources. The address where the modules are located and a type ID uniquely identifies each block found. Once the IDs are found, a design database may be used to ascertain the exact configuration and all system inputs and outputs.
Host computer 120 generally includes at least 64 Mbytes of memory and is capable of running Windows 95, SR-2, Windows NT, or later versions of Windows. Host computer 120 must support one of the communications interfaces required by the emulator. These may include: Ethernet 10T and 100T, TCP/IP protocol; Universal Serial Bus (USB); Firewire IEEE 1394; and parallel port such as SPP, EPP and ECP.
Host computer 120 plays a major role in determining the real-time data exchange bandwidth. First, the host to emulator communication plays a major role in defining the maximum sustained real-time data exchange bandwidth because emulator controller 130 must empty its receive real-time data exchange buffers as fast as they are filled. Secondly, host computer 120 originating or receiving the real-time data exchange data must have sufficient processing capacity or disc bandwidth to sustain the preparation and transmission or processing and storing of the received real-time data exchange data. A state of the art personal computer with a Firewire communication channel (IEEE 1394) is preferred to obtain the highest real-time data exchange bandwidth. This bandwidth can be as much as ten times greater performance than other communication options.
Emulation controller 130 provides a bridge between host computer 120 and target system 140 . Emulation controller 130 handles all debug information passed between debugger application program 110 running on host computer 120 and a target application executing on target system 140 . A presently preferred minimum emulator configuration supports all of the following capabilities: real-time emulation; real-time data exchange; trace; and advanced analysis.
Emulation controller 130 preferably accesses real-time emulation capabilities such as execution control, memory, and register access via a 3, 4, or 5 bit scan based interface. Real-time data exchange capabilities can be accessed by scan or by using three higher bandwidth real-time data exchange formats that use direct target to emulator connections other than scan. The input and output triggers allow other system components to signal the chip with debug events and vice-versa. Bit I/O allows the emulator to stimulate or monitor system inputs and outputs. Bit I/O can be used to support factory test and other low bandwidth, non-time-critical emulator/target operations. Extended operating modes are used to specify device test and emulation operating modes. Emulator controller 130 is partitioned into communication and emulation sections. The communication section supports host communication links while the emulation section interfaces to the target, managing target debug functions and the device debug port. Emulation controller 130 communicates with host computer 120 using one of industry standard communication links outlined earlier herein. The host to emulator connection is established with off the shelf cabling technology. Host to emulator separation is governed by the standards applied to the interface used.
Emulation controller 130 communicates with the target system 140 through a target cable or cables. Debug, trace, triggers, and real-time data exchange capabilities share the target cable, and in some cases, the same device pins. More than one target cable may be required when the target system 140 deploys a trace width that cannot be accommodated in a single cable. All trace, real-time data exchange, and debug communication occurs over this link. Emulator controller 130 preferably allows for a target to emulator separation of at least two feet. This emulation technology is capable of test clock rates up to 50 MHZ and trace clock rates from 200 to 300 MHZ, or higher. Even though the emulator design uses techniques that should relax target system 140 constraints, signaling between emulator controller 130 and target system 140 at these rates requires design diligence. This emulation technology may impose restrictions on the placement of chip debug pins, board layout, and requires precise pin timings. On-chip pin macros are provided to assist in meeting timing constraints.
The on-chip debug facilities offer the developer a rich set of development capability in a two tiered, scalable approach. The first tier delivers functionality utilizing the real-time emulation capability built into a CPU's mega-modules. This real-time emulation capability has fixed functionality and is permanently part of the CPU while the high performance real-time data exchange, advanced analysis, and trace functions are added outside of the core in most cases. The capabilities are individually selected for addition to a chip. The addition of emulation peripherals to the system design creates the second tier functionality. A cost-effective library of emulation peripherals contains the building blocks to create systems and permits the construction of advanced analysis, high performance real-time data exchange, and trace capabilities. In the preferred embodiment five standard debug configurations are offered, although custom configurations are also supported. The specific configurations are covered later herein.
Transmission of a very large timestamp value to a number of timestamp clients uses substantial chip routing area.
SUMMARY OF THE INVENTION
This invention minimizes chip routing resources in transmission of timestamp values to timestamp clients. This invention employs a mix of both parallel and serial methods.
A timestamp generator generates a timestamp value having a predetermined number of most significant bits and a predetermined number of least significant bits. The least significant bits are transmitted to a client via a parallel data bus. The most significant bits are transmitted to the client sequentially via a series data bus. Each client receives the parallel least significant bits and the series most significant bits and assembles a complete timestamp value.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects of this invention are illustrated in the drawings, in which:
FIG. 1 illustrates the visibility and control of typical integrated circuits as a function of time due to increasing system integration;
FIG. 2 illustrates a prior art emulation system to which this invention is applicable;
FIG. 3 illustrates in block diagram form a typical integrated circuit employing configurable emulation capability of the prior art;
FIG. 4 illustrates a first prior art timestamp distribution technique;
FIG. 5 illustrates a second prior art timestamp distribution technique;
FIG. 6 illustrates a third prior art timestamp distribution technique;
FIG. 7 illustrates schematically a first embodiment of timestamp value transmission of this invention;
FIG. 8 illustrates an example of the embodiment of FIG. 7 ;
FIG. 9 illustrates the manner of transmitting the serial most significant bits of the time stamp value of the embodiment of FIG. 7 ;
FIG. 10 illustrates schematically a second embodiment of timestamp value transmission of this invention;
FIG. 11 illustrates an example of the embodiment of FIG. 10 ;
FIG. 12 illustrates the manner of transmitting the serial most significant bits of the time stamp value of the embodiment of FIG. 10 ;
FIG. 13 illustrates schematically a third embodiment of timestamp value transmission of this invention;
FIG. 14 illustrates an example of the embodiment of FIG. 13 ;
FIG. 15 illustrates the manner of transmitting the serial most significant bits of the time stamp value of the embodiment of FIG. 13 ;
FIG. 16 illustrates schematically a fourth embodiment of timestamp value transmission of this invention;
FIG. 17 illustrates an example of the embodiment of FIG. 16 ;
FIG. 18 illustrates the manner of transmitting the serial most significant bits of the time stamp value of the embodiment of FIG. 16 ;
FIG. 19 illustrates various signals in a first embodiment of reception of the serial most significant bits of the time stamp of this invention;
FIG. 20 illustrates hardware for practicing the embodiment illustrated in FIG. 19 ;
FIG. 21 illustrates various signals in a second embodiment of reception of the serial most significant bits of the time stamp of this invention;
FIG. 22 illustrates hardware for practicing the embodiment illustrated in FIG. 21 ; and
FIG. 23 illustrates hardware for distribution of the timestamp value according to this invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 3 illustrates an example of one on-chip debug architecture embodying target system 140 . The architecture uses several module classes to create the debug function. One of these classes is event detectors including bus event detectors 210 , auxiliary event detectors 211 and counters/state machines 213 . A second class of modules is trigger generators including trigger builders 220 . A third class of modules is data acquisition including trace collection 230 and formatting. A fourth class of modules is data export including trace export 240 , and real-time data exchange export 241 . Trace export 240 is controlled by clock signals from local oscillator 245 . Local oscillator 245 will be described in detail below. A final class of modules is scan adaptor 250 , which interfaces scan input/output to CPU core 201 . Final data formatting and pin selection occurs in pin manager and pin micros 260 .
The size of the debug function and its associated capabilities for any particular embodiment of a system-on-chip may be adjusted by either deleting complete functions or limiting the number of event detectors and trigger builders deployed. Additionally, the trace function can be incrementally increased from program counter trace only to program counter and data trace along with ASIC and CPU generated data. The real-time data exchange function may also be optionally deployed. The ability to customize on-chip tools changes the application development paradigm. Historically, all chip designs with a given CPU core were limited to a fixed set of debug capability. Now, an optimized debug capability is available for each chip design. This paradigm change gives system architects the tools needed to manage product development risk at an affordable cost. Note that the same CPU core may be used with differing peripherals with differing pin outs to embody differing system-on-chip products. These differing embodiments may require differing debug and emulation resources. The modularity of this invention permits each such embodiment to include only the necessary debug and emulation resources for the particular system-on-chip application.
The real-time emulation debug infrastructure component is used to tackle basic debug and instrumentation operations related to application development. It contains all execution control and register visibility capabilities and a minimal set of real-time data exchange and analysis such as breakpoint and watchpoint capabilities. These debug operations use on-chip hardware facilities to control the execution of the application and gain access to registers and memory. Some of the debug operations which may be supported by real-time emulation are: setting a software breakpoint and observing the machine state at that point; single step code advance to observe exact instruction by instruction decision making; detecting a spurious write to a known memory location; and viewing and changing memory and peripheral registers.
Real-time emulation facilities are incorporated into a CPU mega-module and are woven into the fabric of CPU core 201 . This assures designs using CPU core 201 have sufficient debug facilities to support debugger application program 110 baseline debug, instrumentation, and data transfer capabilities. Each CPU core 201 incorporates a baseline set of emulation capabilities. These capabilities include but are not limited to: execution control such as run, single instruction step, halt and free run; displaying and modifying registers and memory; breakpoints including software and minimal hardware program breakpoints; and watchpoints including minimal hardware data breakpoints.
Timestamps are generally regarding as part of instrumentation data. In a system where emulation or debug is desired, it is desirable to collect information about system operation with software and hardware monitors. This information becomes even more valuable when the time of information collection is also recorded and made available. The time at which information is collected is typically marked with a timestamp.
One method of timestamping presumes a common time base is available to all functions (timestamp clients) generating a timestamp. As the operating frequency of systems increase, the number of bits used for a timestamp can generally increase proportionally. When the timestamp must be delivered to a number of functions (timestamp Clients) within a chip, the number of routing channels required to deliver the timestamp to all destinations becomes significant. This invention covers methods that may be used to convey a timestamp value to many points in a system while minimizing the number of routing channels needed to provide the timestamp value to the functions.
A timestamp value is generally created with the highest frequency clock within the system when a timestamp with maximum resolution is desired. This may provide a timestamp of 64 or more bits in width. The timestamp value is represented as timestamp[n:00]: where bit n is the most significant bit (MSB); and bit 00 is the least significant bit (LSB).
The characteristics of this timestamp value are listed below. A timestamp value may be coded as: a binary value; a Gray coded value; or some other encoding format. When a timestamp is binary coded, beginning with bit [01], each bit n toggles at one half the rate of bit [n−1]. When a timestamp value is Gray coded, beginning with bit [01], each bit n toggles at one half the rate of bit [n−1]. For both binary coded and Gray coded timestamp values, the toggle rates of more significant bits are slow or very slow when compared to the toggle rates of less significant bits. The point at which bit [n] of the timestamp toggles is determined by the value of timestamp bits [n−1:0]
FIGS. 4 to 6 illustrate several techniques for presentation of timestamps in the prior art. FIG. 4 illustrates a first prior art technique. Timestamp source 401 supplies a timestamp value as n parallel bits to client 402 . The n-bit timestamp is supplied each client 402 synchronous to a clock of client 402 or a sub-multiple of this clock.
FIG. 5 illustrates a second prior art technique. Timestamp source 501 supplies a timestamp value of parallel bits [n−1,0] as an asynchronous Gray coded value. Synchronizer 502 synchronizes each bit of the Gray coded value to a client clock or sub-multiple of the client clock. Synchronizer 502 supplies the bit synchronized MSB bits [n−1:m] of the timestamp value to client 503 . Note that the omitted LSBs are not used. Generally one synchronizer 502 is provided for each client 503 .
FIG. 6 illustrates a third prior art technique. Timestamp source 601 supplies a timestamp value of parallel bits [n−1,0] as an asynchronous Gray coded value. Synchronizer 602 synchronizes the timestamp value change in one of the LSBs to the client bit [x]. Synchronizer 602 transfers MSB bits [n−1:x+y] to client 603 . The omitted LSBs are not used. Generally one synchronizer 602 is provided for each client 603 .
In each of the prior art techniques illustrated in FIGS. 4 to 6 an n-bit wide bus broadcasts a timestamp value to all timestamp clients. When some or all of these clients are located in areas of a chip where routing is congested, the number of routing channels required to provide the timestamp to these clients sometimes seems excessive. This invention is an alternate means of providing the timestamp value to clients on chip.
This invention supplies the MSBs of the timestamp value to the client serially. These MSBs of the timestamp value change infrequently when compared to the toggle rate of the client clock. This invention includes several variations of encoding the serial and parallel presentation of a timestamp value shown in Table 1 and described below.
TABLE 1 Serial Transmission Parallel Transmission (MSBs) (LSBs) Gray coded Gray coded Gray coded Binary coded Binary coded Gray coded Binary coded Binary coded
Other timestamp encoding are possible and are within the scope of this invention. With each of these techniques, the serial transmission of the MSBs of the timestamp is the next value of the MSBs so that this value may be presented to the timestamp in parallel when the count represented by the LSBs presented in parallel rolls over.
FIGS. 7 to 9 illustrate the first technique (Gray coded MSBs and Gray coded LSBs). FIG. 7 illustrates the timestamp value or data transmission schematically. First timestamp source 711 supplies MSBs of a one timestamp value or datum of serial bits [n,m+1] as an asynchronous Gray coded value. The MSB asynchronous Gray coded value is transmitted during periods of no interest. Because these MSBs change slowly this is generally possible. Second timestamp source 712 supplies LSBs of another timestamp value or datum of parallel bits [m,0] as an asynchronous Gray coded value. The LSB asynchronous Gray coded value is asynchronous to the client clock. First synchronizer 721 synchronizes each bit of the LSBs bits [m,0] to the client clock. Second synchronizer 722 keeps a timestamp value corresponding to the MSBs in a shadow register as updated by first timestamp source 711 . Second synchronizer 722 supplies the MSBs of the timestamp value synchronous with the client clock as triggered by a load signal from first synchronizer 721 to client 731 . This load is triggered by a rollover within the LSBs. Client 731 receives the MSB bits [n:m+1] from second synchronizer 722 and the LSB bits [m:0] from first synchronizer 721 . All bits are received by client 731 are synchronous with the client clock.
FIG. 8 illustrates an example of this operation. Column 810 is the serial MSBs, column 820 is the parallel LSBs and column 830 is resultant complete timestamp value. A rollover toggle in LSBs 820 at 811 triggers the load of MSBs 810 . As previously noted, this serial portion of the MSBs is coded for the next value. Therefore the load triggered by the rollover in the LSBs loads the correct value.
FIG. 9 illustrates the manner of transmitting the serial MSBs. Time slots 901 , 903 , 905 and 907 signal when a rollover toggle occurs in the LSBs. During time slot 902 the serial MSBs for the value 1 are transmitted to second synchronizer 722 . This value 1 is loaded into client 731 upon the value 1 signal in time slot 903 . During time slot 904 the serial MSBs for the value 2 are transmitted to second synchronizer 722 . This value 2 is loaded into client 731 upon the value 2 signal in time slot 905 . During time slot 906 the serial MSBs for the value 3 are transmitted to second synchronizer 722 . This value 3 is loaded into client 731 upon the value 3 signal in time slot 907 .
FIGS. 10 to 12 illustrate the second technique (Gray coded MSBs and binary coded LSBs). FIG. 10 illustrates the timestamp value transmission schematically. First timestamp source 1011 supplies MSBs of a timestamp value of serial bits [n,m+1] as an asynchronous Gray coded value. The MSB asynchronous Gray coded value is transmitted during periods of no interest. Because these MSBs change slowly this is generally possible. Second timestamp source 1012 supplies LSBs of a timestamp value of parallel bits [m,p] as an asynchronous binary coded value. The LSB asynchronous Gray coded value is asynchronous to the client clock. First synchronizer 1021 synchronizes each bit of the LSBs bits [m,p] to the client clock. Second synchronizer 1022 keeps a timestamp value corresponding to the MSBs in a shadow register as updated by first timestamp source 1011 . Second synchronizer 1022 supplies the MSBs of the timestamp value synchronous with the client clock as triggered by a load signal from first synchronizer 1021 to client 1031 . This load is triggered by a rollover within the LSBs. Client 1031 receives the MSB bits [n:m+1] from second synchronizer 1022 and the LSB bits [m:P] from first synchronizer 1021 . All bits are received by client 1031 are synchronous with the client clock. Note that bits [p−1:0] are not transmitted to client 1031 . This results in a loss of precision.
FIG. 11 illustrates an example of this operation. Column 1110 is the serial MSBs, column 1120 is the parallel LSBs and column 1130 is resultant complete timestamp value which includes bits to be discarded 1135 . A toggle in LSBs 1120 at 1111 triggers the load of MSBs 1110 . A rollover toggle in LSBs 1120 at 1111 triggers the load of MSBs 1110 . A state change is detected at 1111 which marks this time to load the MSBs 1110 . As previously noted, this serial portion of the MSBs is coded for the next value. Therefore the load triggered by the rollover in the LSBs loads the correct value. As previously described discarded bits 1135 are not transmitted to client 1131 .
FIG. 12 illustrates the manner of transmitting the serial MSBs. Time slots 1201 , 1203 , 1205 and 1207 signal when a rollover toggle occurs in the LSBs. During time slot 1202 the serial MSBs for the value 1 are transmitted to second synchronizer 1022 . This value 1 is loaded into client 1031 upon the value 1 signal in time slot 1203 . During time slot 1204 the serial MSBs for the value 2 are transmitted to second synchronizer 1022 . This value 2 is loaded into client 7101 upon the value 2 signal in time slot 1205 . During time slot 1206 the serial MSBs for the value 3 are transmitted to second synchronizer 1022 . This value 3 is loaded into client 731 upon the value 3 signal in time slot 1207 . Note that bits [3:0] of LSBs 1130 are discarded and not transmitted to client 1031 . This represents a loss of precision in the timestamp value.
FIGS. 13 to 15 illustrate the third technique (binary coded MSBs and Gray coded LSBs). FIG. 13 illustrates the timestamp value transmission schematically. First timestamp source 1311 supplies MSBs of a timestamp value of serial bits [n,m+1] as an asynchronous binary coded value. The MSB asynchronous binary coded value is transmitted during periods of no interest. Because these MSBs change slowly this is generally possible. Second timestamp source 1312 supplies LSBs of a timestamp value of parallel bits [m,0] as an asynchronous Gray coded value. The LSB asynchronous Gray coded value is asynchronous to the client clock. First synchronizer 1321 synchronizes each bit of the LSBs bits [m,0] to the client clock. Second synchronizer 1322 keeps a timestamp value corresponding to the MSBs in a shadow register as updated by first timestamp source 1311 . Second synchronizer 1322 supplies the MSBs of the timestamp value synchronous with the client clock as triggered by a load signal from first synchronizer 1321 to client 1331 . This load is triggered by a rollover within the LSBs. Client 1331 receives the MSB bits [n:m+1] from second synchronizer 1322 and the LSB bits [m:0] from first synchronizer 1321 . All bits are received by client 1331 are synchronous with the client clock.
FIG. 14 illustrates an example of this operation. Column 1410 is the serial MSBs, column 1420 is the parallel LSBs and column 1430 is resultant complete timestamp value. A rollover toggle in LSBs 1420 at 1411 triggers the load of MSBs 1410 . As previously noted, this serial portion of the MSBs is coded for the next value. Therefore the load triggered by the rollover in the LSBs loads the correct value.
FIG. 15 illustrates the manner of transmitting the serial MSBs. Time slots 1501 , 1503 , 1505 and 1507 signal when a rollover toggle occurs in the LSBs. During time slot 1502 the serial MSBs for the value 1 are transmitted to second synchronizer 1322 . This value 1 is loaded into client 1331 upon the value 1 signal in time slot 1503 . During time slot 1504 the serial MSBs for the value 2 are transmitted to second synchronizer 1222 . This value 2 is loaded into client 1331 upon the value 2 signal in time slot 1505 . During time slot 1506 the serial MSBs for the value 3 are transmitted to second synchronizer 1322 . This value 3 is loaded into client 1331 upon the value 3 signal in time slot 1507 .
FIGS. 16 to 18 illustrate the fourth technique (binary coded MSBs and binary coded LSBs). FIG. 16 illustrates the timestamp value transmission schematically. First timestamp source 1611 supplies MSBs of a timestamp value of serial bits [n,m+1] as an asynchronous binary coded value. The MSB asynchronous Gray coded value is transmitted during periods of no interest. Because these MSBs change slowly this is generally possible. Second timestamp source 1612 supplies LSBs of a timestamp value of parallel bits [m,p] as an asynchronous binary coded value. The LSB asynchronous binary coded value is asynchronous to the client clock. First synchronizer 1621 synchronizes each bit of the LSBs bits [m,p] to the client clock. Second synchronizer 1622 keeps a timestamp value corresponding to the MSBs in a shadow register as updated by first timestamp source 1611 . Second synchronizer 1622 supplies the MSBs of the timestamp value synchronous with the client clock as triggered by a load signal from first synchronizer 1621 to client 1631 . This load is triggered by a rollover within the LSBs. Client 1631 receives the MSB bits [n:m+1] from second synchronizer 1622 and the LSB bits [m:p] from first synchronizer 1611 . All bits are received by client 1631 are synchronous with the client clock. Note that bits [p−1:0] are not transmitted to client 1031 . This results in a loss of precision.
FIG. 17 illustrates an example of this operation. Column 1710 is the serial MSBs, column 1720 is the parallel LSBs and column 1730 is resultant complete timestamp value which includes bits to be discarded 1735 . A toggle in LSBs 1720 at 1711 triggers the load of MSBs 1710 . A rollover toggle in LSBs 1720 at 1711 triggers the load of MSBs 1710 . A state change is detected at 1711 which marks this time to load the MSBs 1710 . As previously noted, this serial portion of the MSBs is coded for the next value. Therefore the load triggered by the rollover in the LSBs loads the correct value. As previously described discarded bits 1735 are not transmitted to client 1731 .
FIG. 18 illustrates the manner of transmitting the serial MSBs. Time slots 1801 , 1803 , 1805 and 1807 signal when a rollover toggle occurs in the LSBs. During time slot 1802 the serial MSBs for the value 1 are transmitted to second synchronizer 1622 . This value 1 is loaded into client 1631 upon the value 1 signal in time slot 1803 . During time slot 1804 the serial MSBs for the value 2 are transmitted to second synchronizer 1622 . This value 2 is loaded into client 1631 upon the value 2 signal in time slot 1805 . During time slot 1806 the serial MSBs for the value 3 are transmitted to second synchronizer 1622 . This value 3 is loaded into client 1631 upon the value 3 signal in time slot 1807 . Note that bits [3:0] of LSBs 1730 are discarded and not transmitted to client 1631 . This represents a loss of precision in the timestamp value.
The second and fourth techniques have a loss in precision of the timestamp. Synchronization of one of the binary count values and its edge detection introduces a latency. This latency causes a truncation of timestamp precision.
There are several techniques for the serial transmission of the MSBs of the timestamp. FIG. 19 illustrates a serial clock independent of the client clock. This serial clock is used to transfer the MSBs of the timestamp value to synchronizer for the MSBs. The serial clock triggers a read of serial timestamp_in in synchronism. This forms time_stamp_sr_value in the shadow register. The load_timestamp_value signal is triggered by a rollover toggle of the timestamp LSBs. This triggers a load of the accumulated serial MSBs (timestamp_MSBs) to the client in synchronism with client clock.
FIG. 20 illustrates hardware to implement the technique illustrated in FIG. 19 . Shift register 2001 is clocked by the serial clock. Upon each instance of the serial clock shift register 2001 accumulates the timestamp data serial timestamp_in. The accumulated value within shift register 2001 is designated time_stamp_sr_value. When the load_timestamp value signal is active commanding a load operation, register 2002 loads time_stamp_sr_value from shift register 2001 upon the next client clock. Once loaded into register 2002 the value is available to the client in parallel form as Timestamp MSBs.
FIG. 21 illustrates a second embodiment including an enable signal. This enable signal controls transfer of the MSBs of the timestamp value to synchronizer for the MSBs. A shift signal triggers a read of serial timestamp_in on the next client clock following the enable signal serial_timestamp_enable. This forms time_stamp_sr_value in the shadow register. The load_timestamp_value signal is triggered by a rollover toggle of the timestamp LSBs. This triggers a load of the accumulated serial MSBs (timestamp_MSBs) to the client in synchronism with client clock.
FIG. 22 illustrates hardware to implement the technique illustrated in FIG. 21 . Edge detector 2201 is enabled by serial_timestamp_enable. Edge detector 2201 triggers upon the next clock edge from client clock. Edge detector 2201 enabled shift register 2201 . Upon each enable signal from edge detector 2201 serial clock shift register 2202 accumulates the timestamp data serial timestamp_in. The accumulated value within shift register 2202 is designated time_stamp_sr_value. When the load_timestamp_value signal is active commanding a load operation, register 2203 loads time_stamp_sr_value from shift register 2202 upon the next client clock. Once loaded into register 2203 the value is available to the client in parallel form as Timestamp MSBs.
FIG. 23 illustrates distribution of the timestamp value according to this invention. Timestamp generator 2301 produces the timestamp value including both the MSBs and the LSBs. Timestamp generator supplies the LSBs of the timestamp value in parallel on parallel timestamp bus 2303 . This includes data lines equal in number to the number of data bits in the timestamp LSBs. Timestamp generator supplies the MSBs of the timestamp value sequentially in series on serial timestamp bus 2305 . This includes a single data line to transmit all the timestamp MSBs. Both parallel timestamp bus 2303 and serial timestamp bus 2305 are connected to clients 2310 , 2320 and 2330 . This will describe representative client 2310 . Parallel register 2311 receives the parallel LSBs of the timestamp value from parallel timestamp bus 2303 . Series register 2312 receives the serial MSBs from serial timestamp bus 2305 in the manner described above in conjunction with FIGS. 19 to 22 . As detailed above the timestamp MSBs are serially accumulated and captured upon each load_timestamp_value signal. Merged timestamp register 2313 is connected to both parallel register 2311 and series register 2312 to assemble the timestamp value. The timestamp value stored in merged timestamp register 2313 is used as known in the prior art to capture the time of trace data used for debug.
Within a system, there may be a number of clock domains operating at a different frequency. It may be advantageous to serially transmit s different number of bits of the timestamp serially for each of the domains depending on the client clock frequency. The ratio between parallel LSBs and serial MSBs depends upon the timestamp precision required relative to the serial data transmission rate. The serial timestamp bus 2305 must be able to transmit all timestamp MSBs between each rollover toggle of the timestamp LSBs. Different client clock rates may require differing ratios of MSBs to LSBs. | A timestamp generator generates a timestamp value having a predetermined number of most significant bits and a predetermined number of least significant bits. The least significant bits are transmitted to a client via a parallel data bus. The most significant bits are transmitted to the client sequentially via a series data bus. Each client receives the parallel least significant bits and the series most significant bits and assembles a complete time stamp value. | 8 |
This application claims the benefit of U.S. Provisional Application No. 60/147,399, filed Aug. 6, 1999.
BACKGROUND OF THE INVENTION
Web strapping is widely used to tie down and secure cargo and loads. Web strapping is also used to secure attachments to bases and to secure occupants in place. Webbing straps are also used as belts for clothing.
Needs exists for better, less expensive and easier to make and use buckles which rapidly and securely grip and hold the web strapping, which permit tightening of the web strapping while in the engaged position, and which rapidly and easily release the web strapping when disengaged.
SUMMARY OF THE INVENTION
The buckle of the present invention provides for the needs of the prior art. The new buckle is made of two pieces which preferably are injection molded. The buckles may be made in different sizes and may be used in multiple applications. The buckles work with laminated strap webbing or open weave strap webbing. The buckles allow the webbing to pass through the buckle and allow the users to engage or disengage the locking. The web engagements within the buckle can prevent the web from sliding through in any direction, or can be configured to allow the belting to move in only one direction.
The buckle parts are moldable in multiple materials and are low in cost.
The outer buckle plate is elongated in the strap direction. The flat top of the plate has extensions which extend over the webbing to maintain the flatness of the webbing within the buckle. Two curvilinear cutouts at opposite sides of the flat plate allow flexing, springing or bridging of the major side portions of the upper buckle member. Thin upper edge portions act as springs. Curved inward extending tops rigidify the rounded sides which are pressed inward to relatively move the two-buckle parts into engaged or disengaged position.
Four guide legs extend downward from the flat top near the corners to slide within alignment openings in the sides of the inner plate. Inward extending keeper tabs at lower ends of the legs ride over and engage ledges within the guide openings to snap the members together and to prevent separation of the buckle members once the buckle members have been snapped together.
Alignment projections on the sides of the inner buckle member fit within openings in the sides of the outer buckle member. Opposite central side recesses in the inner member or base plate receive and allow inward movement of the major side portions of the outer member. Curved lateral outer edges of the inner plate prevent overtravel of the movable side portions.
Bases of the side extensions of the inner plate have locking lugs which extend toward the central opening. The movable rounded side portions of the outer plate have locking tabs which engage the lugs to prevent movement out of the locking position when the locking tabs are engaged with bottoms of the locking lugs, and which prevent movement into the locking position when the locking tabs are positioned above the tops of the locking lugs. Locking and unlocking the buckle requires squeezing rounded sides together while pushing or pulling on the outer plate. Alternatively, bottoms of the locking tabs are chamfered so that they automatically override the locking lugs when the two plates are pressed together to lock the buckle.
Teeth extend inward from the outer locking plate. Angled through-holes in the lower plate receive the teeth and hold the locking teeth in engaged position when the buckle is locked.
In one embodiment, the locking teeth are angularly mounted in recesses in the upper plate so that the teeth may be deflected when the webbing strap is pulled in a tightening direction, and so that the teeth in cooperation with the holes in the bottom plate prevent reverse movement of the webbing strap when the buckle parts are locked together.
The lower plate has at one end an extension with a transversely elongated opening for receiving a loop in a fixed end of the webbing strap. The loop is stitched, bonded, welded or interwoven to the strap near its fixed end. The loop-receiving end of the inner plate also has an upper rectangular guide which passes the free end of the webbing strap out of the buckle. The opposite end of the inner plate has a rectangular guide extending from the plate for guiding the free end of the webbing strap as it enters the buckle.
The present invention provides a low cost, readily assemblable and easily usable buckle to selectively permit and prevent webbing straps from sliding through the buckle.
These and further and other objects and features of the invention are apparent in the disclosure, which includes the above and ongoing written specification, with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a webbing strap with a locking buckle of the present invention.
FIG. 2 is a perspective view of the two-part two-position locking buckle.
FIG. 3 is a perspective view of the outer buckle plate or top cover part of the two-part buckle.
FIG. 4 is a perspective view showing a bottom view of the top cover part.
FIG. 5 is a top perspective view of the inner buckle plate or buckle base, which is the second part of the buckle.
FIG. 6 is a detail of connection of a fixed end of the webbing strap to the buckle base.
FIG. 7 is a bottom perspective view of the base.
FIG. 8 is an inverted perspective view of the two parts of the buckle immediately prior to assembly.
FIG. 9 is a perspective view of the assembled buckle parts showing the disengaged position.
FIG. 10 is a view similar to FIG. 9 showing the engaged locking position of the buckle.
FIG. 11 is a cross-sectional view of the buckle showing the locking position.
FIG. 12 is a bottom view of the upper buckle cover showing the one way teeth in the engaged position.
FIG. 13 is across-sectional view showing the locking teeth extending through the guide-deflecting holes.
FIG. 14 is a schematic representation of locking teeth extending in opposite directions to prevent any movement of the web.
FIG. 15A is a cross-sectional detail showing the buckle teeth in an unlocked position.
FIG. 15B is a perspective view of the two-part two-position locking buckle.
FIG. 15C is a cross-sectional view of the buckle showing the locking position with the locking teeth extending in opposite directions to prevent any movement of the web.
FIG. 15D is a perspective view of the outer buckle plate or top cover part of the two-part buckle.
FIG. 16 is a plan view of the preferred buckle.
FIG. 17 is a bottom view of the buckle shown in FIG. 16 .
FIG. 18 is a prospective bottom view showing the buckle in the unlocked position.
FIG. 19 is a prospective view of a preferred embodiment of the base showing the ramps and locks for holding the other cover in unlocked position.
FIG. 20 is a cross-sectional prospective detail of the buckle taking along line 20 20 in FIG. 16 showing the buckle in web-gripping, locked condition.
FIG. 21 is a detail of the buckle lock and: ramp showing the outer plate and inner buckle in closed, web-locking position.
FIG. 22 is a top prospective view of the buckle showing the buckle in open, web-releasing position.
FIG. 23 is a top prospective view of the buckle showing the buckle in closed, web-locking condition.
FIG. 24 is a schematic representation showing the inward pressing movement on the outer buckle cover to change positions.
FIG. 25 is a prospective view of the inner portion of the buckle.
FIG. 26 is a prospective view of the assembled buckle.
FIG. 27 is an overall view showing the buckle mounted on a web belting.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, a webbing strap 1 has a fixed end 3 and a free end 5 . The free end extends through a locking buckle 10 and is tightened by pulling in the direction shown by arrow 7 .
In FIG. 2 the locking buckle 10 has an outer buckle plate 12 , which may also be called a top or cover, and an inner buckle plate 14 , which may be also called a base. The base 14 has a mounting extension 16 with a transverse elongated opening for receiving a loop and mounting the fixed end 3 of the webbing strap. A guide 18 uniformly extends from the base 14 for receiving and guiding the free end 5 of the webbing strap.
As shown in FIGS. 2-4, the outer buckle plate 12 or cover has a flat upper portion 24 with cutout areas 26 and spring areas 28 , which allow inward movement of the major curved side portions 30 . The flat curved edge portion retains rigidity of the side portion 30 . The outer buckle plate 12 also has downward extensions 32 with inward extending retaining tabs 34 , which cooperate with ledges on the inner plate to hold the two parts together. Large recesses 36 in the opposite sides of the outer buckle plate 12 have position locking tabs 38 extending into the recesses for cooperating with lugs on the inner buckle plate to lock the two plates in web disengaging position or web engaging and holding position.
As shown in FIG. 4, inner edges of the openings 36 and the locking tabs 38 are recessed from the curved inner surface 40 of the movable sides 30 . The recessing 42 allows for relative movement of the buckle numbers without disengaging. The bottom surfaces of the locking tabs are chamfered 44 to assist movement into the engaged or locking position. Inner edges 46 of the retaining tabs 34 are chamfered to aid in the overriding and snap fitting of the buckle parts during assembly.
Locking teeth 48 extend inward from the flat part 24 of the outer buckle plate 12 to engage openings in the webbing.
As shown in FIGS. 5-8, the inner buckle plate 14 or base has a curved outer edge 50 that limits inward deflection of the movable sides 30 of the upper buckle plate.
Angled through-holes 52 guide and position the locking teeth from the outer buckle plate when the two members are moved into and held in engaged position. A retaining area 54 receives the retaining extension 32 , and the ledges 56 cooperate with retaining tabs 34 to limit the opening travel of the two parts once the parts have been snapped together.
Guides 58 have inner edges 60 which guide the end surfaces of the movable sides 30 of the upper plate 12 . Inward extending position locking lugs 62 cooperate with the locking tabs 38 on the sides 30 of the outer buckle plate to hold the two plates in the locked position or to release the two plates for movement in the disengaged condition. As shown at the right hand side of FIG. 6, the inner buckle plate 14 has the strap-holding extension 16 with a shelf portion 64 and a transverse elongated opening 66 , which receives the loop 68 on the fixed end 3 of the webbing strap. The opposite end 18 of the inner buckle plate 14 serves as a guide for the free end of the strap.
As shown in the inverted view of FIG. 8, the two parts, the outer buckle plate 12 and the inner buckle plate 14 are aligned before being snapped together. The snapping together occurs by the tabs 34 overriding and then engaging the ledges 56 . When snapped together the locking buckle is in the disengaged position. Engaging the locking buckle requires squeezing the opposite curved sides 30 inward and passing the locking tabs 38 inside of the locking lugs 62 , while the buckle parts are pressed together. After sides 30 are released, the locking tabs 38 spring outward with the sides 30 to engage bottoms of the lugs 62 .
FIG. 9 shows the outer buckle plate and inner buckle plate after they have been snapped together. The buckle plates are in the disengaged position.
FIG. 10 shows the outer buckle plate and inner buckle plate in the engaged position, with the locking tabs 38 held by the locking tabs 62 .
FIG. 11 shows the angled through holes 52 for receiving the teeth 48 after they have extended through the webbing, and holding the teeth in locked position. The angled through locking holes 52 have a sloped surface 72 and an angular opposite surface 74 , which capture the teeth 48 and prevent their being withdrawn through the webbing.
In an embodiment of the invention shown in FIGS. 12 and 13, locking teeth 78 are mounted at angles within, openings 80 in the outer plate 12 . The locking teeth 78 extend into the angled through-holes 52 . The angled sides 74 of the through holes allow flexure and ratcheting movement of the teeth 78 and when the web is pulled in a tightening direction shown by the arrows 80 in FIG. 12, but prevent webbing movement in the reverse direction shown by arrows 82 .
In another embodiment of the invention, the slopes of the teeth 78 alternate so that the teeth cross each other from a side view, as shown in FIG. 14, and prevent the webbing strap from moving through the buckle in either direction.
FIG. 15A shows the locking prongs as they extend inward from the flat part 24 of the outer buckle plate 12 as they are angularly turned by the sloping surfaces 72 of the holes 52 in inner member 14 .
In FIG. 15A the outer member 12 is shown raised which withdraws the teeth 48 into the openings 52 and allows passage of the webbing through the buckle beneath the holes 52 . In the bottom view shown in FIG. 15B, the web-locking prongs or teeth 48 are shown extended from the holes 52 in the inner member 14 . That is the locking condition of the teeth, which engages openings in the webbing and prevents movement of the webbing at least in the reverse direction through the buckle.
FIG. 15C is a cross-section of the buckle showing the prongs 48 extended through the openings in the inner plate to engage the webbing.
FIG. 15D shows a prospective view of the buckle which can be used as an adjusting buckle for straps connected to sporting gear such as backpacks and equipment supporting belts for example.
A preferred buckle is generally indicated by the numerals 100 in FIG. 16 . The buckle 100 comprises an inner member 102 and an outer member 104 . The inner member has a rim 106 around which one end of a webbing belt is secured. That end passes through opening 108 . The free end of the webbing belt passes sequentially over shelf 110 , under the inner and outer members 102 and 104 and over the shelf 112 near the belt and mounting ledge 106 . The cover 104 has a flat outer face 114 and movable outer side elements 116 , which are squeezed inward to change the state of the buckle. The central portions 118 are lifted upward by ramps 120 as the flexible sides 116 of the cover 104 are squeezed inward. Leaf springs 122 urge the outer member 104 to the upward, belt-releasing position.
FIG. 17 shows a bottom view of the assembled buckle. The bottom plate 102 has a flat central portion 124 on the opposite side of which the webbing belt passes as the free end passes successively over shelf 110 , flat central portion 124 and shelf portion 112 .
Central portion 126 of the inner member 102 has openings 128 with sloping surfaces which direct the locking tabs 130 into engagement with the webbing belt.
The projecting surfaces 132 of the inner buckle member 104 support the ramps 120 as shown in FIG. 16. A bridge 134 extends between the extensions 132 and supports the base of the cantilevered spring 122 so that it may pivot within the opening 136 when the flexible sides 116 are squeezed to move the latching members 118 inward.
FIG. 18 shows a perspective view from the bottom of the buckle in the unlocked, web-releasing position. The central member 124 of the base has been removed for clarity.
FIG. 19 is a top view of the preferred buckle showing the opening 138 through which the free end of the webbing enters the buckle. Ends 140 of the buckle inner member are raised so that inner walls 142 guide the end edges 144 of the outer buckle member 104 as shown in FIGS. 16 and 20.
FIG. 20 shows the flexible sides 116 and the springs 122 that urge the outer member upward after the sides have been squeezed inward and lifted by the associated ramps.
FIG. 21 is a detail of the flexible latches 122 and the ramps 120 on the inner buckle member 102 and the collecting of portions of the outer buckle member 104 .
Inward extending bars 146 with curved engaging portions 148 slide upward on ramps 120 as the central portion 118 of the outer member is squeezed inward in the direction of arrows 150 . The latch 122 , which flexes in the directions of the arrow 152 , urges the central portion 118 upward as contact of the inner edge 154 moves along the sloped surface 156 , and as the curved surface 158 contacts the inner surface 160 of the central member 118 . The resilient members 122 tend to fold the cover plate 104 upward.
The latching member 122 may fit within a recess in the bottom of the central portion 118 , holding the member 118 inward. Further inward movement on the members 118 lifts the members on the ramps 120 and disengages the latch, allowing the members 116 to spring outward so that the outer member may be pushed inward on the inner member into latching condition. The webbing strap pulling on the pins extending at an angle through the holes in the inner member tends to keep the buckle locked. Additional latches are provided between the inner and outer members.
As shown in FIG. 22, the upper surface 114 of the outer member 104 is formed with opening 162 . Outer portions 164 of the openings form thin flexible members 166 in the outer walls 168 of the outer members 104 . Position-locking tabs 170 are extended from the inner member and slide within recesses 172 and outer walls 168 of the outer member. The recesses have inward extensions 174 which cooperate with extending lugs 176 on position-locking tabs 170 to hold the inner and outer members in locked condition or in unlocked condition as shown in FIG. 22 .
As shown in FIG. 26, the locking tabs 170 are mounted on outward extensions 178 of the inner member 104 . The curved outer walls 180 of the inner member are spaced inward from the curved walls 168 of the outer member so that the entire central portion of the outer wall 168 may be squeezed inward to allow the inward extensions 174 to be positioned inward of the lugs 176 when the cover is moved between belt-locking and belt-releasing positions.
The buckle is made of two pieces. It can be different sizes and has multiple applications. The buckle works with laminated strap-webbing or open weave strap-webbing, and allows the webbing to pass through the buckle. It allows the user to engage or disengage the locking means. When the engaging means are engaged, they can prevent webbing from sliding or be configured to allow belting to move in only one direction. The buckle is moldable in multiple materials and is low cost.
While the invention has been described with reference to specific embodiments, modifications and variations of the invention may be constructed without departing from the scope of the invention. | The new buckle is made of two pieces which work with laminated strap webbing or open weave strap webbing. Web engagements within the buckle prevent the web from sliding through in any direction, or allow the belting to move in only one direction. Bases of side extensions of the inner plate have locking lugs. Moveable rounded side portions of the outer plate have locking tabs which engage the lugs to prevent movement out or into the locking position. Locking and unlocking the buckle requires squeezing rounded sides together while pushing or pulling on the outer plate. Teeth extend inward from the outer locking plate. Angled through-holes in the lower plate receive the teeth and hold the locking teeth in engaged position when the buckle is locked. Locking teeth angularly mounted in recesses in the upper plate are deflected when the webbing strap is pulled in a tightening direction. The teeth in cooperation with the holes in the bottom plate prevent reverse movement of the webbing strap when the buckle parts are locked together. | 8 |
This is a continuation-in-part of U.S. Pat. application Ser. No. 478,592 filed Dec. 6, 1974 which is now abandoned.
FIELD OF INVENTION
This invention relates to a method and apparatus for shifting heavy supporting structures relative to stationary load carrying structures by means of climbing jacks which engage jack rods secured to the load carrying structure.
BACKGROUND OF THE INVENTION
Load carrying structures are commonly used in concrete forming, in building vertical walls, in lining tunnels with concrete, shoring freshly dug tunnel walls, and the like. With most concrete form work, slip forms are used which are moved along the surface of set concrete. With this type of concrete form work, a supporting structure for the form work is secured to the form work and jacks move the supporting structure in order to advance the form work along the concrete face.
Climbing slip forms are well-known, such as that disclosed in Scharsach, U.S. Pat. No. 2,620,543. He discloses concrete panel forms which are supported by a supporting structure which includes a number of vertical posts attached to the concrete panel forms. Guide rods are secured to the set concrete where the concrete form panels move independently of the guide rods. Jack rods are secured to the guide rods. Jacks are mounted on the supporting posts which engage the jack rods. Operation of the jacks advances the supporting structure. The concrete form panels are advanced simultaneously with advancement of the supporting structure because the concrete form panels are secured to the supporting structure. Like all other slip form concreting apparatus, Scharsach has no provision for permitting the concrete forming panels to remain stationary while the heavy supporting structure for the concrete panels is advanced by the operation of jacks.
In concrete forming and other operations such as lining horizontal tunnels, it is advantageous to have the load carrying panels remain stationary while the supporting structure is advanced and additional load carrying panels attached to and in front of the stationary panels. For example, when concrete form panels are left stationary and new panels attached, the rate of concrete pouring can be varied within broad limits so as to be adapted to other working tasks associated with the concrete pouring operation. In some cases the use of climbing slip forms requires anchoring bolts in the concrete so that the slip forms are not advanced until the concrete has set. Stationary load carrying panels are advantageous for lining horizontal tunnels because the panels remain in position until the concrete has set or the walls of the tunnel are properly shored. Meanwhile, the heavy supporting structure can be advanced with additional panels placed in position, without waiting for the concrete to set so that the same panels may be advanced.
It is therefore an object of the invention to provide apparatus and method for shifting a heavy supporting structure relative to a load carrying structure which remains stationary.
It is a further object of the invention to provide in combination, a heavy supporting structure for a load carrying structure where the heavy supporting structure is advanced relative to the load carrying structure by use of jacks engaging jack rods which are secured to the load carrying structure.
It is another object of the invention to provide a method of concreting where the load carrying panels remain stationary during advancement of the concrete pouring operation.
It is yet another object of the invention to provide method and apparatus for lining tunnels with concrete and to provide methods of shoring tunnels to guard against landslide.
BRIEF SUMMARY OF THE INVENTION
The method according to this invention for shifting a heavy supporting structure used with a load carrying structure which remains stationary comprises simultaneously operating a plurality of climbing jacks which are adapted to engage a plurality of jack rods secured to the load carrying structure. As the climbing jacks move along the jack rods the heavy supporting structure is shifted relative to the load carrying structure which remains stationary. The reactive force caused by operation of the climbing jacks is transferred to the load carrying structure by the jack rods. The heavy supporting structure supports the load carrying structure in a manner such that the heavy supporting structure is moveable relative to the load carrying structure. The plurality of climbing jacks are secured to the heavy supporting structure.
As the heavy supporting structure is advanced by operating the climbing jacks, additional load carrying structures are placed in position and supported by the heavy supporting structure.
The apparatus according to this invention comprises in combination a shiftable heavy supporting structure which supports a stationary load carrying structure. A plurality of parallel jack rods are secured to the load carrying structure. A plurality of climbing jacks are adapted to operatively engage the jack rods and are secured to the heavy supporting structure. The heavy supporting structure supports the load carrying structure in a manner such that the heavy supporting structure is moveable relative to the load carrying structure. The arrangement is such that the heavy supporting structure is shifted relative to the load carrying structure when the plurality of climbing jacks are operated and advanced along the jack rods while the load carrying structure remains stationary. The jack rods may be made up of a plurality of detachable portions which, when no longer under load, may be detached from the panels and placed ahead of the climbing jacks to permit continued advancement of the heavy supporting structure. The load carrying structure may be made up of a plurality of detachable load carrying panels. As the heavy supporting structure is advanced, additional load carrying panels may be secured to the most forward load carrying panel.
The method and apparatus according to this invention allows the load carrying structure to remain stationary as long as desired because the load carrying structure is not moved with advancement of the supporting structure. In addition, because the supporting structure moves independently of the load carrying structure, less jacking force is required to move the heavy supporting structure since there are no frictional forces to overcome between the load carrying structure and the material supported by the load carrying structure.
The method and apparatus according to this invention is also applicable to use in tunnels to guard against landslides. The heavy supporting structure can also be used to support fillings, frames or the like in tunnel construction.
Unlike the apparatus of Scharsach, U.S. Pat. No. 2,620,543, the method and apparatus according to this invention permits the shifting of the heavy supporting structure while the load carrying panels remain stationary by the operation of jacks secured to the heavy supporting structure operatively engaging jack rods secured to the load carrying panels.
DESCRIPTION OF THE DRAWINGS
These and other objects, advantages and features of the invention will become apparent in the following detailed description of the preferred embodiments of the invention as shown in the drawings wherein:
FIG. 1 is a cross section of a horizontal tunnel which is being lined with concrete.
FIG. 2 is a longitudinal section of the tunnel of FIG. 1 along the line 2--2.
FIG. 3 is a cross section of a vertical concrete wall which is being formed by method and apparatus according to this invention.
FIG. 4 is an enlarged section along the line 4--4 of FIG. 3.
FIG. 5 shows an alternate construction for the apparatus shown in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, the tunnel proper is designated 1. The tunnel is lined with concrete 2 where the bottom 9 of the tunnel is left unfinished. In the concrete lining operation stationary load carrying panels 3 are supported by a heavy supporting scaffolding structure 4. The scaffolding structure is erected in the interior of the tunnel 1 and supports the panels 3 in position as the tunnel is lined with concrete 2. The heavy supporting structure 4 is shiftable relative to the stationary panels 3. As shown in FIG. 2, hydraulic jacks 5 are secured to beams 7 of the heavy supporting structure 4. The hydraulic jacks 5 are adapted to operatively engage jack rods 6. Although not shown, the jack rods 6 are secured relative to the panels 3 so that the jack rods remain stationary relative to them. The jack rods 6 are spaced from the panels 3 by pads 8.
In order to shift the heavy supporting structure 4 relative to the load carrying panels 3, the method comprises operating jacks 5 to cause the jacks 5 to move along jack rods 6 in the direction of arrow 30. During such movement of the supporting structure 4, the panels remain stationary.
The beams 7 of the supporting structure 4 support the load carrying panels 3 through jack rods 6 as they rest against pads 8. The beams 7 slide along jack rods 6 when the hydraulic jacks 5 are operated. The reactive forces caused by the jacks 5 are directly transferred to the jack rods. The shifting of the stationary load carrying panels 3 is prevented by the jack rods being secured relative thereto. The jacks 5 may be adapted to push or pull the structure 4 in either direction within the tunnel.
The beams 7 are of substantial length so as to keep the jack rods 6 in position and prevent outward buckling of the jack rods 6 when under load. The beams 7 may be located obliquely of one another as shown in FIG. 2 so that the pouring of the concrete can take place with the oblique casting front as shown in FIG. 2. The load carrying panels 3 are mounted and dismounted if desired in a manner substantially parallel with the casting. As the heavy supporting structure 4 is moved through the tunnel, additional load carrying panels 3 may be attached to the foremost load carrying panels to provide a load carrying structure for freshly poured concrete.
The bottom of the tunnel 9 is left open. Jack rods 6 rest on plates 10 mounted on the tunnel bottom 9. All of the jack rods 6 are located substantially parallel to one another.
In another embodiment of the invention the jack rods 6 may rest on hydraulic jacks or resilient devices which are placed on bottom 9 whereby the load carried by the beam 7 is more uniformly distributed over the jack rods 6. The number of jack rods 6 on which the heavy supporting structure 4 slides is selected with regard to the weight and/or load of the supporting structure 4 and with regard to the inclination of the tunnel bottom 9. In some cases the number of jack rods 6 may be so large that they form a mat along the walls of the tunnel.
The tunnel shown in FIGS. 1 and 2 may merge into a substantially vertical shaft where all walls of the shaft would be lined with concrete. In this instance, panels 3 would be provided on all four walls of the shaft to support the poured concrete.
FIG. 3 shows the concrete forming of a vertical wall of poured concrete 1. The concrete is poured between a sheet metal shell 12 and load carrying panels 13.
A heavy supporting structure 14 supports a load carrying panel 13 against the outward pressure of the poured concrete. The heavy supporting structure 14 includes a number of bracing units 15 and 16. If the concrete wall 11 is for a nuclear reactor, which wall is usually circular, the bracing beams 15 and 16 are formed as continuous annular elements which are round or in the form of a polygon. In the casting of straight concrete walls 11, use is made of straight bracing elements 15 and 16 which at their ends engage guides or like means. Bracing beams 15 and 16 are required with such concrete pouring where the sheet metal wall 12 is not capable of supporting conventional form ties.
Spaced apart vertical beams 17 are braced by bracing beams 15 and 16. Jacks 18 are secured to vertical beams 17.
Jacks 18 are adapted to operationally engage vertical jack rods 19. The jack rods 19 are secured to load carrying panels 13 by clamp means 22. Jack 18 is located above load carrying panels 13 so that operation of climbing jacks 18 does not interfere with the load carrying panels.
Clamps 22 as shown in FIG. 4 secure the jacking rods 19 to the panels 13. Bolts 32 clamp jack rod 19 between plates 34 snd 36 to firmly grasp the jacking rod 19. The outer plate 36 has planar surfaces 20 which are contacted by the edges 38 of vertical beams 17. The edges 38 slide along flat surfaces 20 during movement of heavy supporting structure 14. Bracing beams 16 are secured to vertical beams 17 by nuts 40.
The method according to the invention requires operation of the climbing jacks 18 which shifts the heavy supporting structure 14 in an upwards direction. The reactive forces caused by the operation of climbing jacks 18 are transferred to the stationary panels 13 which do not move during shifting of the heavy supporting structure 14.
It is understood that rollers and the like may be provided at ends 38 of vertical beams 17 to facilitate sliding of the beams 17 over clamps 22.
As the heavy supporting structure 14 is advanced, additional load carrying panels may be placed on top of the most forward load carrying panel 13a. The panels are detachably secured to one another. The jacking rods 19 may be made up of several detachable portions. As the heavy supporting structure is advanced, the lower end portion of the jack rod 19 may be detached and connected to the jack rod in front of the climbing jack 18 to permit continued advancement of the climbing jacks. However, during advancement of the heavy supporting structure, the load carrying panels 13 remain in position until removed.
An alternative arrangement for the clamp means 22 is shown in FIG. 5. The jack rod 19 is clamped between members 23 and 24 which are secured to panel 13 by bolts 42. Surfaces 21 are provided on clamp member 24 on which the ends 38 of beams 17 slide during advancement of climbing jacks 18.
The jack rods 19 are fixed in their positions by clamp means 22 where the clamps 22 are spaced apart a minimum distance to prevent buckling of the jack rods. As the jack rods 19 are relieved of stresses at the lower ends, they can be detached. The jack rods 19 transfer the reactive forces caused by the climbing jacks 18 to the load carrying panels 13.
A concrete supply hopper 25 is secured to the superstructure of the heavy supporting structure 14. In addition, scaffolding 44 may be provided on the superstructure for the operators.
While various preferred embodiments of the invention have been described herein in detail, it will be understood by those skilled in the art that variations may be made thereto without departing from the spirit of the invention or the scope of the appended claims. | Apparatus for shifting heavy supporting structures relative to stationary load carrying structures comprises a plurality of parallel jack rods secured to the load carrying structure. A plurality of climbing jacks adapted to operatively engage the jack rods are secured to the heavy supporting structure. The arrangement is such that the heavy supporting structure is shifted relative to the load carrying structure when the climbing jacks are operated and advance along the jack rods while the load carrying structure remains stationary. The reactive forces caused by the operation of the climbing jacks is transferred to the load carrying structure by the jack rods. A method for shifting heavy supporting structures is also disclosed. | 4 |
PRIORITY
[0001] This is a divisional application of U.S. patent application Ser. No. 10/468,047, filed Aug. 13, 2003, which is a 371 national phase application of PCT/US02/04157, filed Feb. 12, 2002, which claims benefit of priority from U.S. Provisional Patent Application No. 60/268,066, filed Feb. 13, 2001. All three of these applications are hereby incorporated by reference as if fully set forth herein.
FIELD OF THE INVENTION
[0002] This invention relates to the field of antigen presentation for the activation and resultant induction of antigen-specific immune responses and the inhibition of viral replication by the formation of “Biological Carriers.”
BACKGROUND OF THE INVENTION
[0003] In mammals, antigen-presenting cells (APCs) process foreign antigens. The processing of the antigen within the APC triggers an efficient immune response within the host. Antigens are degraded into peptide fragments and become bound to major histocompatibility complex (MHC) molecules that are expressed on the cell surface and are able to interact with other cells of the immune system. Dendritic cells, macrophages, and Kupffer cells in the liver are among the most commonly encountered type of APCs. These cells readily engulf foreign particles and express MHC molecules on their plasma membrane surface. These MHC surface molecules known as human leukocyte antigens (HLA) in humans, are involved in the immune response against disease.
[0004] There are two classes of MHC molecules (class I and class II). MHC class I molecules display exogenous antigens (i.e., antigens taken up from outside the cell), whereas MHC class II molecules display endogenous antigens (i.e., antigens that originate within the cell) to the immune system. Processing of the antigens differ in each case. Processing of exogenous antigens by APCs occurs in stages. The cells first take up the antigens by endocytosis. The internalized endocytic vesicles then fuse with lysosomes where the foreign antigens are hydrolyzed by lysosomal enzymes, resulting in peptide fragments of 10 to 20 amino acids. These peptide fragments bind to a cleft within the MHC molecule and are transported to the cell's surface for interactions with cells of the immune system. The processing that leads to the display of endogenous antigens can arise from viral infection, etc. Such antigens are cleaved in the cellular cytosol, and transported into the lumen of the endothelial reticulum, where they become associated with MHC class I molecules, which are then transported to the cell surface. Foreign antigens can promote an immune response, whereas peptide fragments derived from cellular proteins when bound to MHC class I molecules and presented on the cell's surface are recognized as “self” and will not usually elicit an immune response.
[0005] Processed antigens displayed on self-MHC molecules supply one of the two signals required for T-lymphocyte activation. In addition to recognition of a foreign antigen fragment, simultaneous delivery of a co-stimulatory signal is needed for the activation of naïve T-lymphocytes. These co-stimulatory signals together with both class I and class II MHC molecules are molecules present on professional APCs. The presence of these molecules on professional APCs stimulate the clonal expansion of naïve T-lymphocytes, resulting in their differentiation into armed immune effector cells, and ultimately memory cells. Priming is a process where naïve T-lymphocytes are activated by the first time exposure to an antigen, whereas re-exposure to foreign antigens result in activation of memory cells.
[0006] Activation occurs when the T-lymphocyte's T cell receptor (an antigen-specific receptor) and its co-receptors (either CD4 or CD8 molecules) recognize the foreign peptide-MHC complex, simultaneously with a co-stimulatory signal delivered from the same APC. The best-characterized co-stimulatory molecules on APCs are CD80 (B7-1) and CD86 (B7-2). These structurally related molecules are members of the immunoglobulin superfamily and recognize the CD28 molecule on T-lymphocytes, resulting in T-lymphocyte activation. Activation of T-lymphocytes is controlled by the subsequent expression of CTLA-4. The CTLA-4 receptor is closely related to the CD28 molecule that binds the B7 molecules with a higher affinity than CD28 and prevents further T-lymphocyte activation.
[0007] There are numerous examples of how the addition of co-stimulatory molecules to cells affects cellular processes. In HIV/AIDS research: When CD3 and CD28 receptors on cultured T-lymphocytes are stimulated by immobilized monoclonal antibodies (mAbs), expansion of polyclonal CD4 positive T-lymphocytes occur. If the T-lymphocytes were obtained from FIV-infected donors, HIV-1 viral load declines (in the absence of antiretroviral agents) simultaneously with T-lymphocyte expansion. Moreover, CD28 stimulation rendered these cells highly resistant to HIV-1 infection, mediating an antiviral effect early in the viral life cycle before HIV-1 DNA integration. The HIV-1 resistant state is specific for the macrophage-tropic HIV-1 isolates and is due to the lack of CCR5 receptor transcription, which is a required secondary receptor for HIV-1 macrophage-tropic virus infection. In tumor biology: The introduction of either MHC class II molecules or co-stimulatory molecules to tumor cells results in their efficient rejection in vivo. In virology: Viral infection with a number of the herpesviruses causes a diminution of cell surface co-stimulatory molecule expression, resulting in viral replication without mounting any immune response towards the infected cells.
[0008] Many viruses produce degenerative changes in cells when replicating in a susceptible cell culture. These characteristic changes are called cytopathic effects and are associated with certain morphologic changes in the host cell. The intracellular sites where the events of viral replication take place vary among the viral families. Enveloped viruses mature by a budding process, although some budding occurs with non-envelope containing viruses. For envelope viruses, viral-specific envelope glycoproteins are inserted into cellular membrances and the viral nucleocapsids then bud through the membrane at these modified sites. In this process, the virus acquires their envelope for infectivity and can also acquire cellular-related molecules. Studies with HIV, Influenza, and Chlamydia have shown virus particles that have incorporated HLA molecules into the mature virus particle. During the infection the cell is destroyed and the virus particles are released into the culture supernatant. The amount of infectious virus present in the cell culture fluid can be titrated and infectivity inactivated by a variety of methods. Although inactivated virus particles have lost the ability to replicate they maintain their structure, as detailed in this application, they can be used as a scaffold to carry cell surface expressed molecules.
SUMMARY OF THE INVENTION
[0009] This invention provides for the formation of non-infectious Biological Carrier to deliver signals to cells either in vitro or in vivo (see FIG. 1 ). The Biological Carriers are whole virus particles that are either totally inactivated (by biological, chemical, genetic or mechanical means), or partially inactivated for subsequent viral infection. They are produced in cells that are genetically modified to over-express surface molecules that are able to elicit immune responses (see FIG. 1 for concept in schematic form). The invention is intended for in vivo use in any recipient where enhancement of immune responses can be advantageous to that individual, although in vitro pretreatment of cells can also be envisioned.
[0010] Viruses are ideal candidates for utilization as non-professional antigen presenting carriers. The invention uses viruses not for their infectious abilities (all preparations will be inactivated), but as a scaffold that contain specific antigens and co-stimulatory molecules to induce immune responses. The major advantage of this approach is the ease of production of potential therapeutic and/or vaccine doses. At the end of the virus life cycle, large amounts of virions are released from infected cells, reaching concentrations of 10 12 virus particles per milliliter of culture fluid. Intrinsic to virus release, portion of the cell membrane are removed as the mature virus particle buds from the cell. The cells that support the productive viral infection can be genetically engineered to over-express surface molecules that would be carried with the virus particle as it is released from the cell. In addition, MHC class I and class II molecules containing viral peptides (due to the active viral infection) will decorate the virus particles, thereby presenting the antigens needed to stimulate the CD3 receptor on T-lymphocytes. These interactions supply one of the two signals required for T-cell stimulation. The over expression of co-stimulatory molecules by genetic engineering supplies the second signal, leading to antigen specific immune stimulation. These are distinct advantages over the use of cells (professional or non-professional) to present antigens to T-lymphocytes. The current procedure with professional antigen presenting cells (APCs) involves isolating cells from a patient, growing them in culture, and transplanting them back into that same person, a process that takes weeks. With non-professional APCs, a genetic engineering step (where co-stimulatory and/or MHC molecules would be introduced into the cell) would be added to the process. Even if the cells can be implanted allogeneically, current procedures are cumbersome, labor intensive, time consuming, and expensive. The present invention simplifies the process, thereby making immunotherapy potentially available world-wide in the area of infectious diseases.
[0011] In one aspect, the invention provides a Biological Carrier preparation that (i) contains an antigen (here, the antigen can be a protein, polypeptide, lipid or glycolipid) and/or antigen fragment bound to a primary surface molecule of said host cell such that the Biological Carrier contains at least one antigen fragment presented to initiate an immune response and (ii) at least one co-stimulatory molecule. In one embodiment of this aspect, the Biological Carrier preparation is virus-specific. That is, a specific virus is grown in a fully permissive cell line and while budding from the cells' surface contains at least one antigen specific to that virus processed into an antigen fragment. The Biological Carrier preparation can be prepared by infection of a permissive host cell line (or primary cell), from a chronically infected cell line, from a packaging cell line (a cell engineered to express a virus particle capable of one replicative infectious cycle), or from cells isolated directly from the mammal (cells isolated from the tumor or of non-tumor source). In addition, the Biological Carrier preparation can be from the native harvested culture fluid, or the preparation can be concentrated (e.g. centrifugation, polyethylene glycol-precipitation, or the like) and/or lyophilized for ease of storage and stability. In another embodiment, the Biological Carrier preparation also contains a non-specific immune stimulatory activity. That is, molecules are expressed at the cell's surface that would indiscriminately stimulate T-lymphocytes. Such molecules can be a stimulatory antibody directed against the T-lymphocyte CD3 molecule, but not limited to this molecule, and when the virus buds from the infected viral cells' surface it contains in addition to at least one viral specific antigen processed into an antigen fragment, also a non-specific molecule that can enhance immune responses in the recipient. Preferably, these viral-specific antigens are in a form available for presentation. Further, the Biological Carrier preparation contains at least one co-stimulatory molecule. Preferably the co-stimulatory molecule is cell surface associated and in a form available for presentation. The primary surface molecules for antigen presentation are preferably MHC I, MHC II or CD 1. The co-stimulatory molecule is preferably selected from the group consisting of CD80 and CD86, but not restricted to this group of molecules.
[0012] In another aspect, the invention provides a method for stimulating the presentation of at least one exogenous antigen fragment on the Biological Carrier, which method comprises contacting a virally infected cell that is capable of expressing at least one co-stimulatory molecule along with (i) an endogenous viral antigen (one intrinsic to the viral infection), (ii) an exogenous antigen (one important in initiating an immune response), (iii) an immune dominate peptide (one loaded onto the MHC molecule before or during virus expression). This exogenous antigen can be included in vitro in the culture media where it would be taken up by the virus host cell or can be supplied as genetic material that codes for the exogenous antigen, which the cell processes intracellularly into at least one antigen molecule or fragment. The method can further include contacting the virally infected cell with cytokines (such as tumor necrosis factor-alpha) or by contacting with other reagents (phorbol esters), during the production of the Biological Carriers in order to enhance, stimulate or induce virus expression.
[0013] In another aspect, the invention provides a method of activating or priming a naïve T-lymphocyte to respond to viral antigens, by contacting the T-lymphocyte with a Biological Carrier preparation containing either viral-specific antigen(s) fragments or with non-specific immune activators in the proper conformation for presentation. In addition, the Biological. Carrier may contain at least one co-stimulatory molecule. This T-cell priming can allow for the induction and expansion of not only effector cells but also long-lasting memory T-lymphocytes against a specific virus.
[0014] In another aspect the invention provides a Biological Carrier preparation, which expresses at least one membrane bound exogenous antigen or antigen fragment and also expresses a co-stimulatory molecule. Thus, the Biological Carrier preparations contain the antigen or antigen fragment available to “professional” APCs for their processing and presentation to T-lymphocyte. In one embodiment of this aspect, the Biological Carrier preparation has been contacted with at least one antigen fragment (either exogenous or endogenous), which the viral infected cell displays on its cell surface. In another embodiment, the Biological Carrier contains at least one antigen fragment obtained from the introduction of exogenous genetic material into the viral host cell. Preferably this exogenous genetic material is in an expression vector. Further, the Biological Carrier preparation also contains exogenous genetic material that codes for at least one co-stimulatory molecule. Preferably, this exogenous genetic material is also in an expression vector.
[0015] In another aspect, the invention further provides a method for determining the immune competence or state of activation of the T-lymphocyte population of a mammalian host to a particular class of antigens by contacting the T-lymphocyte population with a specific biological preparation and observing for any change in the state of activation (e.g. Alamar-Blue fluorescence, T-lymphocyte production of gamma interferon, or expression of T-lymphocyte surface activation markers).
[0016] The present invention further relates to the treatment or prevention of a disease in a mammal, which may be a human or non-human, by administering to the mammal a Biological Carrier preparation that (i) contains at least one viral-specific antigen bound to a primary surface molecule that can be presented to initiate an immune response and (ii) also contain at least one co-stimulatory molecule (e.g., B7-1 and/or B7-2). In one embodiment of this aspect of the present invention, the Biological Carrier contains at least one processed viral antigen. In another embodiment, the Biological Carrier preparation contains at least one processed, but exogenously added viral antigen. Such mechanisms of prevention and/or treatment in mammals have application with respect to various diseases (whether viral, bacterial, fungal, or other origin), cancer, toxin exposure (whether viral, bacterial, fungal, or other origin), or antigens of plant origin. (e.g. poison ivy, poison sumac), and the like.
[0017] In summary, the Biological Carrier preparation system has a wide range of applications, including but not limited to, in vitro or in vivo activation and expansion of antigen specific T-lymphocytes for use in adaptive cellular immunotherapy against infectious diseases and cancer, for use of Biological Carrier preparations for vaccines and/or immunotherapeutics, and for an in vitro assay system for determining an individual's immune potential or potentiation to any antigenic epitopes. The present invention provides a method to form non-infectious Biological Carrier to deliver signals to cells either in vitro or in vivo. The Biological Carriers of the present invention are inactivated virus particles that have been specifically modified to exhibit biological properties that differ from those of virus particles deriving from an unmodified host cell. The modified cell that is host to the virus (i) expresses at least one co-stimulatory molecule and (iia) at least one antigen that can initiate an immune response, and/or (iib) express surface molecules that suppress viral replication. The co-stimulatory molecule is one of a class of molecules that either alone or in combination with other molecules is capable of T-lymphocyte stimulation leading to specific antibody formation and/or cytotoxic T-cell activity in the host. Specificity is conferred to the Biological Carrier by the presence of endogenous and exogenous processed antigens that are bound to Class I and Class II major histocompatibility complex (MHC) surface molecules that are present on the modified cell. Processed antigens can be intrinsic to the infectious process or disease specific antigens from said host cell. Also disclosed is a method for inhibiting viral replication by stimulating cells with Biological Carriers containing molecules that stimulate specific receptors that are present on human peripheral blood mononuclear cells that are able to prevent viral entry. Thus, disclosed are methods for the treatment or prevention of a disease in mammals, including humans.
[0018] The present invention particularly concerns:
[0019] 1. A method for inducing an antigen-specific T-cell response in a mammal comprising administering to the mammal an effective amount of a Biological Carrier preparation that has been derived from a host cell that contained at least one fragment of said antigen bound to a primary surface molecule of said host cell, and which also expressed at least one co-stimulatory molecule, said molecules being carried on the Biological Carrier preparation and inducing an immune response against the specific antigens that were processed in said host cell.
[0020] 2. A method to inhibit viral replication and/or viral entry in a mammal comprising administering to the mammal an effective amount of a Biological Carrier preparation that has been derived from a host cell that contained at least one molecule either alone or in combination with one or more other molecules expressed on said host cell, said host cell expressing one or more molecules that prevent expression of molecules required for viral entry, said molecules required for viral entry being carried on the Biological Carrier preparation leading to an inhibition of viral replication.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The invention is further described by the accompanying drawings and the description thereof herein, although neither is a limitation of the scope of the invention.
[0022] FIG. 1A is an illustration of the interaction of the Biological Carrier preparations with dormant T-lymphocyte populations, resulting in their activation and induction of specific immune responses; FIG. 1B schematically represents formation of the carrier particles.
[0023] FIG. 2 shows that when Biological Carriers (either HSV-2 or HIV-1 based) are produced from untransduced host cells the degree of relative fluorescence (a measure of lymphocyte activation) is similar to unstimulated cultures. PHA-stimulated cultures were included to show that the cells were capable of stimulation as measured by the Alamar-Blue fluorescent assay. Values were from day 6 cultures.
[0024] FIG. 3 , Panel A shows the stimulatory ability at day 6 of HSV-2 based Biological Carriers prepared from anti-CD3+B7's transduced cultures (A+B) to stimulate T-lymphocytes compared to HSV-2 based Biological Carriers prepared from untransduced cultures (Un) in three different donor lymphocyte preparations. FIG. 3 , Panel B shows the comparative stimulatory activity of HSV-2 based Biological Carriers prepared from untransduced (Un), anti-CD3 (A), B7-1+B7-2 (B), and anti-CD3+B7's (A+B) on elutriated peripheral blood lymphocytes after 14 days in culture.
[0025] FIG. 4 shows the stimulatory ability at day 6 of HIV-1 based Biological Carriers prepared from either B7-1+B7-2 (B) or anti-CD3+B7's (A+B) transduced cultures to stimulate lymphocytes compared to HIV-1 based Biological Carriers prepared from untransduced cultures (Un) in three different donor peripheral blood lymphocyte preparations.
[0026] FIG. 5 shows the ability of lyophilized HSV-2 based Biological Carrier preparations from anti-CD3 (A), B7-1+B7-2 (B), and anti-CD3+B7's (A+B) transduced cultures to stimulate lymphocytes compared to the same preparation that was not lyophilized after 13 days in culture. The enhanced stimulation in the case of the lyophilized preparation is probably due more to the larger volume (5 mL) of native culture supernatant lyophilized and tested in the experiment than to the lyophilized procedure itself.
[0027] FIG. 6 shows that the concentration of the native culture supernatant (by polyethylene glycol precipitation) maintains the stimulatory activity of the HSV-2 based Biological Carriers obtained from anti-CD3+B7's transduced cultures. This was a 40-fold concentration, allowing smaller volumes (25 μL rather than 1 mL) of the preparation to be used to obtain similar effects. The time point shown is 10 days after the addition of Biological Carriers.
[0028] FIG. 7 shows that the lymphocyte response can be re-activated in the same cultures that where initial stimulated even after the lymphocytes were rested for over one month in culture. The Figure shows two experiments with two different donors. Experiment 1 used native culture supernatants for the initial stimulation and re-stimulation; experiment 2 used polyethylene glycol precipitated culture supernatants for the initial stimulation and re-stimulation. Note that the initial stimulation in experiment 2 is the same as the experiment shown in FIG. 6 .
[0029] FIG. 8 shows the increase in HIV-1 encoded p24 antigen expression after exposure of elutriated T-lymphocytes to either HIV-MN (a lymphocytotropic HIV strain) or HlV-BaL (a monocytotropic HIV-1 strain). Although each HIV strain requires a different secondary receptor for cellular entry (CCR5 for monocytotropic strains and CXCR4 for lymphocytotropic strains) the viral strains used are replication competent in these cells. This experiment used Donor #9 elutriated lymphocytes.
[0030] FIG. 9 shows the effects of exposing elutriated T-lymphocytes to HIV-1 based Biological Carrier preparations. Unlike preparations made from untransduced host cells, the Biological Carrier preparations made from host cells modified to express either B7-1+B7-2 or the B7 molecules+an anti CD3 molecule resulted in a dramatic decrease in the ability of HIV-1 (either lymphocytotropic or monocytotropic) to replicate in human peripheral blood T-lymphocytes. This experiment used Donor #9 elutriated lymphocytes.
[0031] FIG. 10 shows the effects of exposing elutriated lymphocytes to HSV-2 based Biological Carrier preparations. Unlike the HIV-1 based Biological Carrier treatment shown in FIG. 9 , HSV-2 based Biological Carrier treatment did not inhibit HIV-1 replication. This data attests to the specificity of the Biological Carrier preparations. The preparations show specificity only towards the virus used to prepare the Biological Carrier preparation. This experiment used Donor #9 elutriated lymphocytes and was done at the same time as the experiment in FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] The present invention relates to the expression of surface molecules on constructed cell lines that are host to specific viruses or viral-like particles. The virus may contain either a DNA or RNA genome, or be composed of material that induces a budding process from cells. The expressed surface molecules can be endogenous to the cell line selected, or can be specific for one or more molecules expressed on the surface of a given cell by biological, chemical, or mechanical means. The surface molecule can be naturally expressed in nature on a cell's surface, or can be engineered as such by molecular, chemical, or mechanical means. The cell lines can be chronically-infected with the virus or the virus can be introduced into the cell by biological, chemical, or mechanical means. The formation of the budding particle containing native (those surface molecules naturally present on said cell surface) and/or specific molecules (those surface molecules that were intentionally introduced on said cell surface) is used as a carrier (referred to herein as a “Biological Carrier”) of that material for the purpose of signaling or modifying specific cellular events.
[0033] The present invention relates to, but is not limited to, antigen presentation leading to the activation of immune responses. Immune responses can be specific expansion or activation of one or more cell populations. The “Biological Carriers” can behave as antigen-presenting cells for the activation of T cell responses, or as an in vitro method for assessing immune responsiveness to specific infectious disease agents. The present invention provides for use of “Biological Carriers” to present relevant antigens and appropriate co-stimulatory molecules as an immunoprophylactic, immunotherapeutic, or vaccine candidate to treat, for example, infectious diseases, cancer, exposure to toxins, and as an alternative to conventional drug and/or antibiotic therapies on which host resistance has developed. Pursuant of the present invention, both HSV-2 and HIV-1 were chosen as an example of a DNA and RNA virus, respectively. However, any virus including but not limited to or inducing a budding process that incorporates membrane fragments into a scaffold particle can be used to generate a Biological Carrier. Each Biological Carrier preparation was prepared from untransduced, anti-CD3-transduced, or B7-1+B7-2 transduced with and without anti-CD3 and data was presented to demonstrate the ability of the transduced cells to activate T-lymphocytes. Although the transduction of specific surface molecule expression may generally be desired, in some cases, whether it is due to the cells selected or to the virus being used, appropriate molecules or nuances related to the viral life cycle may eliminate the need for virus host cell surface modifications. The invention is further envisioned as a general way of delivering molecules to humans in vivo. The forced surface expression of molecules that are normally secreted or sequestered internally within cells, when expressed in the context of a “Biological Carrier” is anticipated to display increased stability from degradation resulting in longer and/or enhanced biological activity. Genetic engineering of molecules for surface expression and ultimately displayed on the surface of the “Biological Carrier” can include (in addition to molecules that would interact with cellular receptors on the responding cell) molecules whose mode of action require entry internal to the cell Internalization can be receptor-mediated or mediated through biological or chemical modifications that allow passage across the cell's outer and/or nuclear membrane. In the present embodiment, all “Biological Carrier” preparations will be inactivated thereby not allowing for viral replication. However, in some instances partially inactivated, or non-inactivated, preparations might be envisioned.
[0034] The “Biological Carriers” described herein establish an ideal system for assessing the ability of human patients to respond immunologically by testing their T-lymphocyte responses. By assessing an individual's immune competency, the ability to respond to a particular vaccine can be determined, in addition the ability of an individual can be prescreened to be responsive to a specific “Biological Carrier” preparation before receiving the material in order to determine the potential benefit of the administration. The potent accessory cell function of the “Biological Carriers” may be able in vivo to present infectious disease agents and/or tumor antigens to T-lymphocytes obtained from afflicted individuals, whose immune response apparently is inadequate to mount an effective response to eliminate the infectious agent or tumor. In addition to the in vivo expansion of effective T-lymphocytes, activated T-lymphocytes can be expanded in vitro for use in immunotherapeutic applications. Tumor cells isolated from patients or established tumor-derived cell lines can be used as host for virus infections. The virus used in this manner can be related to the tumor in question or can be from, or be derived from, a separate group of viruses that are permissive to grow in said tumor cells for the expressed purpose of budding and thereby removing tumor specific antigens already processed in the proper configuration for T-lymphocyte presentation. These tumor cells can be in addition modified on their cell surface with co-stimulatory molecules or other accessory molecules that would facilitate the “Biological Carrier's” ability to mount an immune response against the tumor.
[0035] Infectious disease agent against which the present invention may be applicable in the induction of an immune response include but are not limited to bacteria, parasites, fungi, and viruses. The multitudes of antigens encoded by these agents that may be processed and presented by the “Biological Carriers” include but are not limited to external surface proteins and structural proteins including intracellular enzymes, transcription factors, and other cell regulatory proteins. For example, antigens encoded by any genes of the HIV-1 genome including gag, pol, vif vpu, tat, rev, env, and nef may be all present as either intact antigens or processed and configured within the MHC molecule as part of the “Biological Carrier” for either presentation of the intact antigens to “professional” antigen presenting cells (macrophages, dendritic cells, etc.) or directly to T-lymphocytes, respectively. In addition, a variety of other infectious agents including hepatitis B, hepatitis C, herpes simplex virus, varicella zoster, Epstein-Barr virus, cytomegalovirus, human herpesvirus-6,-7,-8, HIV-1, HIV-2, HTLV-1, HTLV-2, Rubella, Rubeola, Influenza, and species of Chlamydia, Helicobacter, Neisseria, Mycobacteria (especially M. lymphocytes tuberculosi ) and Toxoplasma are encompassed within the scope of the invention. The antigen(s) can be present on the host cell either as part of the infectious processed, naturally native to the cell, or introduced by pinocytotic uptake, or by biological (viral vectors), chemical (liposomes), or mechanical (electroporatio n) methods.
[0036] The following examples further illustrate experiments using Biological Carrier preparations that have demonstrated reduction to practice and utility of selected preferred embodiments of the present invention, although they are in no way a limitation of the teachings or disclosure of the present invention as set forth herein.
Example 1
Requirement for Host Cell Modification(S) for Biological Carrier-Dependent Lymphocyte Stimulation
[0037] The principle of this invention is demonstrated by proliferation experiments comparing the degree of stimulation of biological carrier preparations obtained from untransduced, anti-CD3, B7-1+B7-2, and anti-CD3&B7-1+B7-2 transduced cultures.
[0038] Elutriated lymphocytes that were treated for six day with a preparation of biological carriers obtained from untransduced cultures showed a degree of proliferation (lymphocyte stimulation) similar to unstimulated (un-treated) cells ( FIG. 2 ). Proliferation was measured by AlamarBlue™ assay. The assay is designed to measure quantitatively the proliferation of human cells by the incorporation of an oxidation-reduction indicator that fluoresces in response to chemical reduction of growth medium resulting from cell growth. The lack of biological carrier dependent stimulation when biological carriers were prepared from untransduced cultures was independent of the virus used to form the biological carrier particles. Both HSV-2 and HIV-1 based biological carriers prepared from untransduced host cells failed to stimulate the lymphocyte proliferation. The host cell for the HSV-2 based biological carriers are Lof(11-10) cells (an SV40 T-antigen transformed stromal cell line that was infected with HSV-2), whereas the host cells for the HIV-1 based biological carriers are 1119ERC cells (a chronic HIV-1 infected cell line established by the electroporation of pHXB2 that contains the HIV genome into A3.01 cells). The introduction of genetic material coding for either or both anti-CD3 and B7-1+B7-2 was accomplished by MuLV-based retroviral transduction and selection of the cells that incorporated and expressed said molecules. The data from PHA stimulated cultures was included in FIG. 2 to show that the elutriated lymphocytes were capable of fluoresces in response to known proliferating compounds. However, HSV-2 based biological carriers prepared from either anti-CD3&B7-1+B7-2 transduced cells in three different donor's lymphocytes ( FIG. 3 , panel A) or anti-CD3, B7-1+B7-2, and anti-CD3&B7-1+B7-2 transduced cells in a fourth donor's lymphocytes ( FIG. 3 , panel B) was able to stimulate T-lymphocyte proliferation. T-lymphocyte stimulation was also observed in three different donor's T-lymphocyte populations when exposed to HIV-1 based biological carriers obtained from B7-1+B7-2 and anti-CD3&B7-1+B7-2 transduced cells, but not from untransduced cultures ( FIG. 4 ). The identity of the donor T-lymphocytes and the key for the abbreviations used in the Figures are listed in Table 1.
Example 2
Biological Carrier Preparations Retain Their Biological Activity After Lyophilization and Storage at Room Temperature
[0039] The principle of this invention is further demonstrated by retention of cellular proliferating biological activity when biological carrier preparations were lyophilized and stored at ambient temperatures.
[0040] The ability of native harvested culture fluid from HSV-2 based biological carriers from anti-CD3, B7-1+B7-2, and anti-CD3&B7-1+B7-2 transduced cells were compared to aliquots of the same sample fluids after lyophilization with respect to the ability of the preparations to stimulate T-lymphocytes in culture. In addition to lyophilization, the lyophilized material was stored at room temperature for two weeks before testing biological activity. After thirteen days in culture with Donor #6 T-lymphocytes (Table 1), the lyophilized culture supernatant from the transduced host cells showed similar stimulation of proliferation to that observed with the native culture supernatants ( FIG. 5 ).
[0000]
TABLE 1
List of Donor Cells and Key for Biological Carrier Preparations
Donors:
1 = Lot#0G0002 Elutriated lymphocytes
2 = Lot#0G0008 Elutriated lymphocytes
3 = Lot#0H0005 Elutriated lymphocytes
4 = Lot#0J0009 Peripheral Blood Mononuclear Cells:
5 = Lot#0J0019 Elutriated lymphocytes
6 = Lot#0H0015 Elutriated lymphocytes
7 = Lot#0H0014 Elutriated lymphocytes
8 = Lot#0H0027 Elutriated lymphocytes
9 = Lot#1A0008 Elutriated lymphocytes
Biological Carrier Preparations: Un (Untransduced Cultures); B (B7-1 + B7-2 transduced); A (Anti-CD3 transduced) A + B (AntiCD3 + B7's Transduced Cultures)
[0041] Table 1 lists the nine different donors cells used in the data presented in the following Figures. Eight of the nine cell preparations were obtained by elutriation of human peripheral blood mononuclear cells and are depleted of monocytes. Donor #4 consists of ficoll-fractionated peripheral blood. In addition, Table 1 gives the meaning for the abbreviations Un, A, B, and A+B that refer to the host cell used to prepare the Biological Carrier preparations.
Example 3
Biological Carrier Preparations Retain Their Biological Activity After Concentration
[0042] The principle of this invention is further demonstrated by retention of cellular proliferating biological activity when biological carrier preparations were concentrated.
[0043] The ability to stimulate T-lymphocytes with native harvested culture fluid from HSV-2 based biological carriers obtained from untransduced or anti-CD3&B7-1+B7-2 transduced cells were compared to the same supernatants concentrated by polyethylene glycol (PEG) precipitation. The addition of PEG to culture fluid results in the formation of a precipitate. Virus (HSV-2) infected harvested culture supernatants were centrifuged at 4,000 times the force of gravity for 10 minutes, removing large particulate material from the culture fluid. Polyethylene glycol was added to the clarified supernatant to 6% and after 4 to 16 hours of incubation at 4° C. a precipitate was collected by centrifugation. Following resuspension of the pellet (40× concentrate), the material was compared to the native culture supernatant in T-lymphocyte proliferation assay. The PEG biological carrier material from transduced cultures stimulated T-lymphocyte proliferation similar to the unprocessed biological carrier preparations ( FIG. 6 ).
Example 4
T-Lymphocytes Stimulated with Biological Carrier Preparations can Undergo a Second Stimulation when Re-Exposed to the Same Biological Carrier Preparation
[0044] The principle of this invention is further demonstrated by observing secondary responses to re-administering the biological carrier preparation to the same population of cells.
[0045] Two donor lymphocytes, #8 and #7 in experiment #1 and #2, respectively, were initially stimulated with untransduced and transduced (anti-CD3, B7-1+B7-2, and anti-CD3&B7-1+B7-2) HSV-2 based biological carrier preparations ( FIG. 7 ). The data shown for the initial stimulation was 7 days after exposure of the cells to the biological carrier preparation. By 14 days there was no observed fluorescent activity over the untransduced cultures (data not shown). These cultures were kept in this resting state for 32 days in experiment #1 and 31 days in experiment #2. After which the cultures were re-exposed to the same biological carrier preparation used in the initial stimulation. The ability of the cultures to show a proliferative response to re-administration of the biological carrier preparation suggests that the biological carrier preparations can be used therapeutically to control and maintain immune responses.
Example 5
Inhibition of HIV-1 Replication Using HIV-1 Based Biological Carrier Preparations
[0046] The principle of this invention is further demonstrated by experiments using HIV-1 based Biological Carriers to inhibit HIV-1 replication. Four day PHA/IL-2 stimulated elutriated lymphocytes support HIV-1 (both HIV-1 MN and BaL) replication as measured by detection of HIV-1 encoded p24 protein released into the culture supernatant over time ( FIG. 8 ). The addition of HIV-1 based Biological Carrier preparation obtained from untransduced cultures ( FIG. 9 ) showed similar p 24 values to the untreated cultures shown in FIG. 8 . However, the addition of HIV-1 based Biological Carriers prepared from either the B7-1+B7-2 or the anti-CD3&B7-1+B7-2 transduced cultures inhibited HIV-1 replication ( FIG. 9 ). The degree of inhibition differed in the two preparations; the anti-CD3&B7-1+B7-2 preparation showing the most significant inhibition. The specificity of HIV-1 inhibition to only the HIV-1 based Biological Carriers formed from either B7-1+B7-2 or anti-CD3&B7-1+B7-2 transduced cultures is further demonstrated when HSV-2 based Biological Carrier preparations from either untransduced or anti-CD3&B7-1+B7-2 cultures did not inhibit HIV-1 replication in the same experiment ( FIG. 10 ). The inhibition of HIV-1 replication is not due to the lack of lymphocyte activation. In fact, cultures treated with either the HIV-1 or HSV-2 based Biological Carriers prepared from B7-1+B7-2 transduced cultures show higher stimulation at earlier times (day 4 for HIV and day 6 for HSV-2) than cultures treated with PHA/IL-2 alone (in the absence of Biological Carriers).
Example 6
HSV-1 & -2 Specific Antibody Reactivity Induced by Exposure of Peripheral Blood Lymphocytes to HSV-2 Based Biological Carrier Preparations
[0047] The principle of this invention is further demonstrated by experiments using HSV-2 based Biological Carriers to induce HSV-1 & -2 specific antibody reactivity. Unstimulated peripheral blood elutriated lymphocytes were exposed to either PHA, HSV-2 based or HIV-1 based Biological Barrier preparations (Table 2). After 3, 6, 10 and 14 days in culture, 200 μL aliquot of the cell suspension was placed into four different wells within a 96-well culture plate. Each of the four wells were coated with a lysate from either herpesvirus type-1 (HSV-1), herpesvirus type-2 (HSV-2), human immunodeficiency virus type 1 (HIV-1), or vesicular stomatitis virus (VSV). The cultures were incubated at 37° C. for 3 days, followed by incubation with a hydrogen peroxidase conjugated anti-human IgG antibody and colorimetric substrate for detection of antibodies formed in vitro against the different viruses. The results illustrate the ability of HSV-2 based Biological Carriers, but not HIV-1 based Biological Carriers, to induce HSV-1 & -2 specific reactivity. If neutralizing in nature, this antibody specific response can inhibit HSV-2 reactivation in vivo.
[0048] Table 2 shows specific antibody reactivity against HSV-1 & -2 when peripheral blood lymphocytes were exposed to HSV-2 based Biological Carriers (BCs), but not when exposed to HIV-1 based BCs. Donor #9 cells were used in this experiment; donor's plasma was positive for the presence of HSV-1 & -2 antibodies at the time of lymphocyte isolation. The data shows some reactivity at day 10 in PHA-stimulated cultures. In this donor HSV-2 based Biological Carriers prepared from untransduced host cells were HSV-1 & -2 antibody reactive. We would expect that in a HSV-1 & -2 negative donor only Biological Carriers prepared from co-stimulatory molecule transduced host cells would be HSV-1 & -2 antibody reactive positive.
[0000]
TABLE 2
HSV-1&-2 Specific Antibody Formation Induced by Exposure of
Peripheral Blood T-lymphocytes to HSV-2 based
Biological Carrier Preparations
Antibody
Culture
Reactivity
Sample Time Point (relative OD units)
Sample From
Against:
Day 3
Day 6
Day 10
Day 14
Control
HSV-1
>4.00
>4.00
>4.00
>4.00
HSV-2
3.09
2.993
>4.00
2.688
HIV-1
2.23
2.187
2.698
1.889
VSV
0.26
0.159
0.245
0.029
Unstimulated
HSV-1
0.007
0.012
ND
0.001
HSV-2
0.006
0.004
0.002
HIV-1
0.003
0.007
0.004
VSV
0.004
0.002
0.004
PHA-stimulated
HSV-1
0.005
0.036
0.586
0.060
HSV-2
0.005
0.015
0.590
0.020
HIV-1
0.007
0.009
0.005
0.003
VSV
0.004
0.002
0.005
0.002
HSV-2 based
HSV-1
0.214
1.876
3.722
0.006
BCs
HSV-2
0.163
1.744
3.503
0.003
HIV-1
0.003
0.004
0.005
0.003
VSV
0.005
0.003
0.003
0.007
HIV-1 Based BC
HSV-1
0.002
0.007
0.031
0.005
HSV-2
0.004
0.004
0.027
0.002
HIV-1
0.004
0.001
0.005
0.001
VSV
0.003
0.002
0.007
0.004
BC = Biological Carrier;
ND = not done
[0049] While the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modifications and this application is intended to cover any variations, uses, or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth. | This application provides a method to form non-infectious Biological Carrier that may be used to deliver signals to cells either in vitro or in vivo. The Biological Carriers are inactivated virus particles that have been specifically modified to give biological properties different from the virus particles deriving from an unmodified host cell that (i) expresses at least one co-stimulatory molecule and (iia) at least one antigen that can initiate an immune response, and/or (iib) express surface molecules that suppress viral replication. | 0 |
RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 537,093, filed Dec. 30, 1974 now U.S. Pat. No. 3,971,574 which in turn is a continuation-in-part of U.S. patent application Ser. No. 329,727, filed Feb. 5, 1973, now U.S. Pat. No. 3,857,588.
BACKGROUND OF THE INVENTION
This invention relates to pipe couplings, and more particularly to pipe couplings that are useable with unthreaded pipes.
Plastic pipes have become widely used in sprinkler systems because of their low cost and ease of connection and repair. Such pipes, commonly referred to as PVC because of their typical polyvinyl chloride composition, may be joined without threading by applying an adhesive such as a solvent cement type to the ends of the pipes and slipping a smooth-bore coupling over the ends.
When a break occurs in an underground sprinkler system of the PVC type, it can be repaired by digging away the dirt over the break, cutting out a small section of pipe containing the break, and connecting a new section of pipe in place using a pair of couplings. In practice, however, great difficulty is encountered in installing the couplings. The couplings can be installed by bending the pipe in the ground far enough so that the gap between them is increased sufficiently to insert the pipes into the couplings, and then releasing the bent pipes so they return to their original straight configuration. However, the dirt around a long section of the pipes may have to be removed to permit sufficient bending, which involves considerable labor and which may not be possible in certain locations. Also, the glue on the pipe may be scraped away while the pipe is fitted into the coupling. A coupling which could be installed without requiring large amounts of pipe bending would facilitate repairs in such sprinkler systems.
SUMMARY OF THE INVENTION
In accordance with one embodiment of the present invention, a pipe coupling is provided for use with unthreaded pipes, which provides a reliable connection without requiring excessive bending of pipes that are fixed in position in the ground. The coupling includes an end cap that can be installed on the end of a first pipe to be joined, and a sleeve which can slide over the second pipe and over the cap for adhesive mounting thereto. A flexible wedge ring is sandwiched between the sleeve and end cap and held in compression.
In accordance with another embodiment, the coupling includes a short pipe section have an enlarged tubular portion fixed at one end thereof and a sleeve slidable on the pipe section adjacent a second end thereof. In use, a section of a damaged pipe is removed to thereby leave open first and second pipe ends in the ground. The fixed enlarged tubular portion is adhered to the open first pipe end. The sleeve is slid over and adhered to an end cap mounted on the second pipe end.
In another coupling of the invention, a flexible coupling sleeve is provided which has rigid inserts at either end. The sleeve is of a flexible material such as a vinyl with plasticizer. Such a material may require considerable time such as hours to form a solvent cement bond with the more rigid PVC material containing less plasticizer which is typically used in sprinkler system pipes. The inserts are of the more rigid PVC material and can be bonded by solvent cement to typical sprinkler pipes in a short period of time such as less than 20 minutes. The coupling is installed by bending the sleeve thereof considerably so that no bending of the emplaced pipes is required. Even greater flexibility can be obtained by utilizing a flexible sleeve which is formed as a bellows. In still another embodiment of the invention, a coupling is provided which is formed from two half-cylindrical sections that can be brought together while their ends receive the ends of pipes to be coupled. Each section has saw toothed edges so that the parts tend to hold themselves in place while cement applied thereto is drying.
The novel features of the invention are set forth with particularity in the appended claims. The invention will best be understood from the following description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional side view of a pipe and coupling of the prior art, showing how the coupling was installed in the prior art;
FIG. 2 is a sectional side view of a pipe coupling constructed in accordance with one embodiment of the present invention, showing the manner of installation in a pipe system;
FIG. 3 is a sectional side view of the coupling of FIG. 2, showing it completely installed on the pipe system;
FIG. 4 is a view taken on the line 4--4 of FIG. 3;
FIG. 5 is a sectional side view of an assembly constructed in accordance with the coupling of FIG. 3, but showing installation in a situation where substantially no bending of the emplaced pipes is possible;
FIG. 6 is a sectional side view of a portion of the coupling of FIG. 3, showing its employment in connection with a T-connector that has a broken pipe end lodged therein;
FIG. 7 is a sectional side view of a pipe coupling constructed in accordance with another embodiment of the invention;
FIG. 8 is a sectional side view of a coupling constructed in accordance with still another embodiment of the invention;
FIG. 9 is a side elevation view of the coupling of FIG. 8, showing the manner in which it is installed on a pipe line;
FIG. 10 is a sectional side view of a coupling constructed in accordance with yet another embodiment of the invention;
FIG. 11 is a perspective view of a coupling constructed in accordance with yet another embodiment of the invention;
FIG. 12 is a side elevation view of the coupling of FIG. 11, showing it installed in a pipe line;
FIG. 13 is a sectional end view of the couplng of FIG. 11, showing how a clamp is applied to hold it together while cement thereon is drying;
FIG. 14 is a perspective view of a further coupling embodiment in accordance with the present invention;
FIG. 15 is a sectional view of the coupling of FIG. 14 showing the elements thereof prior to sealing;
FIG. 16 is a sectional view of the coupling of FIGS. 14 and 15 showing the elements in sealed relations;
FIG. 17 is a plan view of the coupling of FIG. 14 illustrated in sealed position;
FIG. 18 is a sectional view of a still further coupling in accordance with the invention with the elements thereof positioned prior to sealing; and
FIG. 19 is a sectional view showing the coupling of FIG. 18 with the elements thereof in sealed position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1-13 hereof are identical to FIGS. 1-13 of U.S. patent application Ser. No. 537,093, filed Dec. 30, 1974.
FIG. 1 illustrates a pair of couplings C and D of the prior art, showing how they are used to connect a replacement pipe section R to the ends of a pair of pipes S and T. This is accomplished by installing the coupling D to connect the two pipes R and T, and installing the other coupling C over an end of the pipe R, as shown. The mating surfaces of the couplings and pipes are made watertight by applying a suitable solvent cement thereto prior to insertion of the pipe ends into the couplings. Solvent cement is applied to the end of pipe S and to the interior of the free end of coupling C as illustrated in the figure. Considerable bending of the two pipes S and T is required to separate them sufficiently to permit insertion of the pipe S into the coupling C. Thereafter, the pipes are straightened to the positions at S' and C'. As a result of the bending and straightening, the pipes and couplings are somewhat distorted, thereby reducing the strength of the ultimate bond. In sprinkler systems wherein the pipes S and T were in the ground, considerable soil had to be removed to permit the required amount of bending.
FIG. 2 illustrates the coupling 10 of the present invention, which employs a forward end cap 12 that fits over the end of one pipe S, a rearward end cap 14 that fits over the end of another pipe R, and a sleeve 26 that can fit around the two end caps 12, 14 to securely hold them in alignment and therefore securely couple the pipes. The replacement pipe section R may be first connected to one pipe T with an ordinary coupling D, and the coupling assembly 10 of the present invention then may be used to connect the other end of the pipe R. Only a small amount of bending of one or both pipes S, T is required in order to install the first coupling D and to install the end caps and sleeve of the coupling assembly 10. The amount of bending required in the embodiment of FIG. 2 is much less than required in the prior art, so that very little, if any, additional soil must be removed around the pipes S, T to make a repair.
FIG. 3 illustrates details of the coupling assembly 10. The forward end cap 12 has a pipe portion 18 with an inside diameter slightly greater than the diameter of the pipe S, to fit snugly around the end of the pipe. The cap 12 also has an inwardly-extending flange 20 that abuts the end of the pipe S to determine the position of the cap on the pipe, and a short tubular portion 22 that extends rearwardly beyond the pipe S and the flange 20. The cap 12 further has an outwardly extending flange 24 at its forward end. The rearward cap 14 also has a pipe portion 26 that closely surrounds the pipe R, an inwardly-extending flange 28 at its forward end that abuts the end of the pipe R, and a short tubular portion 30 that extends forwardly beyond the pipe R and beyond the flange 28. The tubular portions 22, 30 of the two end caps are constructed to closely interfit, the tubular portion 22 of the forward cap being closely received in the tubular portion 30 of the rearward cap for alignment. It also may be noted that the rearward portion of the rearward cap is tapered at 32 on its outside.
The sleeve 16 has a length approximately equal to the combined lengths of the two end caps 12, 14, and it is designed to closely fit over them. The sleeve has a pipe portion 34 along most of its length that is closely received around the two end caps, and with a forward end 36 that nearly abuts the flange 24 on the forward cap. The sleeve also has a rearward portion 38 that is tapered along its inside to closely fit the tapered rearward portion 32 of the rearward cap.
The coupling assembly 10 is installed by first applying adhesive, such as a solvent cement, to the inside surfaces of the sleeve 16, and then slipping the sleeve onto the pipe R as illustrated in FIG. 2. No glue touches pipe R at this time. Adhesive is then applied to the ends of the pipes S and R, and the two end caps 12, 14 are then installed on the ends of their respective pipes S, R. The adhesive is then applied on the outside of the two caps 12, 14, except on the outside of the forward flange 24 of the forward cap. The short tubular portion 22 of the forward cap is inserted into the short tubular portion 30 of the rearward cap, which is easily done because of the short length of these tubular portions (their overlap is on the order of 1/64th inch). The sleeve 16 is then slid over the two end caps to the position illustrated in FIG. 3. The sleeve 16 is slid forwardly as far as possible, and is normally stopped by engagement of the tapered portions 32, 38 of the rearward cap and sleeve. It should be noted that the gluing surfaces are aligned and undistorted prior to sliding the sleeve 16 over the caps 12, 14.
The coupling assembly 10 provides a reliable pipe connection, because all parts are held along a considerable tubular length. Thus, the pipe portions 18, 26 of the two end caps are joined to their respective pipes S, R along a considerable surface area while the sleeve 16 is joined to the two end caps along a considerable tubular area. Also, in order for water to leak out, it would have to pass along a considerable tubular area where adhesive holds the parts together. The interfitting short tubular portions 22, 30 also aid in sealing. It may be noted that the male tubular portion 22 may be formed on the rearward cap 14 and the female tubular portion formed on the forward cap 12, instead of vice versa, if desired.
FIG. 5 illustrates the manner in which two pipe couplings 10a and 10b of the present invention can be utilized in a situation where essentially no bending of the emplaced pipes S and T is possible. Instead of using one ordinary coupling D of the prior art as illustrated in FIG. 2, two couplings of the present invention are employed at the opposite ends of the replacement pipe R. The installation of FIG. 5 is made by installing two forward end caps 12a, 12b on the two pipes S and T. Two sleeves 16a and 16b are installed on the pipe R and two rearward end caps 142, 14b are installed on the ends of the pipe section R. The pipe section R is then dropped into alignment with the two pipes S, T and the sleeves are then slid into position.
FIG. 6 illustrates how a portion of the coupling assembly of the invention can be utilized to connect a replacement pipe W to a T-coupling (or L-coupling) Z of the prior art. The coupling Z is shown with a pipe end X broken off inside. The installation is made by attaching a rearward end cap 14 to the replacement pipe W, moving the forward end of the cap 14 against the T-coupling Z, and then sliding the sleeve 16 over the rear cap 14 and an end P of the coupling Z. The coupling end P is of the same outside diameter as the rearward cap 14, so that the coupling 16 is closely received thereon. Thus, the same coupling assembly can be utilized to connect to a T-coupling of the prior art, by eliminating the forward end cap.
FIG. 7 illustrates a coupling assembly 50 constructed in accordance with another embodiment of the invention, which utilizes only one end cap 52 and a sleeve 54. The cap 52 is similar to the forward end cap of the assembly 10, except that it has a female tubular portion 56 at its rearward end for directly receiving the end of the pipe R. Also, the cap 52 is tapered along the outside of its rearward portion 58. The sleeve 54 is similar to the sleeve of the coupling assembly 10, except that the taper at 60 occurs along a middle portion, and the rearward portion 62 is formed to closely receive the pipe R. The installation of the coupling assembly 50 is accomplished by applying adhesive to the inner surface of sleeve 54 and sliding the sleeve 54 over the pipe R. Adhesive is then applied around the ends of the pipe S. The end cap 52 is then installed on the end of the pipe S and with its tubular portion 56 receiving the end of the pipe R. Adhesive is then applied to the outside of cap 52 and pipe R, and the sleeve 54 is then slid forwardly over the cap 52.
FIGS. 8 and 9 illustrate a coupling 70 constructed in accordance with a further embodiment of the invention, which utilizes a highly flexible sleeve 72 and a pair of substantially rigid inserts 74, 76 at the ends of the sleeves. The sleeve 72 has sufficient flexibility so that it can be readily deformed by a person to the configuration illustrated in FIG. 9, to thereby shorten the length between the ends of the coupling. A variety of materials such as a vinyl with considerable plasticizer can be utilized to achieve much flexibility. The sleeve 72 cannot be readily used along because solvent cement, which is the most common type utilized in PVC sprinkler pipe repair, requires considerable time to bond to suitable highly flexible material. While the common more rigid PVC pipes can be bonded together with solvent cement in a times less than about 20 minutes, bonding of such rigid PVC to the highly flexible vinyl can require hours. The inserts 74, 76 minimize the bonding time, inasmuch as the inserts are constructed of ordinary rigid PVC. Also, the inserts are internally tapered to facilitate joining to another pipe. The inserts 74, 76 are installed, as with solvent cement, at the factory so that the longer bonding time is not a highly significant factor. A repairman installs the coupling 70 to replace a damaged pipe section, by cutting out the damaged section to leave two pipe ends S and T. The coupling 70 is provided with markings 71 near either end thereof to serve as a gauge that indicated the required gap length. The repairman coats the ends of the pipes S and T and the insides of the inserts 74, 76 with solvent cement and then inserts one pipe T into one insert 76. He then deforms the sleeve 72 as to the configuration illustrated at 72a in FIG. 9 with his thumbs T r and T L and forefingers R r and R L to reduce the length of the coupling. The shortened coupling can then be inserted into the other pipe S and allowed to return to its cylindrical shape, so that it becomes longer while receiving the other pipe end S.
FIG. 10 illustrates a coupling 80 constructed in accordance with yet another embodiment of the invention, wherein a flexible sleeve 82 is utilized in conjunction with end inserts 84, 86 of harder material, in which the flexible sleeve is formed with a bellows portion 88. The flexible sleeve and inserts are of material similar to those described in the coupling of FIGS. 8 and 9. The bellows portion 80 makes compression of the length of the sleeve even easier.
FIGS. 11-13 illustrate a still further embodiment of the invention, wherein the coupling 90 includes a pair of half-cyclindrical parts 92, 94 that can be fitted together over the ends of pipes S, T. The two parts 92, 94 are identical, and each extends slightly more than 180° and has serrated sides 96, 98 or 100, 102. Each part 92, 94 is substantially one of the halves of a pipe cut along an imaginary plane P that extends through the axis 95 of the pipe. The serrated sides of the two parts interfit and serve to hold the parts together while solvent cement dries thereon. Both parts may be constructed of an ordinary largely rigid vinyl that can be rapidly solvently cemented to PVC pipes. The coupling 90 is installed by applying solvent cement to the serrated sides 96-102 of the half-cylindrical parts, as well as to the inside surfaces thereof and to the outside surfaces of the ends of the pipes S and T. The two coupling parts 92, 94 are then placed on opposite sides of the pipes and pressed together so that their serrated sides 98-102 interfit. The coupling parts can be even more securely held together by means of a clamp 104 illustrated in FIG. 13 which is removed after the solvent cement has at least partially dried.
Attention is now directed to FIGS. 14-17 which illustrate a further embodiment of a coupling 120 useful in situations of the type depicted in FIG. 3 for connecting emplaced pipes S and T. The coupling 120 is comprised of three elements; i.e., a tubular cap member 122, a ring 124, and a sleeve 126.
The cap member 122 has inner and outer cylindrical surfaces 130 and 132 respectively. The inner surface 130 has a diameter only slightly larger than the outside diameter of pipes S. The inner surface 130 is slightly tapered to fit tightly onto the open end of tube S. The outside surface 132 is similarly slightly tapered defining an increasing diameter in a direction extending from the pipe T toward the pipe S. Cap member 122 further includes an annular flange 134 which defines a radially extending surface 136. Additionally, the cap member 122 defines a relatively short tubular portion 138 having a reduced outer diameter defined by the surface 140.
The inner surface 130 of cap member 122 defines inwardly extending flange 142 having a radially extending surface 144 which abuts against the end 146 of pipe S.
The ring 124 has inner and outer surfaces 150 and 152 respectively. The inner surface 150 has a diameter slightly larger than the outside diameter of pipe T for slidable movement therealong. The outer surface 152 of ring 124 has a diameter substantially equal to the outer surface diameter 132 of cap member 122 and tapered substantially uniformly therewith. The ring 124 is preferably formed of a flexible PVC material which can be adhesively secured by a suitable solvent to the PVC cap member 122 and sleeve 126 and which in addition is slightly deformable in compression.
The sleeve 126 has a substantially smooth internal surface 160 comprised of a first portion 162 having a diameter slightly larger than the outer diameters of ring 124 cap member 122. Additionally, the internal surface first portion 162 is tapered complementary to the ring outer surface 152 and cap member outer surface 132. The internal surface 160 of sleeve 126 includes a second portion 164 having a diameter only slightly greater than the outer diameter of pipe T.
In use, the cap member 122 is first secured to the open end of pipe S by applying a suitable PVC solvent to the outer surface of pipe S and the inner surfaces 130 of cap member 122. The sleeve 126 is slid to the right (as viewed in FIG. 15) so as to permit the solvent 170 to be applied to the outer surface of pipe T and the outer surface of ring 124. Additionally, the solvent 170 is applied to both the surface 132 and the surface 140 of the cap member 122.
In order to effect a leak free seal, the sleeve 126 is then slid to the left, preferably with a slight twist, thereby carrying the sleeve internal surface first pofrtion 162 into engagement with the cap member outer surface 132 and ring outer surface 152. In so moving the sleeve 126, a portion 172 of the inner surface of the sleeve engages the right end of the ring 124 forcing it over the reduced diameter tubular portion 3. Further, movement of the sleeve 126 puts the ring 124 into compression so as to slightly deform it, as with a traditional "0" ring, to effect an improved seal. Moreover, as the sleeve 126 is moved axially to the left (as viewed in FIG. 15), the portion 164 of the sleeve inner surface wipes over the solvent 170 on the outer surface of pipe T thereby becoming adhesively mounted thereto.
As represented in FIGS. 14 and 17, it is preferable that the outer surface of sleeve 126 be provided with a knurled portion 174 to facilitate manual gripping.
Attention is now called to a still further embodiment of the invention as represented in FIGS. 18 and 19. FIGS. 18 and 19 disclose a coupling 200 for connecting emplaced pipes S and T whose opened ends are separated by a predetermined distance. The coupling 200 is comprised of three pieces including a cap member 202 adapted to be secured on the open end of pipe S, a special pipe section 204, and a sleeve 206 capable of sliding axially along the pipe section 204.
The cap member 202 is similar to the cap member 122 of FIGS. 14-17, just described. More particularly, cap member 202 defines internal surface 208 adapted to be adhered to the outer surface of pipe S. Cap member 202 further defines outer surface 210 having a flange 212 extending therefrom to define outwardly extending radial surface 214. The inner surface 208 has an inwardly extending flange 216 which defines radial surface 218 adapted to about pipe end 220.
The pipe section 204 preferably includes an enlarged tubular end 222 adapted to fit around and be adhered to the open end of pipe T. Additionally, pipe section 204 is comprised of an outer surface defining at least first and second portions of different diameters. More particularly, the major portion 224 of pipe section 204 is a certain diameter and the portion 226 adjacent the left end thereof has a greater diameter. A radially extending surface 228 is defined at the junction between portions 224 and 226.
The sleeve 206 has an internal surface comprise of portions 230 and 231 dimensioned so as to be slightly larger than the corresponding outer surface portions 210 and 211 of cap member 202 for adhesive mounting thereto. Additionally, the sleeve 206 inner surface has portions 240, 242, and 244 of increasing diameter so as to define radially extending surfaces 246 and 248. These surfaces are adapted to engage radial surfaces 228 and 229 on the type section 224 when the coupling is finally assembled. In use the cap member 202 is initially installed on the open end of pipe S and the tubular portion 222 of pipe section 204 is installed on the open end of pipe T. The sleeve 206 is slid to the right (as viewed in FIGS. 17 and 18) in order to permit installation. Appropriate PVC solvent 250 is then applied to the outer surface of cap member 202 and to the outer surface of pipe section 204 adjacent the and thereof approximate the pipe S. The sleeve 200 is then slid to the left with a twist thereby engaging and adhering the inner surfaces 230 and 231 to the outer surfaces 210 and 211 of the cap member 202. Additionally, a portion 240 wipes the PVC solvent along the pipe section toward the pipe S and seals thereto. In moving axially to the left, the solvent is compressed and trapped between the mating radial surfaces on the sleeve 200 and pipe section 204 to form a leak free joint.
Although particular embodiments of the invention have been described and illustrated herein, it is recognized that modifications and variations may readily occur to those skilled in the art and consequently it is intended that the claims be interpreted to cover such modifications and equivalents.
Thus, the teachings of the invention may readily be employed with various fittings other than those specifically illustrated herein. For example only, the cap members 122 and 202 of FIGS. 14 and 18 respectively, may be integrally formed on a T or L fitting for coupling to an emplaced pipe by use of a sleeve 126 or 206. | A coupling for unthreaded pipes of a sprinkler system, which permits the replacement of a small damaged pipe section without bending the pipes already emplaced in the ground. One coupling includes an end cap that can be installed on the end of a first pipe to be joined, and a sleeve which can slide over the second pipe and over the end cap for adhesive mounting thereto. A flexible wedge ring is sandwiched between the sleeve and cap. | 8 |
Latin name of the genus and species of the plant: Carya illinoinensis.
Variety denomination: ‘Morrill’.
BACKGROUND OF THE INVENTION
The present invention relates to a new and distinct variety of pecan tree named ‘Morrill’. My new tree can be used in gardens or for commercial production of pecan nuts. This new tree was selected from seedlings grown from controlled pollination at the University of Georgia Horticulture Farm in Watkinsville, Ga., in 1989. The ‘Morrill’ selection resulted from crossing ‘Wichita’ (unpatented) as the seed parent with ‘Pawnee’ (unpatented) as the pollen parent. The resulting tree was selected when growing in a cultivated area at Watkinsville, Ga.
BRIEF SUMMARY OF THE INVENTION
‘Morrill’ is distinguished from other pecan varieties known to the inventor due to the following unique combination of characteristics: Precociousness, moderately early nut maturity, large nut size, a nut with a high kernel percentage, exceptional kernel quality, moderate resistance to scab and good resistance to powdery mildew and to black pecan aphid.
Asexual reproduction of ‘Morrill’ by grafting, (topworking) onto ‘Kiowa’ (unpatented) pecan trees in 2003 and 2007 at a location in Albany, Ga. was performed in order to evaluate these trees. Asexual propagation of ‘Morrill’ pecan trees has also been performed at other locations in Georgia. Asexual reproduction of ‘Morrill’ has shown that the forgoing characteristics come true to form, are firmly fixed, and are established and transmitted through succeeding propagations.
Certain characteristics of this variety, such as growth and color, may change with changing environmental conditions (e.g., light, temperature, moisture, nutrient availability, or other factors). Color descriptions and other terminology are used in accordance with their ordinary dictionary descriptions, unless the context clearly indicates otherwise. Color designations are made with reference to The Royal Horticultural Society (R.H.S.) Colour Chart.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a photograph showing the original ‘Morrill’ tree grown from seed.
FIG. 2 is a photograph showing a number of leaves of ‘Morrill’.
FIG. 3 is a photograph showing an immature fruit cluster of ‘Morrill’ pecans.
FIG. 4 is a black and white photograph showing a cross-sectional view of a nut of ‘Byrd’ (on the left) and a cross-sectional view of a kernel of ‘Morrill’ (on the right), and illustrating the narrower dorsal grooves of the ‘Morrill’ kernel.
FIG. 5 is a black and white photograph showing ‘Morrill’ nuts in an upper portion of the photograph and ‘Morrill’ kernels in a lower portion of the photograph.
The colors of an illustration of this type may vary with lighting and other conditions. Therefore, color characteristics of this new variety should be determined with reference to the observations described herein, rather than from these illustrations alone.
DETAILED DESCRIPTION
BOTANICAL
The following detailed description of ‘Morrill’ is based on observations of the original tree growing in Watkinsville, Ga. and of asexually reproduced progeny growing in Albany, Ga.
Varietal name: ‘Morrill’. Parentage:
Seed parent .—‘Wichita’. Pollen parent .—‘Pawnee’.
Tree:
Overall shape .—Upright, moderately spreading, height to width ratio is about 1. Vigor .—Vigorous, precocious, ‘Morrill’ fruited the second year after grafting (topworking) onto ‘Kiowa’ trees, and has done so in subsequent years. Original tree fruited 10 years from seed. Height .—Of original tree, about 11 meters. Width .—Of overall tree, about 11 meters. Trunk .—Of original tree (measured ½ meter above ground level) about 0.6 m diameter. Trunk bark texture .—Fissured. Trunk bark color .—Grey (RHS 202B). Patches .—Trunk has no markings. Branch color .—Branch shoots in woody stage are Grey-brown (RHS 199A) in color, with Grey-brown lenticels (RHS 199D) that are elongated and about 1 mm long by 0.05 mm wide. Internodes .—Average internode length is about 1.3 cm, 3 rd and 4 th leaf on a shoot. Disease and insect resistance .—Moderate resistance to scab ( Fusicladosporium effusum ). Good resistance to powdery mildew ( Microsphaera alni Candolle ex Winter). Good resistance to black pecan aphid ( Melanocallis caryaefoliae ).
Leaves: The mature leaf is odd pinnate compound, deciduous with leaflets having a dark green upper surface and a lighter green lower surface. Each mature leaf has from 13 to 17 leaflets. Opposite leaflets are oriented at 180 degrees relative to each other. This flat orientation is most pronounced on basal leaflets with the leaflets becoming somewhat droopy on apical leaflets.
Size of mature leaf ( fourth leaf from base ).—19.8 cm long, 20.0 cm wide. Peduncle .—Oval in cross-section, tan in color (RHS 199B). The length of the peduncle of the fourth leaf from the base is about 5.1 cm. The diameter of the peduncle of the fourth leaf from the base is about 2.7 mm. Leaflet .—Size and shape: Fourth leaflet on fourth leaf from base 10.5 cm long by 3.3 cm wide. Eliptic in shape. Apex acuminate and narrow. Base oblique. Margin serrate. Undulation of leaflet margins is absent on basal leaves, but increases from basal to apical leaves. Texture: Smooth. Sheen: Glossy. Petiole: Sessile. Margin: Serrate. Tip shape: Acuminate. Leaflet color: Upper leaf surface: Dark green (RHS 139A). Lower leaf surface: Green (RHS 138A). Pubescence: Upper leaf surface is not pubescent. Lower surface is pubescent.
Inflorescence:
General .—The ‘Morrill’ pecan is monoecious, anemophilous, and protandrous. Dichogamy is protogynous. Flowers .—Pistal flowers are born on a determinate spike, with staminate flowers born on a determinate pendulous catkin. Three-five individual pistilate flowers per spike, borne alternately on terminally-positioned spikes. The pistilate flower is symmetrical with no stamens or petals. The peticles are sessile. The staminate or catkin length is 156 mm and width is 5 mm. The staminate color is Green (RHS 144B) with gold pollen (RHS 3A). The involucre size, which includes the stigma, is 7 mm long by 1.9 mm wide. The flower has one pistil with a pink stigma. The flower has four bracts, which are green (RHS 144A), linear, lanceolate, 3.9 mm long by 0.4 mm wide and are fused at the bases, forming a copular involucre.
Fruit: Mature fruit is dehiscent.
Shuck .—Green (RHS 144B). Fruit split during water stage .—Not observed to be a problem. Shuck decline .—Shuck dieback during kernel formation has not been observed to be a problem.
Nuts: (Observations from a limited number of typical nuts from several growing seasons in Watkinsville, Ga.).
Size .—Large, length about 47 mm, width about 23.5 mm (width measurement taken midway along the length of the nut and across sutures); length to width ration about 2.0. Nut flatness (ratio of width across sutures to width between sutures) is about 1.1. Form .—Oblong with a blunt (obtuse) base, apex that is broadly elongated and cuspidate to cuspidate asymmetric, with a grooved apex. Sutures .—Subtle, non-elevated. Dorsal grooves .—Narrow, thereby increasing the percentage kernel in the nut. Weight.— 8.7 grams per nut (non-limiting soil moisture). Cluster size .—About 2.9 fruits per cluster. Texture .—Subtle ridges. Shell thickness .—Thin, 0.72 mm. Kernel color .—Good color, Greyed-orange (RHS 165B). Kernel coat .—No specking has been observed. Kernel percentage of nut .—About 65.8 percent. Nut maturity .—October 2 nd . Later than ‘Byrd’ by about 13 days. Harvestability .—Suitable for machine harvest. Cracking/shelling ability .—Cracks exceptionally well, percentage of kernels with intact halves is high. Typically, less than five percent of chipped or broken kernels were observed.
COMPARISONS TO OTHER VARIETIES
The form of ‘Morrill’ trees is moderately spreading and is intermediate to its parents. Thus, ‘Morrill’ spreads more than its male parent ‘Pawnee’, which is more upright, and also more than ‘Byrd’. The timing of bud break of ‘Morrill’ is similar to ‘Stuart’ and ‘Pawnee’ pecan trees but later than many pecan cultivars. Thus, ‘Morrill’ is less susceptible to late-spring freezes in Georgia than most other pecan cultivars. The leaves of ‘Morrill’ are dark green, but not as dark green as ‘Pawnee’ leaves. Leaflet orientation of ‘Morrill’ leaves is similar to ‘Pawnee’, that is, the opposite leaflet is oriented at 180 degrees relative to each other whereas leaflets of most pecan genotypes droop to varying degrees, including ‘Wichita’. Undulation of leaflet margins in ‘Morrill’ is much more pronounced than in ‘Pawnee’ and is similar to leaves of ‘Wichita’. The stigmatic surface of ‘Morrill’ is pink in contrast to the ox-blood red stigmatic of ‘Pawnee’ and the green surface of ‘Wichita’.
Table 1 below compares periods of stigma receptivity and pollen shedding of the ‘Morrill’ cultivar with these characteristics of a number of other cultivars.
TABLE 1
Approximate periods of pollen shedding and stigma receptivity for
‘Morrill’ and other cultivars, Albany, Georgia
April
May
21 22 23 24 25 26 27 28 29 30
1
2
3
4
5
6
7
8
‘Byrd’
xxxxxxxxxxxxx ........
‘Desirable’
xxxxxxxxxxxxxxxx ......................
‘Morrill’
.............. xxxxxxxxx
‘Elliott’
.............................. xxxxxxxxxxxxxx
‘Kiowa’
.......................... xxxxxxxx
‘Stuart’
........................ xxxxxxxxxxxxx
.............. = Period of stigma receptivity.
xxxxxxx = Period of pollen shedding.
Tables 2 and 3 below compare the characteristics of nuts from ‘Morrill’ with nuts of other pecan cultivars.
TABLE 2
Comparison of nut characteristics of ‘Byrd’, ‘Pawnee’ and ‘Morrill’
pecan cultivars, Watkinsville, Georgia
Vol-
Nut
Shell
Nut
ume/
Wt./
Nut
Flat-
thick-
Matur-
nut
nut
length
Length/
ness
ness
Kernel
ity
Cultivar
(cc)
(g)
(mm)
width z
ratio y
(mm)
(%)
date x
‘Byrd’
11.3a
7.8a
42.5a
1.87c
1.04b
0.65c
61.9b
9/19b
‘Pawnee’
10.9a
7.6a
41.9a
1.95b
0.96c
0.77a
59.3c
9/18b
‘Morrill’
12.0a
8.7a
47.1b
2.01a
1.11a
0.72b
65.8a
10/2a
Means followed by the same letter within a column are not statistically different, P ≧ 0.05.
z Length to width ratio = nut length divided by width. Width was measured midway the length of the nut and across sutures.
y Nut flatness ratio = ratio of nut width across sutures to width between sutures.
Measurements were made midway the length of the nut.
x Nut maturity date of ‘Desirable’ is October 15.
TABLE 3
Nut characteristics of ‘Byrd’ and ‘Morrill’, Albany, Georgia
Wt./nut
Nuts/lb.
Kernel
Cultivar
(g)
(no.)
(%)
‘Byrd’
9.6a
47a
63.5a
‘Morrill’
9.8a
46a
67.4b
Means followed by the same letter within a column are not statistically different, P ≧ 0.05.
Greater nut size and percentage kernel in Albany, Georgia as compared to Watkinsville, Georgia (Table 2) believed due to better irrigation and probably higher temperatures in Albany, Georgia. Soil water was non-limiting at Albany, but not at Watkinsville.
Pecan nuts of large size that mature relatively early command a premium price. The price per pound normally declines as the harvest becomes later. Consequently, cultivars that exhibit early maturity at harvest are commercially important. The color of a kernel's seed coat (lighter is preferred), and the percentage kernel of the nut also affects the selling price of pecans. Although the nut maturity of ‘Morrill’ is about 13 days later than nut maturity of ‘Byrd’, it is about 13 days earlier than the ‘Desirable’ cultivar (unpatented). ‘Desirable’ is believed to be the leading cultivar now being planted in new orchards in Georgia. Although the nut maturity of ‘Morrill’ is later than ‘Byrd’, the maturity date is still early enough to be considered an early market cultivar. The later harvest date of ‘Morrill’ is advantageous in one respect because a number of growers of pecans in southwest Georgia also grow peanuts. The harvest date of ‘Byrd’ pecan trees conflicts with the peanut harvest date. ‘Morrill’ matures at the end of the peanut harvesting season, making it a more suitable early cultivar for peanut growers that can harvest ‘Morrill’ pecans following the peanut harvest.
As can be seen from Table 2, the nut volume and weight of ‘Morrill’ nuts are substantially same as those of ‘Pawnee’ and ‘Byrd’. However, the nut length is longer in the case of ‘Morrill’ nuts than either ‘Pawnee’ or ‘Byrd’ nuts and the nut shape differs. As indicated by the length to width ratio, ‘Morrill’ nuts are more oblong than ‘Pawnee’ or ‘Byrd’ nuts. In cross-section, ‘Byrd’ nuts are near round (flatness ratio 1.04) while ‘Pawnee’ nuts are flatter on the suture side than the non-suture side. In contrast, ‘Morrill’ nuts are flatter on the non-suture side than the suture side. Referring to Table 2, the shell thickness of ‘Morrill’ is intermediate between the shell thickness of ‘Byrd’ and ‘Pawnee’. All three have unusually thin shells, which accounts, in part, for their high percentage kernel. However, the percentage kernel of ‘Morrill’ nuts is substantially higher than ‘Byrd’ nuts even though the shells of ‘Byrd’ nuts are thinner. The higher percentage kernel of ‘Morrill’ is due in part to the differences in the morphology of the dorsal grooves in ‘Morrill’ in comparison to ‘Byrd’. The dorsal grooves are deep and wide in ‘Byrd’, but much narrower in ‘Morrill’, thereby increasing the percentage kernel in the nut of ‘Morrill’ nuts. The percentage kernel is a direct function of the shell thickness and the percentage of the shell cavity filled with the kernel.
The percentage kernel of ‘Morrill’ nuts, as can be seen from Table 2, is high and is substantially higher than any existing pecan cultivar known to the inventor.
Under stress, primarily fruiting stress, when ‘Pawnee’ cultivar pecan trees are grown in humid southeastern United States markets such as Georgia, the kernel seed coats of nuts can develop conspicuous and unattractive dark spots. This specking reduces the marketability of these nuts. Specking has not been observed to be a problem of ‘Morrill’ nuts grown in Georgia. In addition, unlike the ‘Morrill’ cultivar, during a heavy “on” nut production year for ‘Pawnee’ trees growing in Georgia, kernel development is relatively poor, resulting in a high percentage of the nuts being unmarketable or of reduced value.
Table 4 below compares the fruiting characteristics of ‘Morrill’ and ‘Byrd’ cultivars.
TABLE 4
Fruiting characteristics of ‘Byrd’ and ‘Morrill’, Albany, Georgia
Cultivar
Years to fruiting z (no.)
Years until alternate bearing z (no.)
‘Byrd’
2
3
‘Morrill’
2
>5
z Years after topworking mature trees to the respective cultivar.
As apparent from Table 4, the ‘Morrill’ variety is precocious. Both ‘Morrill’ and ‘Byrd’ fruited two years after topworking onto older ‘Kiowa’ pecan trees. It does not appear ‘Morrill’ is as precocious as ‘Byrd’ as indicated by the onset of alternate bearing in ‘Byrd’ trees the third year from topworking in contrast to alternate bearing in ‘Morrill’ trees having not occurred by the fifth year. Also, the original ‘Morrill’ tree bore its first fruit the tenth year from planting as seed. In comparison, the original tree of ‘Byrd’ first fruited the seventh year from planting as seed.
As indicated in Table 5 below, the cluster size of ‘Morrill’ and ‘Byrd’ is about the same. It does appear that ‘Morrill’ has lower density of fruiting shoots than ‘Byrd’. Because of ‘Morrill’s precocity, large nut size and large cluster size, it is expected to bear alternately with increasing tree maturity as occurs with most pecan cultivars including its parent trees, ‘Wichita’ and ‘Pawnee’.
TABLE 5
Fruit cluster size of ‘Byrd’, ‘Desirable’, ‘Morrill’ and ‘Pawnee’,
Watkinsville, Georgia
Cultivar
Fruit/cluster (no.)
SD
CV
‘Byrd’
3.1a
0.68
22
‘Desirable’
1.8b
0.59
34
‘Morrill’
2.9a
0.83
28
‘Pawnee’
3.1a
0.83
26
Means followed by the same letter are not statistically different, P ≧ 0.05.
SD = Standard deviation
CV = Coefficient of variation
Table 6 below compares scab and powdery mildew susceptibility of ‘Morrill’ with ‘Byrd’ and ‘Desirable’. In addition, ‘Pawnee’ has been observed to be more susceptible to scab disease than ‘Morrill’ when grown in Georgia. ‘Wichita’, when grown in Georgia's humid climate, is highly susceptible to scab fungus.
TABLE 6
Fruit scab and powdery mildew susceptibility
of ‘Byrd’, ‘Desirable’ and ‘Morrill’
Cultivar
Fruit scab z
Powdery mildew y
‘Byrd’
1.6
2
‘Desirable’
5.0
3
‘Morrill’
2.5
2
z = no scab; 2 = very slight and occasional lesions on fruit, <10% of fruits with scab; 3 = lesions common on fruit by not damaging, 11-50% of fruits with scab; 4 = widespread lesions on fruit but not damaging, 51-75% of fruits with scab; 5 = widespread and damaging lesions on fruit, fruit size suppressed and nut is non-marketable. Ratings from NILO Plantation and were made in 2005 a major scab season.
y = no mildew, 2 = < than 5% of the fruit covered with mildew, 3 = 6-25% covered, 4 = 26-50% covered, 5 = 51-100% covered. Ratings from Watkinsville and were made in 2008.
Table 7 below compares the black pecan aphid resistance of ‘Morrill’ to the resistance of two other cultivars.
TABLE 7
Black pecan aphid susceptibility of ‘Byrd’, ‘Sumner’ and
‘Morrill’, Leary, Georgia
Cultivar
Black pecan aphid y
‘Byrd’
1.0a
‘Sumner’ z
1.8b
‘Morrill’
1.0a
Means followed by the same letter are not statistically different, P ≧ 0.05.z
z During a heavy infestation ‘Sumner’ (unpatented) is highly susceptible to black pecan aphid.
y 1 = no leaf damage, 2 = <1% of leaves with injury, 3 = 1-10% of leaves with injury, 4 = 11-50% of leaves with injury, 5 = >51% of leaves with injury and partial defoliation.
Data taken during a year of low aphid population.
In addition, under these humid growing conditions in Georgia, the fruit is highly susceptible to splitting during the “water stage” (liquid endosperm stage) of fruit development. Fruit split can occur following rain and accompanying high humidity in early August in Georgia. Although ‘Wichita’ has a relatively early nut maturity (7-10 days before ‘Stuart’) and acceptable nut size (57 nuts per pound), and a kernel percentage of 60-61%, which is higher than the 58-59% of ‘Pawnee’, because of the susceptibility to scab fungus and splitting it has become a less desirable cultivar for growing in Georgia. Water split has not been observed in ‘Morrill’. The lack of split may be due to the timing of fruit development. Water split is most likely to occur on cultivars when the maximum liquid endosperm stage occurs during the first two weeks in August that often coincides with the rainy period in Georgia. Typically, rainfall in Georgia sharply decreases after August 15th. The maximum liquid endosperm stage in ‘Morrill’ trees grown in Georgia occurs after August 15th.
The ‘Morrill’ pecan tree is therefore an improved new and distinct pecan. | A pecan tree distinguished by the following unique combination of characteristics: Precociousness, moderately early nut maturity, large nut size, a nut with a high percentage kernel, exceptional kernel quality, moderate resistance to scab and good resistance to powdery mildew and to black pecan aphid. | 0 |
The invention claimed and disclosed herein deals with devices that are useful for converting floating waterfowl decoys to field waterfowl decoys without destroying the floating decoy capability.
Thus, what is disclosed is a mounting device that is used with floating waterfowl decoys to enable the floating decoys to be converted for use in a dry field. This is accomplished by using a mounting platform that is equipped with flexible attaching means that loop over the extended part of the keel on a floating waterfowl decoy.
Also disclosed is the combination of a floating duck decoy and the mounting device along with kits that are the mounting devices for the decoys.
BACKGROUND OF THE INVENTION
The inventor herein is unaware of any prior art devices analogous to the devices of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a full side view of a floating duck decoy mounted to a mounting device of this invention.
FIG. 2 is a full side view of a mounting device of this invention.
FIG. 3 is a full end view of a mounting device of this invention.
FIG. 4 is a full side view of the flat panel without the loops and the detachable rod.
FIG. 5 is a full bottom view of the flat panel without the detachable rod.
FIG. 6 is a full side view of a second embodiment of this invention.
FIG. 7 is a full side view of another mounting apparatus of this invention using two support rods.
FIG. 8 shows the components of the kit for the device shown in FIG. 1 .
FIG. 9 shows the components of the kit for the device as shown in FIG. 6 .
FIG. 10 shows the components of the kit for the device as shown in FIG. 7 plus two elastomeric attachments means.
THE INVENTION
Thus, in a first embodiment of this invention there is disclosed in this specification a field conversion decoy for waterfowl hunting, said field conversion decoy comprising in combination a floatable waterfowl decoy having a keel, wherein the keel has a front end and a back end and a mounting apparatus.
The mounting apparatus comprises a flat panel and attachment means. The flat panel has a predetermined size and thickness. The flat panel has two side edges, each side edge has a center point, a bottom, a top, and the bottom has a centered first opening therein. The centered first opening has a detachable rod inserted therein.
The side edges each have two openings adjoining each other and near the center point thereof to provide a forward pair of openings, one on each side edge of the flat panel and a rearward pair of openings, one on each side edge of the flat panel.
There are two flexible attachment means each having a first end and a second end, one said attachment means has the first end fixed in one side edge forward opening and the second end fixed in the opposite side edge forward opening forming a loop over the front end of the keel.
The remaining attachment means has the first end fixed in one side edge rearward opening and the second end fixed in the opposite side edge rearward opening to form a loop over the back end of the keel.
A second embodiment of this invention is the mounting apparatus for converting floating waterfowl decoys to field waterfowl decoys comprising a flat panel having a predetermined size and thickness, wherein the flat panel has two side edges, each side edge having a center point, a bottom, and a top. In addition, the bottom has a centered first opening in it. The centered first opening has a detachable rod inserted in it.
The side edges of the flat panel each have two openings adjoining each other and near the center point to provide a forward pair of openings, one on each side edge of the flat panel and a rearward pair of openings, one on each side edge of the flat panel.
There are two flexible attachment means each having a first end and a second end, one said attachment means having the first end fixed in one side edge forward opening and the second end fixed in the opposite side edge forward opening forming a loop over the front end of the keel. The remaining attachment means has the first end fixed in one side edge rearward opening and the second end fixed in the opposite side edge rearward opening to form a loop over the back end of the keel.
There is a third embodiment of this invention that is a field conversion decoy for waterfowl hunting, wherein the field conversion decoy comprises in combination a floatable waterfowl decoy having a keel, the keel having a front end and a back end.
There is a mounting apparatus comprising a flat panel having a predetermined size and thickness, a bottom, and a top. The bottom has a centered first opening in it. The centered first opening has a detachable rod inserted in it. There are two separable flexible attachment means for attaching a floating decoy to the mounting apparatus.
In another embodiment, there is a mounting apparatus for converting floating waterfowl decoys to field waterfowl decoys comprising a flat panel having a predetermined size and thickness, a bottom, and a top. The bottom has a centered first opening in it and the centered first opening has a detachable rod inserted in it. There are two separable flexible attachment means for attaching a waterfowl decoy to the mounting apparatus.
In yet another embodiment, there is a field conversion decoy for waterfowl hunting, said field conversion decoy comprising in combination a floatable waterfowl decoy having a keel, the keel having a front end and a back end.
In addition, there is a mounting apparatus comprising a flat panel having a predetermined size and thickness. The flat panel has two side edges, each side edge has a center point, a bottom, and a top. The bottom has two centered first openings in it and each centered first opening has a detachable rod inserted in it.
The side edges each have two openings adjoining each other and near the center point to provide a forward pair of openings, one on each side edge of the flat panel and a rearward pair of openings, one on each side edge of the flat panel.
There are two flexible attachment means each having a first end and a second end, one said attachment means having the first end fixed in one side edge forward opening and the second end fixed in the opposite side edge forward opening forming a loop over the front end of the keel.
The remaining attachment means has the first end fixed in one side edge rearward opening and the second end fixed in the opposite side edge rearward opening to form a loop over the back end of the keel.
Going to another embodiment of this invention, there is a mounting apparatus for converting floating waterfowl decoys to field waterfowl decoys comprising a flat panel having a predetermined size and thickness. The flat panel has two side edges, each side edge having a center point, a bottom, and a top, said bottom having two centered first openings therein. Each centered first opening has a detachable rod inserted in it.
The side edges each have two openings adjoining each other and near the center point thereof to provide a forward pair of openings, one on each side edge of the flat panel and a rearward pair of openings, one on each side edge of the flat panel.
There are two flexible attachment means each having a first end and a second end, wherein one of the attachment means has the first end fixed in one side edge forward opening and the second end fixed in the opposite side edge forward opening forming a loop over the front end of the keel.
The remaining attachment means has the first end fixed in one side edge rearward opening and the second end fixed in the opposite side edge rearward opening to form a loop over the back end of the keel.
Still another embodiment of this invention is a field conversion decoy for waterfowl hunting wherein the field conversion decoy comprises in combination a floatable waterfowl decoy having a keel. The keel has a front end and a back end.
There is a mounting apparatus comprising a flat panel having a predetermined size and thickness, a bottom, and a top. The bottom has two centered first openings in it, each centered first opening having a detachable rod inserted in it.
There are two separable flexible attachment means for attaching the decoy to the mounting apparatus.
Going to another embodiment there is a kit for converting a floating duck decoy to a field decoy. The kit comprises a flat panel having a predetermined size and thickness, said flat panel having two side edges, each side edge having a center point, a bottom, and a top, said bottom having at least one centered first opening in it.
The side edges each have two openings adjoining each other and near the center point thereof to provide a forward pair of openings, one on each side edge of the flat panel and a rearward pair of openings, one on each side edge of the flat panel.
There is at least one detachable rod and two flexible attachment means each said attachment means having a first end and a second end, one said attachment means having the first end fixed in one side edge forward opening and the second end fixed in the opposite side edge forward opening.
The remaining attachment means has the first end fixed in one side edge rearward opening and the second end fixed in the opposite side edge rearward opening.
Finally, there is yet another embodiment of this invention which is a kit for a field conversion decoy for waterfowl hunting, said kit comprising in combination a mounting apparatus comprising a flat panel having a predetermined size and thickness, a bottom, and a top. The bottom has a centered first opening in it.
There is a detachable rod inserted in the centered first opening and two separable flexible attachment means for attaching the decoy to the mounting apparatus.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to FIG. 1 which is a full side view of a floating duck decoy 1 mounted to a mounting device 2 of this invention there is shown a floating duck decoy 1 , having a keel 3 , wherein the keel 3 has a front end 4 and a back end 5 .
Shown in FIG. 2 is a full side view of a mounting device 2 of this invention and FIG. 3 is a full end view of a device of this invention wherein there is shown a flat panel 6 having a predetermined size and thickness. The size and thickness of the flat panel is determined by the size of the decoy that is to be mounted thereon. Thus, duck decoys will require a smaller flat panel 6 than a goose decoy.
Nominally, the duck decoy flat panel 6 will range in size from about 3 to six inches long by about 2 inches wide, an about ½ inch thick, wherein the flat panel 6 for a goose decoy will range about 6 to 10 inches long by about 3 inches wide and about ½ inch thick.
The flat panel 6 is painted or dyed to imitate the bottom of the decoy being used thereon, for example, the common colors are white, gray and black.
The flat panel 6 has two side edges 7 and 7 ′. Each side edge has a center point P for purposes of orientation and clarification of the device with regard to the placement of openings 8 in the rear portion, and the openings 9 in the forward portion.
The bottom 10 of the flat panel 6 has a centered opening 12 in it for purposes of inserting a detachable rod 11 therein. It should be noted that it is not essential that the opening 12 be exactly centered, but in order to balance the decoy, it should be near the center of the flat panel 6 .
The detachable rod 11 is colored to imitate the legs of the various waterfowl, for example, black for geese, yellow for certain ducks, green for certain other ducks and orange for yet other species of ducks.
The detachability aspect of the detachable rod 11 allows for a quick change to accommodate the various species of ducks and geese that are decoyed in to the decoys.
Then, as set forth Supra, each of the side edges 7 and 7 ′ have openings 8 in the rear portion and openings 9 in the forward portion.
The holes 8 and 9 are thus paired in the rearward portion and in the forward portion of the side edges 7 and 7 ′ of the flat panel 6 in order to accommodate flexible attachment means 13 and 14 . The first end 15 of the flexible attachment means 13 is inserted into one side edge rearward opening 8 and the second end 16 is inserted into the opposite side edge opening 8 to complete a loop 17 over the back keel 5 and, the first end 18 of the other flexible attachment 14 is inserted into one side edge forward opening 9 and the second end 19 is inserted into the opposite side edge opening 9 to complete a second loop 20 over the front keel 4 .
The loops 17 and 20 are securely fastened into the openings 8 and 9 to ensure that they securely hold the decoy 1 on the flat panel 6 . It is contemplated within the scope of this invention to provide a recess or groove 27 in the top surface 21 of the flat panel 6 so that the keel 3 can be more securely held in place.
By “flexible” it is meant that the loops 17 and 20 have the capability to be drawn or stretched over the ends of the keel 3 . For example, an elastomeric material may be used that can be stretched and upon placement on the keel 3 , will provide a secure hold on the keel 3 . Yet, the flexibility will allow the elastomeric material to be stretched to remove it from the keel 3 . An example of the elastomeric material would be rubber O-rings that are commercially available. Also, rubber bands would be an example. It is also contemplated within the scope of this invention to use springs to accomplish the same result. It is also contemplated within the scope of this invention to utilize one loop as a non-stretchable material and the other loop to be a stretchable material.
Turning now to FIG. 6 , there is shown another embodiment of this invention which is a floatable duck decoy that is mounted on a mounting apparatus wherein the elastomeric material is rubber O-rings 22 and 22 ′ that are applied around the top 23 of the rod 11 and anchored around the front end 4 and the back end 5 of the keel 3 of the decoy 1 without the necessity of having the ends of the elastomeric material anchored in openings in the sides 24 and 24 ′ (not shown) of the flat panel 25 .
FIG. 7 is a full side view of a mounting apparatus 26 of this invention using two rods 11 as support.
FIG. 8 shows the components of a kit for the embodiment using attachable elastomeric materials for attaching the decoy to the mounting apparatus 2 .
FIG. 9 shows the components of a kit for the embodiment of FIG. 6 and FIG. 10 shows the components of a kit for the double rod embodiment shown in FIG. 7 , wherein in FIG. 8 , there is shown the flat panel 6 , with the channel or groove 27 , the support rod 11 and the elastomeric attaching means 13 and 14 , while in FIG. 9 , there is shown the flat panel 25 , the support rod 11 and the flexible attachment means 22 and 22 ′.
Shown in FIG. 10 is the mounting apparatus 26 , shown in FIG. 7 which comprises the flat panel 25 , with the groove 27 , the flexible attachments means 22 and 22 ′, and two support rods 11 .
The mounting devices of this invention can be manufactured from any water resistant material, such as wood, plastics, metals, such as aluminum, and the like. It is preferred to manufacture the devices of this invention from plastics, because they have the integrity to withstand continuous use and can be manufactured very inexpensively.
The inventive devices herein are used to convert floating decoys having a keel, to use in the field without having to remove or destroy the floating decoy keel. Using floating decoys in a field set up is not desirable because the keels will not allow the decoys to remain upright in the field.
Thus, by this means, a hunter will need to buy only floating decoys, and will not have to buy another set which are field decoys. | A mounting device that is used with floating waterfowl decoys to enable the floating decoys to be converted for use in a dry field. This is accomplished by using a mounting platform that is equipped with flexible attaching means that loop over the extended part of the keel on a floating waterfowl decoy. | 0 |
BACKGROUND OF THE INVENTION
The present application is a divisional of the parent application Ser. No. 10/643,472, filed on Aug. 19, 2003, with claim of priorty of German application 101 36 612.4 file 17 Jul. 2001; and a 317 of PCT/EP02/07321 filed Jul. 3, 2002.
The present invention concerns mechanical controls that, during the operation of an internal combustion engine continuously vary the strokes of individual valves and groups of valves from maximally open to constantly closed, while simultaneously varying how long the valve or valves remain open. The valves are actuated by rocker levers that are in turn driven by subsidiary rocker levers, or by tilting or angled levers. The particular positioning of the subsidiary rocker tilting, or angled levers dictates the length and duration of the stroke. With the exception of one set, the valve-stroke controls allow actuation of the valves in the lower engine speed ranges. In accordance with manufacturers' specifications, once a shorter stroke has been selected, a considerably more acute angle of rotation for the open range of the valves and an angle even more acute in relation to the angle of rotation associated with valve opening will be available for the procedure of opening and closing the valves.
With the exception of further valve-stroke controls, only a little shift in the valve actuation phasing, if any, occurs.
These controls cam be employed for controlling valves without throttling and for valve-and-cylinder turnoff.
Furthermore, valves can be alternately actuated with these controls by using different cams, the shift resulting from the adjustment of control levers and without using switchover coupling bolts. Accessories can be employed to extend maintenance intervals.
These controls feature characteristics of the controls disclosed in Patent Application 100 36 373.3-13, the priority of which is hereby claimed.
SUMMARY OF THE INVENTION
FIG. 1 illustrates valve-stroke controls with an angled lever, actuated by a lateral roller, whereby adjustment involves the action of a planetary gear with rollers on the rocker lever that actuates the valves acting on a sun wheel, the angled lever acting as a planet wheel, and the setting lever acting as a planet carrier.
FIG. 2 illustrates valve-stroke controls with an angled lever laterally actuated by a cam that, by way of rollers fastened to an adjustable articulated rod, drives rocker levers that actuate valves.
FIG. 3 illustrates valve-stroke controls with an angled lever driven by a lateral cam that is articulated to a setting lever such that the lever will execute the motion of a tilting lever, deiving a rocker lever that actuates a valve.
FIG. 4 illustrates valve-stroke controls with two rocker levers, one on each side of a setting lever and each being driven by a cam and driving a rocker lever that actuates a valve.
FIG. 5 illustrates valve-stroke controls wherein the cammed roller is fastened to a horizontal steering lever, preventing a phase shift in valve actuation while the controls are being adjusted.
FIG. 6 is a sectional view of another embodiment of FIG. 4 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates valve-stroke controls accommodated in a cylinder head for the purpose of actuating a valve 1 . A more or less upright angled lever 2 driven by a revolving cam 3 mounted at one edge. One angled-lever setting lever 5 is mounted on each side of angled lever 2 and acts as an accommodation for the swivel 4 that angled lever is mounted in. Angled lever 2 is provided with two structures 6 and 7 that project downward at more or less of a right angle to the longitudinal axis of angled lever 2 . Structure 6 actuates a rocker lever that actuates valve 1 by way of a roller 9 . Structure 7 on the other hand maintains the valve constantly closed.
These valve-stroke controls continuously vary the stroke of the valve from maximally open to constantly closed, while the engine is in operation, but the duration decreases with the length of the stroke. Only a slight phase shift of the valve actuation is possible.
The valve-stroke controls in accordance with the present invention operate on the same principle as a planetary gear, a roller 9 on the swiveling gear representing the sun wheel ad angled lever 3 exercising the function of planet wheel.
Structure 7 has a positively circular curvature and constitutes the roll-over surface of a planet wheel. Angled-levers setting levers 5 act as planet mounts and are provided with a swivel 11 that swivels on cylinder head 10 around the same axis as the “sun” roller 9 on rocker lever 8 as long as valve 1 remains closed. When angled-lever setting levers 5 pivot, accordingly, angled-lever 2 pivots along the circumference of a circle around swivel 11 and hence around the shaft of rollers 9 . When, on the other hand, angled lever 2 pivots, valve 1 is not actuated and its “play” is unaffected as long as the circular structure 7 engages the circumference of roller 9 . In this situation, the distance L between the common axis of rotation of lower swivel 4 on levers 5 and rollers 9 and the one and the axis of rotation of the upper common swivel 4 on levers 5 and angled lever 2 on the other will be the total of radius R 1 of curvature of structure 7 and the radius R 2 of roller 9 : L=R 1 +R 2 when, subsequent to an adjustment on the part of setting levers 5 , negative structure 6 engages the circumference of roller 9 , rocker lever 8 will initially be actuated with only a brief rocking motion around an acute angle of rotation, whereby, as the structure continues to engage the circumference of the roller, the rocking motion and angle of the rocking lever will increase.
For purposes of adjustment, setting lever or setting levers 5 are provided with a contour in the form of an arc of a circle provided with cogs and extending around the axis of rotation of swivel 11 , which is engaged by a driveshaft 13 with matching cogs. The two setting levers, however, can also be driven by an articulated rod subject to an eccentric shaft or crankshaft.
In State A, the controls are set for maximal valve stroke and, in State B, to maintain valves 1 closed. Two valves can be actuated simultaneously, and two angled levers 2 can be employed, one on each side of a setting lever 5 , every angled lever driving a rocker lever that actuates a valve 1 .
The end of the rocker lever 8 that actuates a valve 1 is provided with a valve-play compensator 14 , its upward motion limited by an appropriately positioned adjustable counterbearing 15 . Counterbearing 15 is fastened to the cylinder head and provided with a dashpot. The position of counterbearing 15 allows the controls to function normally even when the upper surface of valve 1 is hit by a valve head and raised. In this event, counterbearing 15 will maintain the engagement between angled lever 4 and the roller 9 on rocker lever 8 unaffected, whereby any displacement of valve 1 will be compensated by compensator 14 .
Since cams 17 can drive angled lever 2 in only one direction, it must be driven in the opposite direction by a resetting component 18 that forces roller 3 against cams 17 .
FIG. 2 illustrates valve-stroke controls accommodated in a cylinder head and intended for the simultaneous actuation of two valves 19 . Each of the two rocker levers 20 is driven by a single roller 21 at the top. Rollers 21 are mounted on the same axis 17 . Axis 22 is secured to the fork uprights of a longitudinally variable articulated rod 23 . Another roller 21 rotates between the others and between the fork uprights.
A more or less upright angled lever 24 is positioned above middle roller 21 and laterally driven by a cam 28 mounted on a roller 29 . The upper end of angled lever rotates on a swivel 25 integrated into the cylinder head. The lower end of the lever is provided with structures 26 and 27 that extend at more or less a right angle to its longitudinal axis and engage middle roller 21 . Structure 26 is responsible for maintaining valve 19 constantly closed and its contour is in the form of a positive circular arc.
The radius R of the arc exhibits a center located in the axis of rotation of swivel 25 . Adjacent to structure 26 , structure 27 , in the form of a negative curve, is responsible for generating a valve stroke. Articulated rod 23 is accommodated in a swivel 30 in a setting lever 31 driven by a driveshaft 32 , and the controls are adjusted by displacing articulated rod 23 over structures 26 and 27 .
These controls make it possible to continuously vary the length of the valve stroke while the engine is in operation from a maximum to constantly closed, whereby the time during which the valve remains open decreases with the length of the stroke.
There is no phase shift.
At angular State A, the valve-stroke controls are set for maximal stroke and, at State B, for maintaining valves 19 constantly closed.
When only one valve 19 is to be actuated, angled lever 24 drives middle roller 21 , while rocker lever 20 is simultaneously driven by the outer rollers 21 . The middle roller has a shorter diameter, preventing torque on articulated rod 23 . It is alternatively possible for the two outer rollers 21 to be driven by angled levers 24 , with the middle roller driven by angled lever 24 (sic).
Cams 28 can drive angled lever 24 in one direction, and it is driven in the other direction by a resetting mechanism 33 that forces the lever and its roller 29 against cam 28 . Resetting mechanism 33 is fastened to angled lever 24 by a swivel 34 and at a swivel 35 to a lever 36 connected to setting lever 31 such that, when the controls are adjusted for a shorter stroke, the restoring force of resetting mechanism 33 will simultaneously increase.
FIG. 3 illustrates valve-stroke controls accommodated in a cylinder head and intended for actuating a valve 37 . A more or less upright angled lever 38 is driven at the top by a cam 40 mounted on a lateral roller 34 . There is a setting lever 41 on each side of angled lever 38 , acting as an accommodation for a swivel 42 in angled lever 38 . Swivel 42 is located at the bottom of lever 38 . Setting lever 41 rotates along with a driveshaft 43 in the cylinder head.
The angled lever 38 in accordance with the present invention operates on the principle of a tilting lever, whereby, however, the lever, in order to actuate a valve 37 , is provided with structures 42 and 45 that extend down at more or less a right angle to its longitudinal axis, with structure 44 driving a rocker lever 46 by way of its roller 47 . Engagement on the part of structure 45 with roller 47 on the other hand maintains valve 37 constantly closed. Structure 47 is in the form of a positively circular arc, its radius R being provided with a center along the axis of rotation of angled lever 38 .
These valve-stroke controls can continuously vary the length of a stroke from maximum to constantly closed while the engine is in operation, whereby the length of time the valve remains open decreases with the length of the stroke.
The phase shift is only slight.
In State A, the controls are adjusted for maximal stroke length and, in State B, for maintaining valve 31 constantly closed.
Cam 40 can drive angled lever 38 in only one direction, and it must be driven in the other direction by a resetting mechanism 48 that forces angled lever 38 and its roller 38 against cam 40 . Resetting mechanism 38 is connected on the one hand to angled lever 38 by a swivel and on the other accommodated in the swivel 49 common to the two setting levers 41 .
FIG. 4 illustrates valve-stroke controls accommodated in a cylinder head and intended for actuating two valves 51 simultaneously. The controls in accordance with the present invention are provided with a setting disk 52 that rotates in a bearing block 54 fastened to a cylinder head 53 . Bearing block 54 also acts on a bearing for accommodating a camshaft 55 and a driveshaft 56 and as a holder for recuperating springs 51 . Setting disk 52 has an axis 58 at one side. On each side of the setting disk is a rocker lever 59 . Each rocker lever 59 is driven by a separate cam 61 mounted on a roller at the top. Rocker levers 59 are provided with downward directed structures 62 and 63 that more or less parallel the longitudinal axis of rocker lever 59 . Each structure 62 drives a rocker lever 64 by way of its roller 65 , whereas structures 63 maintain valves 61 constantly closed.
These valve-stroke controls can continuously vary the length of a stroke between a maximum and constant closure. The duration that a valve is open decreases with the valve stroke. The valve actuation is subject to phase shift, the replacement of one camshaft adjustment mechanism if the camshaft is rotating in the right sense.
These controls operate on the principle of a planetary gear, the rollers 65 associated with the two valves executing the function of a sun wheel, rocker lever 64 that of a planetary wheel, and the positively circular arc the rollover edge of a planet wheel.
Setting disk 52 acts as a planet carrier, its axis of rotation simultaneously being the axis of rotation of the rollers that act as a sun wheel when valves 51 are closed. Thus, as setting disk 52 turns, rocker lever 59 , mounted on axis 58 , will move in a circle around the axis common roller 65 and setting disk 52 , whereby during the rocking motion of rocker lever 59 , valves 51 will not be actuated, and the valve play will remain unaffected as long as positively circular structure 63 engages the circumference of roller 65 . Structures 63 , which maintain valves 51 constantly closed, are in the form of positive circular arcs with a radius R 1 . The center of the circle is along the axis of rocker lever 59 . Radius R 1 plus the Radius R 2 of rollers 65 are as long as the distance L between the common axis of setting disk 52 and rollers 65 on the one hand and the axis 58 of setting disk 52 . Once setting disk 52 has turned and negative structures 62 have come into engagement with the circumference of rollers 65 , rocker lever will be driven, initially around an acute angle, whereas, on the other hand, as the structures continue to engage the rollers, the rocking motion will increase along the angle.
The circumference of setting disk 52 is provided with cogs 66 that extend along it in a circle. These cogs are engaged by the cogs around the driveshaft that rotate in bearing block 54 .
In State A, the controls are set for maximal stroke and, in State B for constantly closed valves 52 .
One valve 51 or three valves 52 simultaneously can be actuated by two setting disks 52 . A rocker lever 59 driven by a cam 61 is mounted between the setting disks 52 on an axis 58 that extends between the setting disks. To actuate three valves 51 simultaneously, another rocker lever 59 driven by a cam 61 is mounted outside setting disks 52 on an axis 58 extending out of the disks. All rocker levers 59 actuate their valves 51 by way of their associated rocker levers 64 .
Since cams 61 drive rocker levers 59 in only one direction, they must be shifted in the other direction by recuperators in the form of rotary springs 57 that force rocker levers 59 and its associated roller 60 against cams 61 .
The shanks of the springs, to simplify their installation and assembly, are inserted into and clamped in the impact range of the divided bearing for camshaft 55 in bearing block 54 .
Due to rocker levers 58 , adjacent and oppositely oriented on various axes 58 of setting disks 52 , valves 51 can be actuated by different cams 61 . Rocker levers 59 are mounted on setting disk 52 on at least two axes 58 such that a rotation on the part of the setting disk group of rocker lever 59 pointing in one sense of rotation will move into the range of engagement with the cams, whereas another group, pointing in the other direction, will simultaneously move out of the range.
FIG. 5 illustrates valve-stroke controls accommodated in a cylinder head and intended for actuating a valve 67 . Resetting of the controls does not result in any valve-actuation phase shift. The controls in accordance with the present invention are provided with a cammed roller 69 mounted on a more or less horizontal driving rod 68 . Driving rod 68 rotates around a control shaft 70 . Below and paralleling driving rod 68 is a rocker lever 71 . Rocker lever 71 is mounted at one end in a swivel 72 that is part of a setting lever 73 that rotates along with control shaft 70 . At its other end, rocker lever 71 is mounted in a swivel 74 in a predominantly perpendicular articulated rod 75 connected to the axis of cammed roller 69 . Below rocker lever 71 is another rocker lever 78 that is provided with a roller 77 . Upwards, roller 77 engages a structure 78 in the form of a negative circular arc on rocker lever 71 . The distance L between the axis of rotation of roller 69 and that of swivel 74 equals the distance between the axis of rotation of control shaft 70 and that of swivel 72 . The radius R 1 of the downward facing structure 78 on rocker lever 71 equals the distance L plus the radius R 2 of the roller 77 on rocker lever 76 —R 1 =L*R 2 .
Since cam 79 can be driven in only one direction, driving rod 68 and rocker lever 71 plus articulated rod 75 must be driven in the opposite direction by a resetting component 80 . Resetting component 80 is connected to the cylinder head at one end and, at the other, by way of a swivel 81 that is part of a lever 82 connected to driving rod 68 , forcing roller 69 against cam 79 .
The controls illustrated in FIG. 4 also make it possible to employ as a setting component a setting lever 83 as represented in FIG. 6 instead of the setting disk 52 hereintofore specified. The axis of rotation of setting lever 83 must, as with setting disk 52 , align with the axis of rotation of roller 65 when its associated valve 51 is closed. Setting lever 83 can be in the form of an angled lever, in which case it will be provided with, remote from its axis of rotation, an axially parallel pivoting accommodation with an axis 58 for a rocker lever 59 . In this event, setting lever 83 will perform the function of setting disk 52 .
Either setting disk 52 or setting lever 83 can be mounted on one side, or, overlapping the controls, on both sides. Setting lever 83 can be turned indirectly by way of a control shaft 56 as depicted in FIG. 6 or directly. | Mechanical controls for continuously varying the length of the stroke of the valves in an internal-combustion engine and for maintaining the valves constantly closed while the engine is in operation while simultaneously varying how long the valve or valves remain open, whereby the valves are actuated by rocker levers that are in turn actuated by an angled lever, whereby the positions of the levers are varied in order to vary the length and duration of the stroke.
The valves are actuated at low engine speeds by assigning a specific narrow angle of rotation to each abbreviated stroke to be established.
FIG. 1 illustrates valve stroke controls with an angled lever ( 2 ) actuated by a cam ( 17 ) mounted on a lateral roller ( 3 ). In the event of a misalignment, a planetary gear comes into play, wherein a roller ( 9 ), mounted on the rocker lever ( 8 ) that actuates the valve ( 1 ) acts a sun wheel, the angled lever ( 2 ) acts as a planet wheel, and a setting lever ( 5 ) acts as a planet bearing. | 8 |
FIELD OF INVENTION
This invention relates to computer systems, and more particularly to an outliner-driven data entry and data retrieval system for use in database management.
BACKGROUND
It has been common to make use of outliners in document preparation systems such as Lotus Manuscript™ and Microsoft Word™. These systems are considered advanced word processing systems intended for the production of hardcopy documents. Outliners have also come into common use as so-called "thought processors" such as the Living Videotex program Thinktank™. However these systems limit the user to outline editing only as opposed to using the outline for defining any database structure. While the Living Videotex follow up program More™ allows the user to perform simple time-management operations and organizational chart preparation in addition to simple outlining, none of the above outliners directly control a complex relational database or permit rearrangement thereof without complex database language reprogramming.
Note, with respect to word processors, these produce "linear" documents which have a clear beginning and end. All word processors provide simple word search and locate features but they perform these functions by locating the word searched in terms of its distance from the beginning of a document. This is a time-consuming scroll search function. Thus they lack advanced key word searching and word occurrence indices.
Also to full-text systems used in on-line and CD-ROM applications, they are constructed in a conventional word processing manner as linear documents having a clear beginning and clear end, with a table of contents. Although these systems use word occurrence indices for information retrieval, the index is invariant and prefabricated.
Thus, in all linear document systems, each selected word is located in the linear document solely from its distance from the beginning of the document. The context in which a particular word is used cannot be stated in a logical expression such as those used in database management systems, thereby making full-text or other linear document systems quite distinct from relational database management systems. Note a relational database is one in which there are one or more databases, each of which contain multiple fields having multiple records; and relations can be made between the fields of the databases. What this means is that in prior full-text or linear document databases, one cannot look for the occurrence of a word in a given field in a particular database, but rather the prior art linear document systems define the position of the word in the document by, for instance, stating how many characters to move from the beginning of the document.
Having discussed common linear document systems and their relative inflexibility as compared with relational database systems, common relational database capabilities nonetheless impose severe limitations. One of the most severe limits to relational database use is the requirement of a complex programming language to define and edit the structure of the database. This programming must be done by a skilled programmer, not the user of the system, which adds cost and complexity both when the database structure is to be changed. Also limits are imposed as to the number of fields per database, the number of records per database, and the number of databases in use during a query operation. Field lengths commonly must be preset to a specific length, typically not greater than 256 characters and must be "predeclared" as a specific type, such as numerical, alpha-numeric, date, or time. Record entry editing is limited to very simple single-line editing operations and commonly allow no carriage returns or text formatting of any kind. Alteration of the structure of such a relational database such as the insertion of a new field, renaming, deletion, or repositioning of an existing field is commonly an extremely cumbersome, if not impossible, operation once data records have been entered into a database. These limits make relational databases unsuitable for use in complex, text-oriented database management tasks.
It should be noted that no relational database management systems utilize an outliner-style text editor for the design of a set of databases and automatic generation of data entry forms. Data entry forms are expressed in a predetermined format and are that which, enable specifying the category definition and structure of the database for data entry. Also, no relational database management system uses an outliner as an interface for querying the database. Outlines reflecting the structure of interrelated databases are simply not utilized.
It should also be noted that so-called text databases commonly support the use of only one database at a time, thereby precluding any true relational operations between databases. Word occurrence indices are often utilized in text databases, but complex, multiple-criteria queries are either not supported or require the use of complex database programming language. Again, outlines are not used for the definition of the database or to perform data retrieval operations.
By way of example of the difficulties in the use of prior relational database systems, and considering the example of a medical student who wishes to construct a database about microbiology, using a common database program like Dbase™ II or III from Ashton Tate, the student must first define his database structures, one database at a time. As the database is defined he must declare the type of field, i.e., alpha-numeric, date, time, or formula, and the field length which is normally limited to a maximum of 256 characters. This field length remains fixed thereafter. As each database is defined, the user has nothing on screen that allows him to view the structure of other databases while he is designing a new one. Normally, users rely on printouts and other visual reminders. Once the structures are established for a set of databases, they cannot be conveniently changed. Thus the addition of new fields, changes of position, or changes of names is inconvenient at best. Databases like those in the Lotus products 1-2-3™ and Symphony™ only allow changes in the database to occur by having the user go through an arduous process of redefining numerous spread sheet ranges used in database operations and inserting or changing fields in all the ranges. The user interface provides no assistance in this process, so the user must remember that a change is only made when all the steps are gone through. The only assistance offered by the system is to deliver messages to the user that certain functions cannot be performed because the database is incorrectly defined; but no specific information about the nature of the error is given. Because of these restrictions on the structure and definition of the database, the student is severely hampered in the data entry phase, particularly in constructing a database for a complex subject such as microbiology where the student will come across facts for which no adequate database field exists and a change must be made. This frequently requires that the user start over which often results in lost data.
Database users, like the medical student, are most frequently non-programmers. Since common databases require the use of a database programming language to execute queries, non-programmers commonly employ database programmers or computer consultants to design and implement their database applications. Each time the user of a database application wants to ask a query that hasn't been asked before or wants to restructure the response, he must call upon the database programmer to write a query and revise the application. This requirement impacts negatively on user productivity and cost containment.
SUMMARY OF THE INVENTION
In the subject system, it was recognized that an outliner in combination with a powerful text-oriented relational database management system would provide the basis for a powerful computer-based information manipulation environment. In order to solve the above problems involved with textual information manipulation and common database systems, the subject invention includes a full-featured outline editor used to define an outline, and a system for automatically generating data entry forms from the database descriptions reflected in the outline. The subject invention also includes a system for updating database records after structural changes are made to the outline and a system for retrieving information from the databases by utilizing the outline to formulate database queries, providing user flexibility, ease of data entry, and powerful information retrieval without the use of a database programming language.
The first major advantage of the Subject System is the use of the outline itself to define the database structure. Both the presentation to the user of an outline and the use of the outline to control, set, change, or query the database, permit complex database creation and use by non-programmers.
It should be noted that another major advantage of the subject system is that the database structure can be changed without losing data. This obviates the need in the prior art for an "import routine" in which all data is stored separately while database changes are made, at which time all the data is re-entered or "imported" from the temporary storage.
Note, since the system is outline driven, it takes advantage of the operator's understanding of the original structure of a topic and displays this structure at all times, so that the interrelationship between data elements of a particular topic is immediately accessible both to the person entering in the data and also to the person retrieving the data.
It will be noted that an outline is commonly utilized to define the structure of whole bodies of knowledge. Because an outline has an inherent tree-type structure, it is possible for an expert in a given field to piece together information in a meaningful way which suits the particular subject addressed by that expert. Thus, the use of the outline is one of the easiest ways to organize thoughts or bodies of knowledge and make the structure intelligible to others. It also makes alterations or corrections to the structure less cumbersome and to a certain extent, error-free.
Thus, with respect to database design and data entry, utilization of an outliner-style text editor allows the rapid and simple design of a complex dataset or set of relational databases. The automatic generation of data entry forms from the database definition specified in the outline without the necessity of declaring the type of field, i.e. numerical, alpha-numeric, date, or time, or having to declare the maximum length of a field simplifies the preparation necessary before actual data entry begins. Data is entered into database fields via a text editor which has many of the capabilities of a true word processor. The lack of limits on the size of fields and therefore records provides the utmost flexibility for the operator.
In one embodiment, a specialized global field is utilized in outline definition, data entry, and data retrieval operations. With respect to outline definition, a global field can be used to insert an identical field name into different databases in order to relate information between databases. In data entry, the global field can be assigned a value which is inserted into records automatically as they are created in any database containing that global field. In data retrieval, if a global field is selected as a search criteria field and a criteria value is set for the search, the system automatically displays only those databases and fields which contain a record for that value in the selected global field, thereby helping to eliminate searches which come up with no information and immediately giving the operator a truncated outline which eliminates irrelevant and confusing information.
In one embodiment, a field mapper, placed in operation only when a database record entry has been made and an outline change of that database category has been indicated, allows the operator to immediately see the changes in the outline prior to updating the records, with the option of going back to the outline should the changes be incorrect or incomplete. In the field mapper, field changes in records are accomplished by a mapping function displayed by the field mapper screen, in which a "one-to-one", "one-to-many", or "one-to-nothing" mapping function may be specified. When the operator is satisfied with a change, the field mapper generates an internal list of update tasks to update the records that already exist upon user confirmation. Updating of the records is therefore accomplished only after the operator is satisfied with the outline changes, insuring that no inadvertent loss of data occurs.
With respect to retrieval, the system utilizes a windowed display, having the database outline, or a portion thereof constantly displayed in an Outline Window. A Criteria Window is provided which indicates fields selected as criteria fields and the values assigned as search criteria. A Response Window is also provided in which records matching the selected criteria are displayed. Complex logical expressions can be constructed in the Criteria Window by combining criteria fields and values with logical operators such as AND, OR, and NOT.
Additionally, it should be noted that the system provides the ability to search for the occurrence of a word anywhere within the databases. The system displays the records in which the word is used in the Response Window and simultaneously highlights in the outline the location or database which contains the occurrence in the Outline Window, thus orienting the user to the context in which the word was used.
In summary, without the utilization of a readily accessible outline and the ability to flexibly modify the outline an expert preparing a large complex database is gravely hampered. It is thus extremely advantageous to provide to the operator inputting information in a database with a system which is both flexible enough to permit rapid insertion of data in database records, relate data throughout a long and complicated outline, and to permit the individual formulating the outline to readily change the outline, check the entered changes, and immediately cause the records to be updated to reflect changes in the structure of the outline.
By preservation and display of the outline, the subject system preserves the structure of the information in the database for the user to see. The outline format uniquely eliminates the retrieval of extraneous data characteristic of full-text database systems, if the original outline is produced in such a fashion that it adequately represents the knowledge entered into the database. Since the outline format is capable of providing the individual with a convenient categorization of the knowledge entered, the outline format permits enhanced productivity both of data entry and data retrieval operations.
Thus, the relational database is defined through the use of an outliner-style text editor which permits rapid error-free definition, editing and rearrangement of information in databases, and automatic generation of data entry forms for the creation of records. Data entry and editing are simplified because changes in the outline are automatically reflected in the forms and thus the records. Data retrieval is driven through the manipulation of the outline to allow simple and complex queries without utilizing a database programming language. An outline defines one or more databases each composed of as many as 32,000 fields, each field capable of arbitrary length determined solely by the amount of data entered into individual records and available memory and storage. In addition to text, fields also can contain graphic images. The number of databases in an outline is limited only by available memory. A specialized global field is utilized in which identical field names may be repetitively inserted into several databases within an outline.
In the data entry mode, a global value can be set and that value is automatically inserted into each database record containing that global field as they are created so that relations are made automatically within the various databases. In the data retrieval mode, the global field can be used to control the display of the outline to truncate the outline to only those categories and fields containing data for a specific global field value, thereby displaying only relevant outline portions.
A field mapper allows the operator to immediately see the changes in the outline and direct old fields to new names or positions and indicate new fields which are to be inserted into the existing records.
The query mode features a continually displayed outline in an Outline Window. Also displayed are a Criteria Window and a Response Window. Criteria are specified in the Criteria Window in which one or more fields are assigned specific values for record call-up. Fields are selected in the Outline Window. Records which match criteria are presented in the Response Window. It is a feature of the query mode that the system highlights categories of the outline which include the particular word selected in the Criteria Window to rapidly orient the user as to where in the outline his query resides.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the subject invention are described in connection with the Detailed Description taken in conjunction, with the Drawings of which:
FIG. 1 is a diagrammatic illustration showing a typical personal computer workstation;
FIG. 2 is a diagrammatic illustration, showing the use of outliners in the prior art of document preparation;
FIG. 3a is a diagrammatic illustration showing the automatic generation of forms from an outline description and the corresponding databases;
FIG. 3b is a block diagram of this subject automatic form generation;
FIG. 3c is a flow diagram of the routine of how form generation proceeds initially and which also examines the outline to determine if any changes have taken place since the outline forms were generated;
FIG. 3d is a flow diagram illustrating the processing of the task list;
FIG. 3e is a diagrammatic illustration of the data entry form from a database category definition;
FIGS. 4a-4h are diagrammatic illustrations showing successive screens indicating the repetitive insertion of a global field into an outline;
FIGS. 5-5k are diagrammatic illustrations showing successive screens indicating the use of the subject global field in the data entry process;
FIGS. 6a-6n are diagrammatic illustrations showing successive screens indicating the operation of the subject field mapper;
FIG. 7 is a flow diagram of the field mapping process;
FIG. 8 is a flow diagram of the updating process of database records called upon successful completion of the field mapping process;
FIG. 9 is a diagrammatic illustration showing the record updating process when a new field, i.e., "field x", is inserted into previously created records after a field mapping process;
FIG. 10a is a diagrammatic representation illustrating prior art outline search and word search retrieval systems;
FIG. 10b is a diagrammatic illustration of the subject query process, illustrating a constantly presented outline in an Outline Window and highlighting of the Criteria Window field in the outline;
FIG. 11 is a flow diagram of various query methods in an embodiment of the subject invention;
FIGS. 12a-12g are diagrammatic illustrations of screens showing one type of query system for the subject invention; and,
FIG. 13 is a diagrammatic illustration showing data retrieval in which a global field is the criteria field, also showing the associated truncation of the outline to only those categories in which the global field contains the criteria value.
DETAILED DESCRIPTION
Referring now to FIG. 1, in a relational database management system, one embodiment of the subject invention is illustrated to include a personal computer system 10 such as an IBM PC or IBM PC compatible computer running the operating system MD-DOS. A typical system includes a monitor display 11, a CPU 12, which includes disk drive units for storage and a keyboard 14, for user input. In the embodiment shown in FIG. 1, for a query mode, the screen pictured includes an Outline Window 16, in which the system displays the outline, or a portion thereof, created by the user defining the structure of a set of databases, or a dataset. As will be discussed in connection with FIG. 10b, during a query, the outline in the Outline Window is constantly displayed for reference. Monitor screen 11 also includes a Criteria Window 18, in which the user specifies the criteria field or fields and a criteria value or values prior to initiating a query or search. This screen also includes a Response Window 20, in which database records which match the search criteria are displayed.
FIG. 2 illustrates one prior art usage of an outliner-style text editor in which an outliner generates an outline 22 which is used in conjunction with a word processor in the preparation of hardcopy documents 24. This Figure depicts the process in which a user, in this case the author of a drug compendium, must go through in order to insert a new section, in this case "Contraindications", into selected portions of document 24. First the user inserts a new heading into the appropriate positions 26 and 28 in the document outline and then the user must scroll through the document and enter text under each "Contraindications" heading 30. As can be seen, this is a cumbersome process. For repetitive entries, errors are commonly made during this transposition process. In short, it is a brute force process which is error-prone.
In contradistinction, FIG. 3a illustrates how an outliner 32 is utilized by the subject system to automatically generate data entry forms 34. A data entry form is defined as a format by which one can systematically enter records into database files. The data entry forms are used in the creation of one or more records which define the contents of a database. Each form is utilized to define one category in the illustrated embodiment. The automatic outline-to-forms generations process is activated by selecting the "DATABASE/GENERATE" menu option in one embodiment of the system. How this is accomplished will be discussed in connection with FIGS. 3b-3e.
Referring to FIG. 3b, the automatic forms generation and resulting database creation is accomplished by the read-out of an outliner 141 which defines an outline established at input 142. This is accomplished by a unit 143 which examines the outline and generates a task list at 145 as further discussed in FIG. 3c. Thereafter, the task list is executed at 147 which defines a format in which database category definitions are entered at 149a. Once having entered the category definitions in a predetermined format by a separate forms generation routine, the automatic forms generation of FIG. 3a is completed through the use of a form display routine as discussed in connection with FIG. 3e, which results in a data entry display 151 which displays the format and selected categories to permit creation of records in files as illustrated at 149b. The display includes a Record Entry Window under control of keyboard 157, with record entries provided at 149b to database 159.
Thus, the automatic database definition takes place by the elements within dotted box 161, via automatic form generation from examination of the outline.
In operation, beginning with the root node, i.e., the first headline of the outline, the program uses a series of recursive calls to find nodes that are candidates to be headings for categories. If the candidate is logically valid as described below, a "task", which describes what actions must be done to the various database files, is generated and appended to the task list. This is the "first pass" phase. After the entire outline has been examined and the user did not interrupt the process, each task is performed. This is the "second pass" phase.
In one embodiment, tasks are generated before they are performed because some may take a long time to execute. Any dialogue can take place during the first pass, with minimal delays for execution. Then the user may let the tasks run without constant attention. Also, this prevents a cascading of errors which might otherwise develop in a badly formed outline.
When the outline fails to meet a logical requirement or when an existing category has been changed, a "stop-test" is generated by the Subject System. The portion of the outline in question is highlighted on the screen, and a short message is printed. The user may elect to stop the process, in which case, none of the tasks are performed.
In one embodiment, the transformation process is also activated implicitly when the Database/Record Entry option is selected. In this instance, only the "node" and "leaves" which are related to the specific category defined by the area around the current node are considered. That is, the recursion starts not at the root node, but a node N, where N is the current node or "owner" of the current node if current is a leaf. For the present purposes a "node" is defined as a "headline" in the outline. A "leaf" is defined as a terminal or final branch on the outline. The "owner" of a current node is defined as the closest prior node at a higher level.
While an outline may generally look any way the user desires, there are certain logical constraints. An outline not meeting these constraints is said to be badly formed. Portions of an outline that are badly formed are generally ignored. That is, they do not lead to the construction of a set of database files, although that may have been the intention of the user.
Generally speaking, a node whose children are all leaves defines a valid category. The headings of the leaves become the field names for the category. An exception to this is that the root heading cannot be a category heading because leaves that are meant to be fields cannot exist on level 1, i.e., the second level of the outline.
During generation, a node whose first child has no children becomes a candidate as a category headline. If the candidate fails further tests, i.e., all of the children are not leaves, a stop-test is generated. There are further constraints placed on an outline after it has once been used to generate a database. These are discussed in the database updating discussion concerning the field mapper which follow.
To illustrate how this accomplished, FIG. 3c is a flow diagram of the automatic outline to data entry form generation inspection system which is invoked by "DATABASE/GENERATION" and "DATABASE/RECORD ENTRY" in the illustrated embodiment of the Subject System. The output of this portion of the system is a list of tasks required to create or update the database files necessary for data entry. Each database definition, consisting of a name of the database and the field names, is displayed through the use of a forms routine. This is shown in FIG. 3d. In FIG. 3c, the system starts by examining the first or current outline node at 154 and determines whether this node is the start of a category definition at 156 by determining if it is the "parent" of a "childless child" or a terminating leaf. If yes, the system checks to determine if this will constitute a new category definition at 158, i.e., did this database category exist in a prior database generation. If yes, a "generate new category task" is generated at 160. If the system determines at 156 that a node is not the start of a category definition, the system determines if it is the location of an old category at 163. If yes, the system adds a "generate location category task" at 165 to the task list and passes on to test for the end of the outline at 165. If a node is not the location of an old category at 163, the system passes to the end of outline test at 165. If a node is the start of a category definition at 156, but is not a new definition at 158, the system determines if the node's category definition has changed at 166. If it has, the system generates a "location change task" at 168 and proceeds to determine if any changes have been made to fields at 170. If the location of the definition has not changed at 166, the system proceeds directly to determine field changes at 170. If any field changes have taken place at 170, the system generates an "update task" at 172 which passes control to the field mapper. If no changes have been made to the fields, the system passes directly to the end of outline test at 164. If this node is not the end of the outline, the system moves to the next outline node at 176 which loops to the beginning process at 154. If the node is the end, the system proceeds to the end of the routine at 174 and subsequent updating processes.
When a structural change to the database is necessary, a task is generated, detailed above in the discussion of FIG. 3c. In the illustrated embodiment of the subject invention, a task is represented by a "struct xform-rec," which actually contains one of the four structures defined for each type of task: the New Record Task, referred to in FIG. 3c as the "new category task" at 159; the Modify Desc Task, referred to in FIG. 3c as the "location category task" at 168 and 162; the Modify Fields Task, which invokes the field mapper at 172; and the Lose Records Task, which is not referred to in FIG. 3c, but is implied by way of failing to satisfy the logical constraints of outline structure imposed by the current embodiment of the subject invention. In this case, a database cannot be constructed, even though the user may intend for it to be. That is the reason the system forms a list of tasks to perform at the end of the inspection and requires confirmation from the user to proceed with the actual updating process, in order to minimize the inadvertent loss of data.
These different tasks are defined by the following subordinate structures containing the parameter necessary to actually perform the appropriate tasks:
______________________________________New Record: Generated when a well formed category has been defined, but its database files have not been created. Parameters are as follows: struct node *pnode - node marking start of category char *fname - the base name of database files char *desc - string that holds recdescModify Desc: The relative location of a category has been changed, so that its category name description must be updated in the fnames database. char *fname - base name of database files char *rdesc - string that holds recdescModify Fields: The leaves of a category have been changed in some way. The structure of the category must be modified. struct node *pnode - node at start of category struct upd-rec *pupd - the update record struct rec-hd *oldhd the old form of the categoryLose Records: A node which once marked a category definition has been found, but it is now badly formed (for example, what used to be a leaf is no longer). The database files will be removed. struct node *pnode - node at start of bad form______________________________________
The update process is actually a subset of the transformation process. If during transformation, a node is found which contains a category name, some update function will be called. If an existing category is found, and it is still well formed, it is tested to see if any changes have been made. First, the current record description is compared to the old one found in the fnames database. If they differ, the appropriate task is generated. Then, the structure of category is tested. The old skeleton is set up and is tested against the category as defined in the outline. They may differ in the number of fields, or just in the spelling of the field names. If there is a change, a stop-test is generated, allowing the user to abort the entire generation process. If it is allowed to proceed, the field mapper is invoked to make an update-rec. The "update-rec" is a linked list, which contains, in order, a record for each field of the new version of the category. Each record contains the old position of the field. The field mapper itself presents lists of the old and new fields. The user chooses fields from the old list to be moved into the fields of the new list. When a node is found with a category, but is now badly formed, a "stop-test" is performed, and if allowed, a "lose-record" task is generated to remove the database files that no longer have a valid category definition.
FIG. 3d is a flow diagram illustrating the processing of the task list generated by the routine which analyzes the outline. First, the routine examines the first item or task in the task list 177. Then, the program calls the appropriate routine to execute the task 179. If the item is a new category task, the program calls this routine 181. First, the routine writes the database category definitions 183 which consists of the set of fields in the category and the category name. The category name is simply a concatenation of the headings on nodes leading to the category. For instance, consider the following outline definition:
+Outline example 1
+Category 1
+Subcategory x
-field 1
-field 2
-field 3
+Subcategory y
-field 4
-field 5
The database category defined starting at the headline node "Subcategory y" has the fields "field 4" and "field 5" and the name of the database category is defined as "Outline example 1/Category 1/Subcategory y".
After the database category definition is written, the program creates the database files 185 which will store the data records on the storage medium. Each database category has two record files: one is for the actual data entered into the records; the other is an index consisting of the first field of each record. The index is used for sorting the records alphabetically. After the files are created and ready to receive data, the program tests for the end of the task list 187. If the end has been reached, the program proceeds to the end of this routine 189 into the data entry routine of FIG. 3e. If not, the program increments the task list 191 and examines the next item 177.
If the task examined is an update task 177, the program 179 calls the update task routine 193. The operation of this routine is fully discussed in FIG. 8. After the update task is complete, the program tested for the end of the task list 187.
If the task examined is a location change task 195, this routine updates the database category definitions to reflect a change in position of the category in the outline 197. This is done by changing the database category name to the new concatenation of node headlines leading to the new position. If the change in position somehow makes the category invalid, the database category files are deleted 199. The routine then examines the list for the end 187 and proceeds either to the end 189 or increments the list pointer 191 and examines the next item 177.
FIG. 3e illustrates the generation of the data entry form from a database category definition. The generalized form 201 consists of a field pointer 203 which moves through the list of field names and a Data Editing Window 205 which is used to enter data into fields in records and operates like a rudimentary word processor. A database category 207 is passed to the form routine and the resulting data entry form is generated 209. Note that the database category name is displayed 211, along with the number of records in the database 213, initially zero, the "New Record" indicator 215, and the list of field names 217 with the field pointer 219 positioned on the first field in the database category.
GLOBAL FIELD-OUTLINE DEFINITION
Frequently, users want to make associations between databases equating or comparing the values of fields which reside in different databases. The subject invention facilitates this type of operation through the use of "GLOBAL" fields. Global fields are used in data entry to provide default value settings.
FIGS. 4a through 4h illustrate the creation and use of a global field in the outline definition phase of one embodiment of the Subject System. What is depicted are successive screens displayed in the global field routine. In FIG. 4a the category "second", here illustrated at 236 has several fields 238 in its definition. A space 240 is inserted into this category where a global field is to be inserted. This is done by pointer or cursor movement and highlighting with an inverse video mask. In one embodiment, the position is moved using the up and down arrow keys on the keyboard. It can be seen that this outline contains one global field 242 easily identified in the illustrated embodiment by the use of an "!" as the first character of the headline. In FIG. 4b, the "Global" 244 menu is displayed and the specific menu item "Set List" 246 is selected and highlighted on screen. The global field list 248 is then displayed, as in FIG. 4c. In this case, there is only one global field 242 defined in the database description as seen in FIG. 4a and therefore only one field value, "omega" is displayed as illustrated at 250. FIG. 4d shows how an asterisk(*) appears next to the global field name "omega" here illustrated 252 when the user presses the space key to select it, making it an element of the current global list. The user presses the Escape key (ESC) to return to the outline in this embodiment of the Subject System. FIG. 4e shows the still unchanged outline. In FIG. 4f, the user has inserted the global list, currently consisting of the single element "omega" into the previously created headline as illustrated at 254 in which the global value is highlighted. This is an operation accomplished by issuing a "CTRL-G" from the keyboard or selecting "GLOBALS/INSERT GLOBALS" from the menu of one embodiment of the system. In FIG. 4g, the user has moved up into another category, in this case "first" and inserted an empty headline 256 into this category by an appropriate keystroke entry. FIG. 4h displays the outline with the highlighted new field at 258 after the global field has been inserted once again.
GLOBAL FIELD-DATA ENTRY
FIGS. 5a through 5k show the use of the global field during the data entry process in one embodiment. Referring to FIG. 5a, the data entry form 260 in the record entry mode highlighted at 261 displays the database category "OUTLINE/FIRST" at 262. A window 264 is provided which serves as a Record Entry Window or a Text Editing Window that includes many of the capabilities of a rudimentary word processor. A "field pointer" 266 is an inverse video mask over field names which is moved from field name to field name by pressing the TAB key on the keyboard entry device. In FIG. 5a the field pointer is pointing to the global field 266.
Global fields are either enabled or disabled during data entry, and the mode is changed through the use of menu item 268 i.e. "DISABLE/ENABLE". If disabled, a global field behaves exactly like a regular field in that data is entered by setting the field pointer on the field name and simply typing the data into the Edit Window.
If enabled, the global field "value" or data is to be entered into all records as they are created and must be entered in a special Edit Window in the global field editor.
FIG. 5b shows the menu item "GLOBAL/DISABLE-ENABLE" 268 being selected. FIG. 5c shows the global field selection screen 270 and the highlighted "GLOBAL FIELDS" window label 271. In this example, there is only one global field 272, "omega". The space key is used to toggle the DISABLE/ENABLE setting and the asterisk appears when the field is enabled. In FIG. 5d the user has enabled "omega" and the asterisk 274 appears next to the field name. ESC, i.e., the escape key, allows the user to leave this screen, which presents the screen in FIG. 5e which displays the global value in the Global Edit window 275 and the enabled global field 277, as well as labeling the window with "GLOBAL VALUES" as shown at 279. For instance, the enabled global field is shown to be "OMEGA"; and the displayed global value is "XYZ". The user types in the text which will constitute the current global value 278 in window 275 and FIG. 5f shows the user selecting the "GLOBAL/EXIT" menu item highlighted at 280. In FIG. 5g, the global value 278 is displayed in the Edit Window 264 when the field pointer is set at the global field as illustrated at 284. This value will be inserted into all records created until it is changed explicitly in the global value editor or the global field is disabled.
Note, the user cannot type directly in the Edit Window 264 when a global field is enabled as indicated at 271 and the field pointer is on that global field.
In FIG. 5h, the user selects the the Record menu 285 and menu item "RECORD/NEXT CATEGORY" as highlighted at 286. Selection of this menu item advances the user from the first category name 262, i.e., "OUTLINE/FIRST" to the data entry form of the next category or database defined by the outline. FIG. 5i shows that the Record Entry mode 261 is selected and that the data entry form of the next category 288 is "Outline/second". Note that the field pointer is on the first field name 290 and the Edit Window 264 is currently empty since the system is in a new record mode as illustrated at 294. In FIG. 5j, the user has advanced the field pointer to the global field 296 with the TAB key. Note that the Edit Window now displays the current global value 278. Next, the user has selected the "RECORD/NEXT CATEGORY" menu item and has advanced to the "Outline/third" 300 category of the outline as illustrated in FIG. 5k. Note that the current global value 278 is again displayed in the Edit Window 264.
In this manner a global field value can be inserted into all records created while the global is enabled and a value is set at the database that has that global field. This can help eliminate transposition and/or typing errors in data entry, in that once a global value has been established it will appear in all relevant records at the appropriate place and all with exactly the same text.
FIELD MAPPING
FIGS. 6a through 6n detail the operation of an embodiment of the subject field mapping system. This mechanism allows the outline description of databases to be edited after database generation and data entry have occurred. FIG. 6a shows the Field Mapping Screen 304 by way of introduction. Here, the field mapper mode is highlighted at 305, with the old field list displayed at 306, the proposed new field at 307, and a match column at 308. Here a cursor arrow 309 points to the new field entry, with the old field entry highlighted at 310. The match is shown at 311. In this screen "delta" is a new field shown at 312, and "--empty--" at 313 in the match column indicates no corresponding old field. This screen thus shows the relative positions of the old and new fields, whether there has been a new entry to the outline and where it is to be located in the outline. As will be seen, the order of the fields can be rearranged in the outline, or otherwise altered so that a revised outline can be created and checked prior to consequent record update and data entry as illustrated by box 316. An --empty-- is illustrated at 318 in old field column 306. This item is matched to any field that is entirely new and not just a change of position or name. FIG. 6b shows a sample outline for purposes of illustration. Note that the field pointer 320 is on the field "!omega". FIG. 6c shows that the user has moved the cursor, inserted a new line and typed in a new heading, in this case "new field" 321. In FIG. 6d it can be seen that the user has moved the cursor to the field formerly titled "gamma" and has now changed it to "gamma rays" as illustrated at 322. In FIG. 6e, the user selects the database menu 323 item 324 "DATABASE/RECORD ENTRY". This action automatically invokes the process described above in the discussion of FIGS. 3a and 3b. In this case, it is found that the outline definition has changed and so in FIG. 6f, the category in question is highlighted as shown at 325 and a message 326 is displayed. A positive reply to the request to continue invokes the field mapper, as seen in FIG. 6g.
Field mapping is a process of matching new field names to old in order to determine how record updating will be done on those records created under the previous database definition. FIG. 6g shows that the "Match" column is initially empty. The list 306 of "Old Fields" includes the highlighted non-field name "--empty--" 318. This item is matched to any field that is entirely new and not just a change in position or name. Note that pointer 309 initially points to the first field name in the list of 307 new fields. FIG. 6h shows "alpha 1" matched at 327 with "alpha 1" in the new field list 307. Note also that the pointer 309 is now moved down one position to the field name "beta 1". FIG. 6i shows the Field Mapper screen after "beta 1" has been matched with itself at 328. Note that the field pointer 309 is now on "new field" illustrated at 330. At this point the "old field" highlighter 310 moves upwardly as shown by arrows 331, until the highlighting cursor reaches the --empty-- notation at the head of the old field list as seen in FIG. 6j at 332, and "--empty--" is matched with "new field" at 334. Now the new field pointer 309 is moved to "gamma rays" as shown at 336. FIG. 6k shows the old field cursor 310 on "gamma 1". Here "gamma 1" is matched with "gamma rays" at 340 and the new field pointer 309 is at "!omega". In a similar manner, the old field name "!omega" is matched with "!omega" in the new field list as highlighted cursor 310 is brought down as illustrated by arrow 343. Once satisfied with the outline as checked by the field mapper, the outline changes are reflected in the automati- cally updated records and database category definition. Thus upon keyboard command in FIG. 6l, the system proceeds directly to the data entry form 344 as indicated by Record Entry mode 261. Note that the system is ready to except a new record as illustrated at 294. Previously created records can be viewed by pressing "PAGE-UP". FIG. 6m shows one such record 348. Note that the value 350 in the first field is preserved in the Record Editing Window 264 by the field mapping process. FIG. 6n shows that the field mapper inserted "new field" but the field is empty in this record 352 window 264.
The ability to freely change the structure of a database definition repeatedly is a crucial feature in a system meant for complex textual information. The field mapper aids this process by allowing the user to make any selected mapping in a highly defined manner and forces confirmation before changes are made to the database records. This forces the user to explicitly enter the exact changes to be made in the database structure when the outline is initially changed and an attempt is made to enter data in the records. The user is informed that the category has been modified and is asked if he wishes to continue. If yes then the field mapper is called and the user is then forced to explicitly define the changes in the database structure with the aid of mapping display.
FIG. 7 is a flow diagram of the routine controlling the field mapping process. After setup as illustrated at 378, the user picks a field from the old list to be paired with the "nth field" in the new list in a selection process as illustrated at 380. The position of the selected field stored in the update record is appended to the update list at 382. As illustrated at 384, the next step increments to the next element of the list to be set as the target in the list of "new fields". The test for the end of list step as illustrated at 386 either returns to selection process 380 or passes control to the system which updates records to reflect the changes.
FIG. 8 is a flow diagram of the update record process after a successful field mapping operation. The process starts as illustrated at 388 by creating a new database to receive the update records and opening the old database for the existing records. Next, as illustrated at 390, the system obtains the position of a field in the old record for the "nth" position, starting at 1, of the new record. The system then determines if the field is new at 392 by determining if the position is greater than zero. If not and the field is new as illustrated at 394, the system creates an empty field and moves the pointer to a new record, increments the update record and determines in the last field that it has been done as illustrated at 396. If not, the process is repeated at 390. If the position is greater than zero as determined at 392, the system moves the pointer to the contents of the field of the new record and increments the update record as illustrated at 398; and tests to see if it is the last field as illustrated at 396. The process is repeated at 390 if it is not the last field as determined at 396. When the last field is processed at 400 the system add the new record to the new database and retrieves the next oldest record, if one exists as illustrated at 402. After repeating the process for all the records, the old database is deleted as illustrated at 404 and the updating process finishes.
FIG. 9 shows a data entry form 406 in which a new field 408 has been inserted, called "field x". Records R1 through Rn are shown after the updating process has inserted the new field "field x" into records 412, but no data has yet been inserted into the records. The data for the new field must be specifically entered by the user or these fields remain empty in the records. What this figure shows is that "field x" is automatically inserted into all records associated with category 1 at the appropriate place. If there are numerous records associated with category 1, the Subject System assures that the repetitive entry is made. This eliminates errors in that when it comes time to give "field x" a value in a record, the record will come up with "field x" at the appropriate place, from whence its value can be entered. Thus no relevant record will be skipped, since each relevant record will have a "field x" blank indicating need for a value if one is desired.
RETRIEVAL
FIG. 10a is an illustration of two prior art retrieval methods. Outline searches as illustrated at 414 are really only of service in the preparation of hardcopy documents. Any outline is typically displayed on the screen and the user positions the cursor 416 on the headline of the section he wishes to edit. Some sort of "Go To" command is given to the system and the system scrolls through the entire linear document until the system positions the document display at that part 418 of document 419. From there, the user must scroll around the document or return to the outline to relocate himself within the document. This method of retrieval is completely different from the subject system. The FIG. 10a system assumes a document, as in word processing, not a set of database records. An outline item here is a headline of a block of text in a document, whereas an outline item in the subject system is a field name in a database with multiple records.
The other major prior-data retrieval method illustrated in FIG. 10a is the word search method commonly utilized in full-text database systems. This type of retrieval does not rely on the user having any prior knowledge of the structure of the underlying information. The user simply enters a word for the system to search for at 420, the system either searches a prefabricated word occurrence index or searches through the text as illustrated at 422 and displays to the user the number of occurrences found at 424, if a word occurrence index is utilized. The user can then as illustrated at 426 view occurrences in the document. In this type of system, it is common for the user to have to sort through several blocks of extraneous information until the user finds the information he's looking for.
In contradistinction and referring now to FIG. 10b, this illustrates the method of data retrieval implemented in the subject invention. In general, the user positions the cursor 428 on a field in the outline for a given database and initiates the query by issuing a command such as "DATABASE/QUERY" at the keyboard of FIG. 1. The criteria field placed in the Criteria Window 430 is that field on which the cursor is positioned in outline 437. The user then assigns a criteria value 432 for the criteria field. The system then examines a word occurrence index 434 which contains the category, record, field and offset into the field for each word in the database, for an occurrence which matches the criteria set by the user. By "offset" is meant the number of characters from the beginning of the field value at which the criteria word occurs. If none are found, the user is notified "Word not Found". If at least one occurrence is found, the system fetches all the records containing the occurrences from the database 436 and displays them in the Response Window 438. The user can freely page through the record occurrences and then return to the outline to initiate another query.
This database querying system thus does not require a document wide search required by a full-text system in which the entire database must be searched. Nor does it simply display the single block of text within a document as in outline/document preparation system.
It will be noted that one's place in the outline is continually available during retrieval in the Outline Window as illustrated by the highlighted cursor 428 and it corresponds to the field in the Criteria Window as illustrated by arrow 439. This convenient display is one part of the subject invention.
Referring now to FIG. 11, this figure illustrates in a more graphic format the query process in the subject invention. Here a pharmacopoeia example is useful and is given for illustrative purposes only.
The user initiates a query by pointing to an outline 440 item 441. The system determines whether a database contains more than one record at 442. If there is only one record, the system fetches at 445 the indicated field from the database record 444 and displays the field as the response to the query at 446. If at 442 the indicated database contains more than one record, the system asks at 448 if the user wants to set a criteria for the query. If not, the system asks at 450 if it should display all the records of a database. In one embodiment of the system, the user can cease this mode of "record browsing" at any point as illustrated at 452. If the user wishes to set a query criteria at 448, a criteria field and criteria value are set by the user at 454. The system finds the record 456 in the indicated database which matches the criteria field and value established by the user and fetches the field 458 indicated when the query was initiated, in this case also displaying the set criteria. This system thus has the advantages of rapidly retrieving information in exactly the desired context.
More particularly, FIG. 12a through 12g describes the operation of the query system in greater detail. In FIG. 12a, the user retrieves a database from off-line storage by entering a retrieve command as illustrated at 459. The outline 460 appears in the Outline Window 437 in FIG. 12b with the cursor positioned on the first item of the outline. The cursor moves freely from item to item in the list by simply using arrow keys to move or utilizing a pointing device for input, such as a "mouse". The user positions the highlighted cursor 461 on "field 2" at 462 in FIG. 12c and selects via keystroke "QUERY/SET CRITERIA FIELD" at 464 to initiate a query. FIG. 12d shows the selected outline item at 466, i.e., "field 2" in the Criteria Window 432 at 466 and the user issuing a "QUERY/SET CRITERIA VALUE" command which is depicted at 468. In FIG. 12e, the criteria value 470 may be set to "xyz" as shown in the Criteria Window 432. FIG. 12f shows a "QUERY/GO" command 472 being issued by the user with the outline cursor 461 on the query or response field "field 1" shown at 474. The system searches for an occurrence of the word "xyz" within field 2 of the database category "Category 1", when it locates a record in which this requirement is fulfilled, it displays the contents of "field 1", the query field in the same records as the occurrence of "xyz" in field 2, the criteria field. For instance if "field 2" is the "name" field and "xyz" is the name; and field 2 is the "street address" field. Then what is displayed in FIG. 12g is, for instance, person "xyz" address 198 Crowninshield Road. FIG. 12g shows first the criteria field and value at 476 and then the query field at 477 and its value 478 from the same record in which the criteria field contains at least one occurrence of the criteria value. The subject query system thus allows the outline to function as a query interface, or opposed to menu prompts or programming language with the outline eliminating the need for remembering the structure of the databases.
FIG. 13 illustrates the special case retrieval involving the use of the global field as the criteria field. When the global field "!Field x" in outline 480 is set as the criteria value, there is an option in one embodiment of the system which examines the database records and displays at 482 only the categories and fields in the outline which include at least one occurrence of the criteria value in the global field specified as the criteria field. This option allows the user to selectively narrow the search to only those areas of the database containing the specified global criteria. Thus, for instance, category 2 is skipped as illustrated at 484 because there is no "field x"; and category 4 is skipped as illustrated at 486 because "field x" has no value. This results in truncated outline 482 being presented on screen which leaves out any extraneous outline entries and permits easier conceptualization for retrieval. Note, as shown at 490 records 492 containing "field x" may have a value assigned as illustrated at 494; or no value as illustrated at 496.
Having above indicated a preferred embodiment of the present invention, it will occur to those skilled in the art that modifications and alternatives can be practiced within the spirit of the invention. It is accordingly intended to define the scope of the invention only as indicated in the following claims. | A relational database is created and queried through the use of an outliner-style text editor which permits automatic generation of data entry forms for the creation of records. Data entry and editing are simplified and errors are minimized because changes in the outline are automatically reflected in the data entry forms and thus the automatically updated records. Data retrieval is driven through the manipulation of the outline to allow simple and complex queries without utilizing a database programming language. A specialized global field is utilized in which identical field names may be repetitively inserted into several databases. In the data entry mode, a global value can be set and that value is automatically inserted into each database record containing that global field as they are created so that relations are made automatically within the various databases. In the data retrieval mode, the global field can be used to control the display of the outline to truncate the outline to only those categories and fields containing data for a specific global field value, thereby to display only relevant outline portions. A field mapper allows the operator to immediately see the changes in the outline and direct old fields to new names or positions and indicate new fields which are to be inserted into the existing records, all prior to execution of the changed outline in terms of data entry. The query mode features a continually displayed outline in an Outline Window. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to an accessory or attachment for semi-automatic firearms, and more particularly to an accessory removably attached to the trigger guard of a conventional semi-automatic firearm allowing the user to achieve burst firing of the firearm.
Semi-automatic firearms presently available on the market do not permit burst firing of several rounds of ammunition through a single pull of the trigger. Only military weapons are provided with control means, generally associated with a safety, which permit, at will, either single shot firing of the weapon or burst firing according to the selected firing mode.
Private ownership of automatic firearms generally violates the firearm registration laws of the United States. Conversion of semi-automatic firearms into automatic firearms through reconstruction or modification of the trigger and sear mechanism, and possession of such converted firearms is also prohibited under the United States registration laws for firearms. However, it is permissible to convert a conventional semi-automatic firearm to one capable of firing a short burst of rounds through repeated actuation of the trigger, thus duplicating the normal action of a finger during normal rapid firing of the weapon.
In U.S. Pat. No. 4,276,808, there is disclosed a burst firing attachment consisting of a device removably attached to the firearm trigger guard. The device comprises a crank rotating a rotor operating a striker rod. The striker rod projects against the firearm trigger and is reciprocated by lobes or cams on the rotor, when the crank is rotated.
While such a device accomplishes the purpose of permitting burst firing of a firearm, rotation of the crank with one hand while attempting to hold and stabilize the firearm with another hand is "unnatural" and awkward, is disruptive of careful aiming, and may somewhat be considered as being dangerous as the crank may be accidentally rotated, or may become caught in clothing or in bushes.
SUMMARY OF THE INVENTION
The present invention provides a simple and low-cost burst firing attachment or accessory for conventional semi-automatic firearms, such as a semi-automatic rifle, removably attached to the trigger guard of the firearm, and comprising an actuating member in the form of a trigger-like lever allowing burst firing of a few rounds of ammunition as a result of a single stroke of the trigger-like lever.
The many objects and advantages of the present invention will become apparent to those skilled in the art when the following description of the best mode contemplated at the present for practicing the invention is read in conjunction with the accompanying drawing wherein:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevation view of an example of structure according to the present invention, shown attached to a firearm trigger guard and with portions broken away to show the internal construction;
FIG. 2 is a transverse section substantially along line 2--2 of FIG. 1; and
FIG. 3 is a section substantially along line 3--3 of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawing and more particularly to FIG. 1, a rapid fire accessory or apparatus 10 according to the invention is illustrated removably attached within the trigger guard 12 of a semi-automatic firearm, such as for example a 22-caliber semi-automatic rifle, a portion of the stock 14 of the rifle being only shown in the drawing. A trigger guard 12 surrounds the firearm trigger 16 which projects from below the stock 14 and which, as is well known, it normally pulled by a finger for firing the rifle. The trigger 16, which pivots around a pivot point within the stock 14, is normally urged toward its forward position by appropriate spring means, not shown, such forward non-firing position being illustrated at FIG. 1.
The burst firing apparatus 10 of the invention comprises a housing 18, which may be made of rigid high impact plastic or of metal, preferably light metal such as aluminum. The housing 18 is clamped to the trigger guard 12, as shown, for example by being provided on one side with a groove 20, FIG. 2, engageable over an edge of the bottom portion of the trigger guard 12, and by being provided, on the other side, with a clamping thumbscrew 22, or preferably a pair of clamping thumbscrews 22, each threadably disposed transversely through a threaded bore 24 in a boss 26 integrally formed in the housing 18 and having a tapered tip 28 projecting below the opposite edge of the bottom portion of the trigger guard 12 when the thumbscrews 22 are tightened, thus drawing the lower surface 29 of the housing 18 in firm engagement with the bottom interior surface of the trigger guard 12.
A shaft 30 is transversely disposed in the housing 18, and has an end journalled in an appropriate bore 32 formed in a boss 34 on one side of the housing 18. The shaft 30 is supported at its other end in a bore 36 formed in a cover plate 38 closing the other open, side of the housing 18. The shaft 30 has an end projecting beyond the cover plate 38 around which is mounted a pinion 40. The pinion 40 is appropriately attached to the projecting end of the shaft 30 such that rotation of the pinion 40 causes rotation of the shaft 30. The pinion 40, FIGS. 2 and 3, is capable of being driven in rotation by a sector rack 42 mounted on, or made integral with, a pivotable lever 44. The pivotable lever 44 is provided at its upper end with a pin 46 projecting laterally through a bore 48 disposed in a boss 50 formed at the upper end of an integral flange extension 52, FIG. 1, of the housing 18. The pin 46 is, for example, press-fitted in an appropriate bore 52, FIG. 2, formed in the end of the lever 44, and is prevented from being pulled from the bore 48 by any conventional retaining means such as a spring snap ring retainer 54, FIG. 2, engaged in a groove, not shown, in the projecting portion of the pin 46.
A ratchet wheel 56, FIG. 2, is fixedly mounted on the shaft 30 on the other side of the cover plate 38 and has a side face provided with inclined teeth 58 normally engaged with similarly disposed inclined teeth 60 formed on a side face of a lobed rotor 62 mounted freely rotatable on the shaft 30. A compressed coil spring 70, disposed around the shaft 30 between the other side of the lobed rotor 68 and a shoulder abutment on the shaft 30, in the form of a snap spring ring 72 disposed in an appropriate groove, not shown, in the periphery of the shaft 30, constantly urges the lobed rotor 68 with its teeth 60 on its side in engagement with the teeth 58 of the ratchet wheel 56. As a result of the inclined ratchet wheel lateral teeth 58 co-operating with the inclined rotor lateral teeth 60, there is formed a one-way clutch arrangement, generally designated at 74 which, when the pinion 40 is rotated, thus rotating the shaft 30 and in turn rotating the ratchet wheel 56, causes rotation of the lobed rotor 62 in one direction only, the direction of rotation of the lobed rotor 62 being clockwise, as illustrated at FIG. 1. A striker member 76 which, preferably, is in the form of a rectangular plate, is slidably disposed through an aperture 78 in the side of the housing 18 proximate to the rifle trigger 16 such that the end 80 of the striker member 76 is engaged with or disposed proximate the end portion of the trigger 16.
The lever 44 is provided with a trigger-like extension 82, or secondary trigger, which, upon pulling by a finger, pivots the lever 44 and therefore drives the pinion 40 through the arcuate rack 42. Rotation of the ratchet wheel 56, coupled to the pinion 40 through the shaft 30 causes the lobed rotor 62 to be rotated clockwise, thus in turn reciprocating the striker member 76, with the result that the rifle trigger 16 is sequentially reciprocated, and a burst of ammunition rounds is fired. The rifle trigger 16 is returned to the position shown in full line at FIG. 1 by the spring bias associated with the trigger, and after the secondary trigger 82 has been displaced from the position shown in full line at FIG. 1 to the position shown in phantom line during burst firing, it is returned to its original position by means of a return helical spring 84 having a bent up portion 86 engaged in a slot 88 in the housing 18 and another end attached, for example, to an abutment tang, not shown, on the ratchet wheel 56. During return of the secondary trigger 82 under the action of the return spring 84, reverse rotation of the ratchet wheel 56 causes reverse rotation of the pinion 40, thus driving the arcuate rack 42 and the lever 44 to their return position. The lever 44 has a lateral abutment surface 89, FIG. 3, engageable with the top of the teeth of the pinion 40 in the return position of the secondary trigger 82 formed at the end of the lever 44. The direction of inclination of the lateral teeth 58 and 60 of, respectively, the ratchet wheel 56 and the lobed rotor 62, allow reverse rotation of the ratchet wheel 56, shaft 30 and pinion 40 while, even if the lober rotor 62 were frictionally urged in a counter-clockwise rotation by the rotation of the shaft 30, one of the lobes 68 abutting against the upper surface of the striker member 76 prevents counter-clockwise rotation of the lobed rotor 62.
If so desired, a secondary trigger guard 90, FIGS. 1 and 2, is mounted around the secondary trigger 82, for the purpose of safety. The secondary trigger guard 90 may be removably attached to the primary trigger guard 12 or, in the alternative and as shown, it may have an end 92 attached to the bottom of the housing 18, as shown at FIG. 1 and another end 94 in the form of a bracket attached below the housing 18 at the boss 26, FIG. 2.
It will be appreciated by those skilled in the art that the present invention can take forms other than the example of structure specifically illustrated and described hereinbefore. For example, the one-way clutch arrangement 74 can take the form of any one of a variety of well known one-way clutch drive mechanisms, incorporated in the lobed rotor 62 or, alternatively, in the pinion 40, such one-way clutch drive mechanism being, for example, of the pawl and ratchet type, or of the wedging ball or roller type. It will also be appreciated that the lobed rotor 62 may be provided with a smaller or greater number of lobes 68, and with different lobe shapes, without departing from the spirit and scope of the present invention. | An attachment or accessory, for semi-automatic firearm, comprising a housing releasably attached to the trigger guard of the firearm, a rotor member rotatably supported in the housing and having cams or lobes adapted to repeatedly actuate the firearm trigger through the intermediary of a rocker member actuated by the rotor cams when the rotor member is rotated. A lever-supported crank and a meshing pinion arrangement rotates the rotor through a one-way clutch coupling when the lever is displaced in one direction, the one-way clutch coupling disconnecting the rotor from the pinion when the lever is displaced in an opposite direction to a return position. | 5 |
BACKGROUND
1. Field of the Invention
Generally, the invention relates to holders for circular saw blades. More specifically, the invention relates to such holders which retain the circular saw blade for display at a point of sale wherein substantially the entire face of the circular saw blade is exposed.
2. Description of the Prior Art
Numerous methods exist to display circular saw blades at a commercial sales outlet where the circular saw blades may be examined by a consumer prior to a sales transaction taking place.
It is known to position the circular saw blades for inspection without any packaging about the circular saw blades. A plurality of identical circular saw blades will often be positioned on a shaft slightly offset from vertical with the central mounting aperture of the circular saw blades engaging the shaft where each circular saw blade may freely rotate about the shaft. Similarly a plurality of identical circular saw blades will often rest on two spaced parallel shafts which extend from a back member. The circular saw blades engage the shafts at the working edge of each respective circular saw blade while the circular saw blades lean against the back member or the preceding circular saw blade. When the circular saw blades are displayed without any packaging it is difficult, if not impossible, to provide for anti theft security devices against potential theft.
The circular saw blade or circular saw blades may be displayed with a packaging thereabout for various useful reasons. These reasons include providing for inclusion of anti theft security devices, providing for a proper rotational orientation of the circular saw blade where printed material on the face of the circular saw blade may readily be examined and presenting the circular saw blade in a more appealing manner.
When a packaging is provided a single circular saw blade may be contained within the packaging, a plurality of identical circular saw blades may be contained within the packaging or a plurality of circular saw blades having unique characteristics may be contained within the packaging. Many types of packaging are known in the art. Examples of applicable packaging include those: of a type which permits the circular saw blade to be removed from the packaging for inspection and replaced in the packaging, of a type which permits touching of the working edge of the circular saw blade without removing the circular saw blade from the packaging, of a type which restricts removal of the circular saw blade from the packaging while permitting visual inspection of the circular saw blade without permitting touching of the working edge of the circular saw blade or of a type which restricts removal of the circular saw blade from the packaging and which does not permit either visual inspection of the circular saw blade nor touching of the working edge of the circular saw blade.
An example of the type which permits the circular saw blade to be removed from the packaging for inspection and replaced in the packaging involves a simple paper sleeve or envelope of paper which may have a transparent window therein where the sleeve or envelope is not sealed.
An example of the type which permits touching of the working edge of the circular saw blade without removing the circular saw blade from the packaging involves a sealed envelope of cardboard which partially surrounds the circular saw blade while leaving at least a portion of the working edge exposed.
An example of the type which restricts removal of the circular saw blade from the packaging while permitting visual inspection of the circular saw blade without permitting touching of the working edge of the circular saw blade involves a cardboard backing panel with the panel and the circular saw blade contained in a transparent wrapping.
An example of the type which restricts removal of the circular saw blade from the packaging and which does not permit either visual inspection of the circular saw blade nor touching of the working edge of the circular saw blade involves a sealed paper sleeve or envelope.
Some packaging methods fall within more than one of the above identified types of packaging. One example of this involves the closest prior art relevant to the present invention and depicted in the drawings and labeled as ‘prior art’. This packaging permits full visual inspection of the circular saw blade while attached to the packaging, permits touching of the working edge of the circular saw blade while attached to the packaging and permits removal of the circular saw blade from the packaging and replacement of the circular saw blade relative to the packaging.
Various deficiencies exist with each of the above identified methods of display of circular saw blades and each of the above identified types of packaging for circular saw blades. Additionally, each of the above identified methods of display of circular saw blades and each of the above identified types of packaging for circular saw blades present problems with inclusion of security tags to prevent theft. In the case of individually displayed circular saw blades without any packaging the only option available is to adhesively attach the security tag directly to the circular saw blade where consumers can readily identify the security tag and can easily remove the security tag from the circular saw blade. Due to the thickness of commonly used security tags such attachment renders a plurality of circular saw blades awkward to stack whether stacked vertically or generally horizontally utilizing a shaft or shafts. In the case of circular saw blades in packaging where the circular saw blade may be readily removed from the packaging the security tag may either be adhesively attached to the circular saw blade or to the packaging. In either instance theft of the circular saw blade may readily occur by separating the circular saw blade from the security tag. Depending upon the attachment location of the security tags a similar stacking problem may arise due to the thickness of commonly used security tags. In the case of sealed packaging the security tag may be positioned inside of the packaging to prevent separation of the circular saw blade from the security tag but such packaging also prevents inspection of the circular saw blade by the consumer.
As can be seen various attempts have been made to provide for presentation of circular saw blades and/or packaging of circular saw blades for sale to the public. These attempts have been less efficient than desired. As such, it may be appreciated that there continues to be a need for a circular saw blade holder capable of adequate display of a circular saw blade for inspection, both visual and tactile, by a consumer while the blade is securely attached relative to the circular saw blade holder where the circular saw blade may not be readily removed from the circular saw blade holder or otherwise tampered with and which provides for a secure placement of a security device to reduce the likelihood of theft of the circular saw blade. The present invention substantially fulfills these needs.
SUMMARY
In view of the foregoing disadvantages inherent in the known methods of displaying circular saw blades, your applicant has devised a method of retaining a displayed circular saw blade utilizing a circular saw blade holder. Applicable circular saw blades have a face, a back, a central mounting aperture and a working edge circumferentially disposed about the central mounting aperture. The circular saw blade holder provides for point of sale display of the displayed circular saw blade wherein substantially the entire face of the displayed circular saw blade is exposed for viewing when the displayed circular saw blade is retained by the circular saw blade holder. The circular saw blade holder has a blade contact surface and means to secure the displayed circular saw blade relative to the blade contact surface. The blade contact surface provides for a contact with at least a portion of the back of the displayed circular saw blade when the displayed circular saw blade is retained by the circular saw blade holder. The securing means utilizes the central mounting aperture of the displayed circular saw blade. The securing means also has release means to provide for a single release of the displayed circular saw blade from the circular saw blade holder. The release means prevents a secured replacement of the displayed circular saw blade relative to the circular saw blade holder subsequent to the single release of the displayed circular saw blade from the circular saw blade holder by a consumer.
My invention resides not in any one of these features per se, but rather in the particular combinations of them herein disclosed and it is distinguished from the prior art in these particular combinations of these structures for the functions specified.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
It is therefore a primary object of the present invention to provide for means to secure a circular saw blade within a circular saw blade holder wherein substantially the entire face of the circular saw blade is exposed for viewing.
Other objects include;
a) to provide for the means to secure to prevent a secured replacement of the circular saw blade relative to the circular saw blade holder by a consumer subsequent to release of the circular saw blade from the circular saw blade holder.
b) to provide for the means to secure to utilize a bonding of a portion of the circular saw blade holder relative to another portion of the circular saw blade holder utilizing a sonic welding procedure where the circular saw blade is retained between the two portions.
c) to provide for a pull release of the securement of the circular saw blade from the circular saw blade holder.
d) to provide for circular saw blade holder to have a radial perimeter where the circular saw blade holder has a circular shape.
e) to provide for a radially disposed surrounding lip to provide for restricting incidental contact with at least a portion of the working edge of the circular saw blade when retained by the circular saw blade holder.
f) to provide for a hanging portion having an aperture therethrough to extend from the radial perimeter of the circular saw blade holder for positioning the circular saw blade holder in a hanging manner on a retail display hook.
g) to provide for means to contain a security tag on the circular saw blade holder where ready access to a security tag by a consumer is prevented.
h) to provide for the means to contain the security tag to utilize a containment housing sealed utilizing a sonic welding procedure.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated the preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein;
FIG. 1 is a front exploded perspective view of a circular saw blade holder, having a body and a pull tab, and a circular saw blade and a security tag.
FIG. 2 is an exploded perspective view of the components shown in FIG. 1 with the circular saw blade and the security tag positioned relative to the body of the circular saw blade holder.
FIG. 3 is a perspective view of a fully assembled circular saw blade holder including placement of the circular saw blade.
FIG. 4 is a sectional view of the body of the circular saw blade holder as taken from the section line ‘ 4 ’ shown in FIG. 1
FIG. 5 is a sectional view of the pull tab of the circular saw blade holder as taken from the section line ‘ 5 ’ shown in FIG. 1 .
FIG. 6 is a rear exploded perspective view of the body and pull tab of the circular saw blade holder shown in FIG. 1 through FIG. 3 .
FIG. 7 is a side plan view of a portion of the body with the pull tab positioned thereon and a portion of a sonic weld device positioned thereon during a bonding procedure.
FIG. 8 is a front exploded perspective view of a prior art circular saw blade holder having a body and a retaining nut and labeled as ‘Prior Art’.
FIG. 9 is a rear exploded perspective view of the assembly shown in FIG. 8 and labeled as ‘Prior Art’.
FIG. 10 is a perspective view of the prior art circular saw blade holder shown in FIG. 8 and FIG. 9 with a circular saw blade retained thereon and labeled as ‘Prior Art’.
FIG. 11 is a sectional view of the body of the prior art circular saw blade holder as taken from the section line ‘ 11 ’ shown in FIG. 8 and labeled as ‘Prior Art’.
FIG. 12 is a sectional view of the retaining nut of the prior art circular saw blade holder as taken from the section line ‘ 12 ’ shown in FIG. 8 and labeled as ‘Prior Art’.
DESCRIPTION
Many different systems having features of the present invention are possible. The following description describes the preferred embodiment of select features of those systems and various combinations thereof. These features may be deployed in various combinations to arrive at various desired working configurations of systems.
Reference is hereafter made to the drawings where like reference numerals refer to like parts throughout the various views.
Many types and sizes of circular saw blades may be retained by a circular saw blade holder having features of the present invention for various useful purposes including point of sale display of the displayed circular saw blade. When so retained by the circular saw blade holder the working edge and substantially the entire face of the displayed circular saw blade are exposed for inspection by a consumer including visual inspection as well as tactile inspection of the working edge of the circular saw blade.
An example circular saw blade 20 , as conventionally known and shown in FIG. 1 through FIG. 3, has a face 22 , a back, not shown, a central mounting aperture 24 and a working edge 26 circumferentially disposed about central mounting aperture 24 . As depicted various information 28 associated with a respective blade is often printed on face 22 of circular saw blade 20 . Central mounting aperture 24 is conventionally utilized to mount circular saw blade 20 on a circular saw, not shown. Central mounting aperture 24 is utilized by circular saw blade holders having features of the present invention for retention of circular saw blade 20 relative to the respective circular saw blade holder.
Circular saw blade holders having features of the present invention may have various configurations including variations in size and shape. An example is depicted in FIG. 1 through FIG. 6 where a circular saw blade holder 30 has a body 32 and a securing tab 34 . Body 32 and securing tab 34 may be formed by various manufacturing methods from various materials. Preferably body 32 and securing tab 34 are each formed from a plastic material utilizing a molding process.
Body 32 has a front 36 and a back 38 , see FIG. 6 . Body 32 has a blade contact surface 40 to provide for a contact with a portion of the back, not shown in the various views, of a displayed circular saw blade 20 . While a solid blade contact surface 40 is possible preferably blade contact surface 40 will utilize as little material as possible to reduce manufacturing costs and reduce weight. To this end a plurality of openings 42 are provided within blade contact surface 40 while retaining structural integrity.
Blade contact surface 40 has a central area 44 , a plurality of spokes 46 and a radially disposed section 48 . Blade contact surface 40 has a central position 50 which in the embodiment depicted defines a passageway 52 through body 32 . Passageway 52 may be utilized to hang circular saw blade holder 30 on a display hook, not shown, in a retail setting. Each spoke 46 extends from central area 44 to radially disposed section 48 . The plurality of openings 42 are defined within blade contact surface 40 by each adjacent pair of spokes 46 and radially disposed section 48 .
The spokes may have any desired orientation on the circular saw blade holder. Additionally, the deployed spokes may be identical or have a mixture of sizes and/or shapes on the circular saw blade holder. Similarly the openings defined in part by the spokes may have any desired orientation on the circular saw blade holder including a mixture of sizes and/or shapes.
A blade engagement portion 54 , a blade engagement post in the embodiment depicted, is radially disposed about passageway 52 and extending generally perpendicularly outward from blade contact surface 40 . Blade engagement portion 54 is of a size to provide for radial containment of circular saw blade 20 utilizing central mounting aperture 24 of circular saw blade 20 when retained by circular saw blade holder 30 . Passageway 52 is aligned with central mounting aperture 24 of circular saw blade 20 when circular saw blade 20 is retained by circular saw blade holder 30 .
A surrounding lip 56 is radially disposed about blade engagement portion 54 and blade contact surface 40 and partially defines a holder perimeter 58 . Holder perimeter 58 is radially disposed about central position 50 of blade contact surface 40 . Surrounding lip 56 provides for restricting incidental contact with working edge 26 of circular saw blade 20 when circular saw blade 20 is retained by circular saw blade holder 30 . This acts to prevent injury to consumers which may result from contact with working edge 26 and also prevents damage to working edge 26 during transport and handling. Preferably holder perimeter 58 does not extend beyond surrounding lip 56 other than for a hanging display portion 60 in order to reduce manufacturing costs and weight. It is possible to provide for additional surface areas beyond surrounding lip 56 for various useful purposes.
Hanging display portion 60 extends from surrounding lip 56 . Hanging display portion 60 has a modified slot 62 for the embodiment depicted. Modified slot 62 has a rod engagement portion 64 thereon. Modified slot 62 provides for positioning of circular saw blade holder 30 in a hanging manner on various types of retail display hooks, not shown. Preferably circular saw blade 20 will be oriented during installation on circular saw blade holder 30 where information 28 is positioned relative to hanging display portion 60 .
Securing means provides for a securing of circular saw blade 20 utilizing central mounting aperture 24 relative to circular saw blade holder 30 and specifically relative to blade contact surface 40 of circular saw blade holder 30 . Many different securement methods and associated structures may be employed to perform this function. Preferably a first securement portion, positioned on body 32 of circular saw blade holder 30 , and a second securement portion, being a separate component, cooperate to provide for the securing of circular saw blade 20 relative to circular saw blade holder 30 utilizing an engagement of the first securement portion and the second securement portion together with circular saw blade 20 therebetween. Various engagement methods may be employed to secure the two portions together. Examples of such engagement methods include binding engagement securing, adhesive securing and thermal securing such as sonic welding. In the most preferred embodiment depicted a sonic welding procedure, as conventionally known in the art and not depicted, is employed wherein a vibratory friction is created between the two components to slightly melt the contacting surfaces areas to bind them together.
FIG. 7 depicts a portion of body 32 with pull tab 34 positioned thereon and a portion of a sonic weld device 65 positioned thereon during a bonding procedure, as conventionally known in the art.
Without regard for the engagement method selected it is a strong desire to provide for release means where the retained circular saw blade may easily be removed from the circular saw blade holder. Preferably the release means provides for a single release of the displayed circular saw blade from the circular saw blade holder. This single release prevents a secured replacement by a consumer of a displayed circular saw blade relative to the circular saw blade holder subsequent to the single release. This prevents tampering or substitution of another circular saw blade for the circular saw blade intended for the circular saw blade holder.
It is possible to provide the blade engagement portion with a series of release slots thereon where the bonding between the blade engagement portion and the pull tab is not radially complete but rather has a series of gaps in the bonding to provide for easy release during the pulling procedure to release the secured circular saw blade from the circular saw blade holder.
In the preferred embodiment depicted securing tab 34 is utilized for cooperation with blade engagement post 54 of body 32 to provide the desired securing. Securing tab 34 has a front 66 and a back 68 , see FIG. 6 . Securing tab 34 anchors to blade engagement post 54 to provide for the securing of the displayed circular saw blade relative to blade engagement post 54 . Securing tab 34 has a post engagement portion 70 and a gripping portion 72 . Post engagement portion 70 of securing tab 34 slips over blade engagement post 54 of body 32 with circular saw blade 20 positioned on blade engagement post 54 and is secured there utilizing a sonic welding procedure. Gripping portion 72 has opposing elevational humps 74 , see FIG. 6, which touch circular saw blade 20 following installation to elevate gripping portion 72 slightly above face 22 of circular saw blade 20 where ready access is provided for the consumer to grip gripping portion 72 . In use the consumer grips gripping portion 72 of securing tab 34 and exerts a pulling action to separate securing tab 34 from body 32 . Following such removal of securing tab 34 circular saw blade 20 may readily be removed from circular saw blade holder 30 . Securing tab 34 has a passageway 76 therethrough which aligns with passageway 52 of body 32 following assembly.
Various anti rotation methods may be employed to prevent circular saw blade 20 from rotating within circular saw blade holder 30 relative to hanging display portion 60 . Separate structural elements may be provided on circular saw blade holder 30 to perform this function. When the preferred securing method of sonic welding is employed this is not required due to the tight containment obtainable between blade contact surface 40 and securing tab 34 which prevents rotation of circular saw blade 20 positioned therebetween.
While blade engagement post 54 is depicted as being part of body 32 the portion which engages the interior wall of central mounting aperture 24 of circular saw blade 20 may be positioned on the pull tab portion and secured to body of circular saw blade holder 30 following placement of circular saw blade therebetween.
A security tag, as conventionally known in the art, may be used with the circular saw blade holder. Such security tags have means to operate with a retail security system to prevent theft. Many such security tags will have a bar code printed thereon or attached thereon.
Security tag containment means, depicted in the form of a containment housing 78 and a pivotal door 80 , provide for securing of a security tag 82 , as conventionally known in the art, therebetween where ready access to security tag 82 by a consumer is prevented. Pivotal door 80 is formed on body 32 of circular saw blade holder 30 during a molding process. This arrangement provides for a pivoting of pivotal door 80 to readily occur relative to containment housing 78 following placement of security tag 82 within containment housing 78 . Various securement methods may be employed to seal pivotal door 80 relative to containment housing 78 . Examples of such securement methods include binding engagement securing, adhesive securing and thermal securing such as sonic welding. In the example depicted in the various views both binding engagement securing and sonic welding securing are utilized to secure pivotal door 80 relative to containment housing 78 . Opposing snap tabs 84 are positioned on pivotal door 80 while opposing engagement slots 86 are positioned on containment housing 78 . Following a pivotal displacement of pivotal door 80 relative to containment housing 78 each snap tab 84 engages a respective engagement slot 86 to seal containment housing 78 . Following this sealing sonic welding is utilized to secure pivotal door 80 relative to containment housing 78 wherein detectionless tampering is prevented. In the example depicted the structures which provide for the security tag containment means are positioned on hanging display portion 60 . Other placement locations are of course possible. While pivotal door 80 is depicted as being formed during a molding process to extend from containment housing 78 a separate component may be provided which attaches relative to containment housing 78 . Preferably, as depicted, modified slot 62 of hanging display portion 60 is positioned below the structure which encompasses the security tag containment means. As depicted a separate bar code printed label 88 , see FIG. 3, may be attached to circular saw blade holder 30 , as shown in FIG. 3, or circular saw blade 20 to permit computerized checkout of the product at a checkout aisle in a retail setting. If desired a more expansive area may be provided which extends into one of the openings defined by the spokes where a label, having a bar code and/or printed information, may be attached for viewing from the rear of the circular saw blade holder.
When the security tag is contained, and concealed, utilizing security tag containment means, the security tag does not have to have a bar code printed thereon. If the security tag does have a bar code printed thereon, that bar code does not have to relate to the product retained by the circular saw blade holder. This provides for use of surplus security tags generally associated with other products for use of the security feature but not the identification feature.
When assembled circular saw blade holder 30 , including body 32 , circular saw blade 20 and securing tab 34 have a minimal thickness compared to conventionally known circular saw blade holder described below. This provides for a great many assembled circular saw blade holders having features of the present invention to be stacked, either horizontally in a hanging orientation or vertically, in a minimal space.
An information card, not shown, may be attached to circular saw blade holders having features of the present invention. Various placement locations exist for attachment of such information cards. One example involves adhesive attachment to back 38 of body 32 of circular saw blade holder 30 . Another example involves placement between blade contact surface 40 of body 32 of circular saw blade holder 30 and the back of circular saw blade 20 . In this position the information contained on the information card can be viewed through openings 42 . Proper orientation of the information card can be maintained due to the pressure between circular saw blade 20 and blade contact surface 40 or and adhesive may be applied between the information card and portions of blade contact surface 40 .
Prior Art
FIG. 7 through FIG. 11, labeled as ‘prior art’, depict a prior art circular saw blade holder 100 as conventionally known in the art to retain a circular saw blade 102 . Circular saw blade holder 100 has a body 104 and a retaining nut 106 . Body 104 has a front 108 , see FIG. 7 and FIG. 9, and a back 110 , see FIG. 8 . Both body 104 and retaining nut 106 are formed by a molding process. Body 104 has a depression 112 on front 108 having a radial measurement sufficient to permit placement therein of circular saw blade 102 . A radially disposed outer wall 114 of depression 112 provides for protection of a working edge 116 of circular saw blade 102 when positioned within depression 112 , see FIG. 9. A threaded passageway 118 receives threads 120 of retaining nut 106 to secure circular saw blade 102 relative to depression 112 of body 104 , see FIG. 9 . Retaining nut 106 is rotationally positioned within threaded passageway 118 and may easily be removed from threaded passageway 118 to release circular saw blade 102 from body 104 . Such ready removal of circular saw blade 102 from body 104 of circular saw blade holder 100 eliminates any potential security measures from being employed with circular saw blade holder 100 by the retailer. Additionally, circular saw blade holder 100 does not have a passageway corresponding to a central mounting aperture, not shown, of circular saw blade 102 .
Circular saw blade holder 100 has the advantage over many retail display methods for circular saw blade of displaying substantially the entire face 124 of circular saw blade 102 where ready inspection by the consumer may occur and where the consumer may touch circular saw blade 102 during the inspection process. Additionally, an information card, not shown, may be attached to back 110 to advise the consumer of features of the product including safety warnings. The information card has a central aperture and is adhesively attached to a plate surface 126 of back 110 .
Body 104 of circular saw blade holder 100 has a generally square shape which requires a great deal of material which are beyond the limits of depression 112 . This configuration makes circular saw blade holder 100 much more expensive to manufacture than circular saw blade holders having features of the present invention. Additionally, circular saw blade holder 100 , due to the shape, weighs more than circular saw blade holders having features of the present invention thus increasing costs associated with shipping.
In conventional usage security tag 82 typically is adhesively attached to back 110 of body 104 , see FIG. 8, where security tag 82 is visible and accessible to the consumer. Such placement renders the benefits of deployment of security tag 82 virtually useless. Security tag 82 may simply be removed by the consumer eliminating the advantages of such security tags. Even worse a security tag, including the bar code identification associated with another specific product, may be taken from a less expensive circular saw blade by a dishonest consumer and placed on circular saw blade holder 100 having a more expensive circular saw blade while removing the security tag originally attached to circular saw blade holder 100 . At this point the dishonest consumer may simply present circular saw blade holder 100 , with an expensive circular saw blade 102 retained thereon, at a checkout and gain possession of the expensive circular saw blade 102 while paying substantially less than required.
Body 104 of circular saw blade holder 100 has a series of slots 128 positioned across an upper extent to permit hanging display of circular saw blade holder 100 in a retail setting. The middle slot 128 is used when a single support rod, not shown, is utilized for display. When two (2) spaced support rods are utilized for display typically the opposing outer slots 128 are used. During display typically a plurality of circular saw blade holders 100 are positioned on the deployed rod(s).
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size,. material, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A simple molded packaging device for a circular saw blade where the packaging securely retains the circular saw blade where a full inspection, both visual and tactile, may be made by a consumer prior to purchase of the circular saw blade while preventing the consumer from removing the circular saw blade from the packaging and securely replacing the circular saw blade relative to the packaging. Means provide for simple one time release of the circular saw blade from the packaging. Means provide for securement of a security tag relative to the packaging where ready undetectable tampering by the consumer with the security tag is prevented. Sonic welding is disclosed as the preferred method of both securing the circular saw blade relative to the packaging and securing a closure of a security tag compartment with a security tag contained therein. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to a Liquid Crystal Displays (LCD) assembly in portable computing devices and electronic specialty products where the user can define the visible regions of an LCD display. More specifically, this invention relates to an LCD display where multiple polarizers define visible regions of a portable computer display to preserve computing privacy or provide a means on electronic novelties to amuse or educate a user via selective display of an answer or acknowledgement. The LCD configurable polarized region may also serve to gain access to or to facilitate usage of the electronic device.
Liquid crystal displays are a common display means on a large variety of portable computing devices and electronic novelty products. They are the display means of choice because of their power efficiency and high contrast characteristics. The images displayed on liquid crystal devices can be alphanumeric, graphic, pictorial, or video in nature. Liquid crystal displays are actually light valves that utilize cross polarization to effectively transmit or block light. To accomplish the graphic, alphanumeric, pictorial, or video display of information, a majority of common LCD systems are configured with two fixed polarizers sandwiching two glass plates with embedded electrodes that confine a mesomorphic material. Certain mesomorphic material (liquid crystals) have two useful properties. Light passing through the crystalline material rotates its plane of polarization, and mesomorphic crystals will freely align themselves to an electric field. When the crystals are illuminated by a polarized light source and aligned by an electric field, the change in light polarization over the aligned crystalline region is uniform, and can be cross-polarized to impede transmission of light. When the electric field is removed, the crystalline alignment is random and light polarization becomes effectively scattered, allowing transmission of light. There are three functional classifications of LCDs: reflective(watches without a backlight), transmissive (LCD projection) and transflective (laptop computers) which allow use of ambient light or backlighting. All three require one polarizer to polarize incident light, the liquid crystal to scatter or rotate the polarized light, and another polarizer to cross-polarize (block) all light rotated by the aligned liquid crystal. The cross polarizer can be located proximal to the display or remotely by the user. U.S. Pat. No. 4,859,994 issued to Zola et al. discloses a closed caption movie subtitle system where the LCD assembly comprises one fixed polarizer and the liquid crystal assembly. Audience members that required closed captioning would wear glasses correctly polarized and see a changing display beneath the movie screen. The rest of the audience would not be distracted by the constant messaging. In this embodiment the LCD always requires a set of glasses for remote cross-polarization to read the screen and viewing is absolute, where the user sees the entire display or nothing.
In portable computing devices such as laptop computers, the user frequently is in a public place such as an airport or on an airplane. The majority of these computing devices are carried for business purposes, and the nature of the work is proprietary. The screens normally display 20-30 lines of text while working on a word processing document. As the last line on the screen is typed, the entire text scrolls upward one line at a time. For added confidentiality, the users may display only the text line that they are currently writing and hide the rest of the document. For ultimate security, the users may wish to make the entire screen blank and use remote cross-polarized glasses so only they can see the text on the screen. Another portable computing application uses the new personal digital assistant technology such as the Apple Newton, made by Apple Computer Inc., Cupertino, Calif., A salesman may partition a portion of the screen where the customer sees retail prices and warranty information, and the salesman using cross-polarized glasses can see cost, inventory levels, and sales tips on the rest of the screen. He may repartition the screen for full viewing by the customers so they can answer a survey or any other function.
Some electronic novelties such as databanks are commonly used as dictionaries, language translators, and telephone address books. Many contain multi-line displays learning tools. When using these as reference tools, the user would configure the screen for complete viewing. However in a flash card mode, only the first line of the screen would be visible until the users would want to confirm their guess. The first line would contain a phrase to translate, a word to be defined, or a math problem. After guessing, they could make the consecutive lines visible by changing the cross-polarized region and determine the validity of their answer. The same configuration can be used for electronic novelties that ask trivia questions, or provide amusement by encrypting or disguising some puzzle or game.
LCD projection technology such as video projectors could have user defined cross-polarized regions to allow complete viewing, partial viewing, or selective viewing. On airplanes, inflight entertainment is provided using projection video. The system is employed for FAA safety instructions to all passengers at the beginning of the flight. Later for paid entertainment, headsets for audio are purchased to enjoy the feature film. The stewardess could set the cross-polarized region to display the entire screen for safety instructions. Later the screen can be set so the entire cabin views the top 10% of the screen, where the flight crew can display relevant text messages to the entire planeload of passengers. The lower 90% of the screen would contain the feature film, where passengers interested in entertainment can purchase cross-polarized glasses to view it. The remainder of the passengers wouldn't be disturbed by the video only portion of the film.
It can be seen that by creating a user-defined, cross-polarized region of an LCD display, electronic devices incorporating such a display can be made to provide computing privacy, accessibility to the device, strategic information separation, and information separation to multiple users.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide a liquid crystal display system where at least one of the polarizers associated with creating a cross-polarized image on the liquid crystal display is displaceable. The alignment of said polarizer determines the visible and invisible regions of the display and a retaining means assures alignment until a new partioning of the display region is desired.
It is yet another object of this invention to provide computing privacy by incorporating said liquid crystal display system into a portable computing device such as a laptop computer and providing an additional remote polarizer to provide a narrow viewing angle of the display. The combination of selective partioning of the liquid crystal display and narrow viewing angle via remote polarizer allows a user to acquire text and graphic visual feedback from their computing session without others in their vicinity receiving the same.
It is yet another object of the invention to provide or deny user access to an electronic device or display means by selective partioning of the liquid crystal display and enabling usage of said device by providing discreet polarizng means. It is yet another object of this invention to provide strategic separation of information displayed on electronic devices using liquid crystal displays by selectively aligning at least one displaceable polarizer with known data containing regions of a liquid crystal display.
It is yet another object of this invention to provide strategic separation of information displayed on electronic devices using liquid crystal displays by providing at least one polarizer proximal to the liquid crystal display to segment information between users with and without remote polarizers.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitive of the present invention, and wherein:
FIG. 1 is prior art of a movie subtitle viewing sytem.
FIGS. 2A, 2B, and 2C are partial cross-sectional views of an LCD assembly, while it is in use, according to the invention.
FIG. 3 is a partial cross-sectional view of an LCD assembly according to one embodiment of the invention.
FIG. 4 is a partial cross-sectional view of an LCD assembly according to another embodiment of the invention.
FIG. 5 is a partial cross-sectional view of an LCD assembly according to another embodiment of the invention.
FIGS. 6A, 6B, and 6C are perspective views of a laptop computer utilizing an LCD assembly, while it is in use, according to the invention.
FIGS. 7A, 7B, and 7C are perspective views of an electronic pocket-sized databank utilizing an LCD assembly, while it is in use, according to the invention.
FIGS. 8A, 8B, and 8C are prior art schematic views of different LCD configurations.
FIG. 9 is prior art schematic of a typical LCD Projection system.
FIGS. 10A and 10B are partial cross sectional views of an LCD assembly while it is in use, according to another embodiment of the invention.
FIGS. 11A, 11B, and 11C are partial cross sectional views of an LCD assembly while it is in use, according to another embodiment of the invention.
FIGS. 12A, 12B, and 12C are partial cross sectional views of an LCD assembly while it is in use, according to another embodiment of the invention.
FIGS. 13A, 13B, 13C, and 13D are partial front views of an LCD assembly while it is in use, according to another embodiment of the invention.
FIG. 14 is a schematic of a typical LCD Projection system, according to another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, Prior art, there is shown a movie subtitle system where a liquid crystal display 24 is located below a movie screen 18. A polarizer 22 is placed between a light 20 and liquid crystal display 24 such that light passing through the liquid crystal is polarized. The liquid crystal display 24 after being driven by a proper driving circuit, produces alphanumeric text cross-polarized to the polarized light background. A second polarizer 30 worn by an audience member in the form of glasses enables the audience member to view the text. Those members in the audience not wearing the polarizer 30 will not be able to view the subtitles, and will only see polarized light emanating from the display 24 as a faint haze. It can be infered from the prior art that the system depicted in FIG. 1 cannot provide the ability to selectively partition the liquid crystal display 24 into visible and non-visible regions. Further, viewing of the liquid crystal display system without remote polarizer 30 is not possible.
FIGS. 2A, 2B, and 2C refer to the first embodiment of the present invention. Using a liquid crystal display 24 capable of displaying images comprising alphanumerics, graphics, pictorials, or video, optically aligned with a rear polarizer 22 and light source 20, cross-polarized images on a plane polarized background are formed. With the addition of a movable polarizer 28 that is held proximal to liquid crystal display 24 by retaining means 26, the images prompted to liquid crystal display 24 are completely visible to both the first viewer using remote polarizer 30 and the second viewer with no remote polarizing means. Referring to FIG. 2B, movable polarizer 28 has been displaced in an upward manner so that it is aligned with the top part of the liquid crystal display 24. Visibility of images displayed on liquid crystal display 24 are now limited to the upper region of the display for the second viewer and is still completely visible to the first viewer utilizing remote polarizer 30. Referring to FIG. 2C the movable polarizer 28 has been displaced in a downward manner so that it is aligned with the bottom part of the liquid crystal display 24. Visibility of images displayed on liquid crystal display 24 are now limited to the lower region of the display for the second viewer and is still completely visible to the first viewer utilizing remote polarizer 30. In FIGS. 2A, 2B, and 2C it can be appreciated that the retaining means 26 can have many enabling means to provide relative alignment of movable polarizer 28 and liquid crystal 24, and should not be limited to the sliding means illustrated. Further, the linear displacement of movable polarizer 28 is shown in a vertical manner. It should be appreciated that the movable polarizer displacement can occur vertically, horizontally, diagonally, or in any random manner. Although the system is illustrated with three polarizers, any number of polarizers can be used proximally to create any pattern of visible and non-visible regions for the viewers. The plane of polarization of polarizer 22, polarizer 28, and polarizer 30 impacts the performance of the system herein described. Given identical planes of polarization of rear polarizer 22, movable polarizer 28, and remote polarizer 30 with cross-polarized text on liquid crystal display 24, provides dark text on a light background with visiblity as described above. Given the plane of polarization of rear polarizer 22 with cross-polarized text on liquid crystal display 24 and cross-polarized planes of polarization on movable polarizer 28 and polarizer 30, provides light text on a dark background with visiblity as described above. However, if polarizer 28 is cross-polarized to polarizer 30, then the visibility of first and second viewers in FIG. 2B would be reversed. The first viewer with remote polarizer 30 would see the upper portion of liquid crystal display 24 blacked out and the lower portion visible, and the second viewer with no remote polarizer would have the upper portion visible and would see a light haze with no distinguishable images on the lower portion of the liquid crystal display 24. It should be known that either rear polarizer 22 or movable polarizer 28 can be displaced with respect to liquid crystal 24 to afford visible region partitioning of the liquid crystal display 24. Both polarizers may be displacable in different directions affording variable partitioning in multiple directions. These embodiments apply to gray scale and color liquid crystal displays. In FIG. 3 another embodiment of the present invention where a liquid crystal display system 40 is shown. In addition to liquid crystal display 24 and rear polarizer 22, a light wedge 32 has been added to distribute light from light source 20. Two cylindrical rollers 42 have been placed above and below liquid crystal 24, rear polarizer 22, and light wedge 32. A handle 38 has been attached to the top roller 42 to provide a means to induce rotational translation of top roller 42. A clear transparent, continuous belt 34 made from a material such as acetate film is tensioned between the two rollers 42. On a region, that is the height and width of the liquid crystal display 24, of the belt 34 a polarizer 36 is constructed. The plane of polarization of polarized region 36 is such that it is polarized or cross-polarized to polarizer 22 to enable the viewing mode desired, light background or dark background. Via rotational translation of top roller 42, the polarized region 36 can be positioned in perfect alignment with liquid crystal display 24 allowing complete viewing of images displayed. With further rotational translation of roller 42, a portion of liquid crystal display 24 is not aligned with polarized region 36, and is no longer visible. Optionally, a remote polarizer 30 not illustrated may be used to see regions of liquid crystal display 24 not properly cross-polarized. The handle 38 may be attached directly to roller 42 or be attached via some means of transmission to reduce or accelerate rotational translation. Rollers 42 may be sprocketed 62 and corresponding features on belt 34 will be required. The transparent portion of belt 34, if not continuous, may be formed by an elastomer or rigid open belted structure. The handle 38 may be replaced by any manual, rotationally-inducing means such as a thumbwheel or knob.
In FIG. 4 another embodiment of the present invention where a liquid crystal display system 60 is shown. In liquid crystal display system 60, the rotationally inducing handle means for translation of the polarized region 36 in system 40 has been replaced by a linearly translating lever 44 which is attached to belt 34. The user can align polarized region 36 to partition the visible region of liquid crystal display 24 by dragging the lever 44 to the desired alignment.
FIG. 5 shows another embodiment of the present invention wherein liquid crystal display system 70 is shown. The manual means for displacing the polarized region 36 of belt 34 has been replaced by an automated or semi-automated means. The motor 46 coupled with transmission means 48 rotates roller 42 to displace belt 34. The motor has a control means 50 which may be initiated by a switch or software contained within the electronic device the liquid crystal display system 70 is used in. The motor control means may have an optional sensing means 52 to determine the positioning of the polarized region 36 as it translates past the liquid crystal display 24. The motor control means start/stop switch, may use positional feedback from sensing means 52 to close-loop control the motor displacement or may simply drive the motor 46 to a hard stop or a predetermined distance. The motor controls elements mentioned here are well known in the art and will not be discussed in detail. The transmission means 48 may be a belt as illustrated or gearing or any other transmission means known in the art.
In FIGS. 6A, 6B, and 6C liquid crystal display system 60 has been integrated into a laptop computer 80. The laptop computer 80 contains a computing means such as a CPU, a data entry means such as a keyboard, and a data storage means such as a floppy disk drive or hard disk drive. With levers 44 at the top of the display screen, the entire screen is visible to the user, and the laptop computer is functional as common in the art today. The entire screen with the message "TEXT" is portrayed and the user and everyone within a forty-five degree viewing angle can view it.
In FIG. 6B the levers 44 have been pushed to the middle of the screen where below the levers 44 the polarized region 36 displays the text on the lower portion of the screen, and above levers 44 transparent belt 34 renders text invisible. The user and everyone within a forty-five degree viewing angle can view information displayed on lower portion of the laptop display 60. In FIG. 6C the levers 44 have been pushed to the bottom of the screen where transparent belt 34 renders text on the entire display invisible. A user with remote polarizer 30, having the correct plane of polarization, can see the entire display and can compute with complete privacy. All others within any viewing angle will see a faintly glowing display with no text.
In FIGS. 7A, 7B, and 7C liquid crystal display of FIG. 2 has been integrated into a hand-held electronic databank 90. The databank 90 contains a computing means such as a microcomputer and a data entry means such as a keypad. This particular databank has a two line alphanumeric display and is programmed as a language translator between English and Spanish. An English word is displayed on the first line, and Its Spanish equivalent is displayed on the second line. The databank is programmed in two different modes. In the first mode, the user would enter an English or Spanish word, and the databank would display the word's translation. For this mode the user would want to view both lines of text to view the word and its translation. FIG. 7A shows the configuration of a databank to use in this fashion. The liquid crystal display 24 has a polarizer 28 that is as tall as liquid crystal display 24 and is formed to wrap around the outer housing of the databank. The wraparound feature provides the retaining element 26 that is portrayed in FIG. 2. The second mode is a flashcard mode where English and Spanish words are randomly displayed on the screen. Here the user can align the polarizer 28 with the top line of liquid crystal display 24 as in FIG. 7B, see the English word, and guess its translation. After guessing, the users can slide the polarizer 28 back to its position shown in FIG. 7A and confirm their answer. If the user would like to test their skills at translating Spanish to English then they would align polarizer 28 as shown in FIG. 7C, see the Spanish word, then guess the English translation. After guessing, the users can slide the polarizer 28 back to its position shown in FIG. 7A and confirm their answer. This configuration not only lends itself to flashcard modes, but quiz games, puzzles (Word Scramble) etc.
In FIGS. 8A, 8B, and 8C various prior art LCD representations are illustrated. Twisted Nematic (TN) liquid crystal display 96 and Super Twisted Nematic (STN) liquid crystal display 94 differ in optical characteristics and construction but are functionally subsets of previously described liquid crystal displays 24. The construction of active or passive TN and STN liquid crystal displays vary by manufacturer and are known to those skilled in the art. In FIG. 8A the liquid crystal display system illustrated has a TN liquid crystal display 96 with two linear polarizers 22 to polarize incident light and cross polarize the image created by TN liquid crystal display 96. In FIGS. 8B and 8C the liquid crystal display system illustrated has an STN liquid crystal display 94 with two linear polarizers 22 to polarize incident light and cross polarize the image created by the STN liquid crystal display 94. Additional retardation films 92 are added to compensate for optical color shifts due to the birefringent nature of STN LCDs. FIG. 8B represents a single compensated LCD assembly and FIG. 8C represents a double compensated assembly. Partitioning of displays into visible and invisible regions is possible independent of the type and construction of the LCD.
In FIG. 9 prior art of a representative LCD projection system is shown. Light produced from lamp 20 travels through condensor lens 100, is polarized by polarizer 22, an image is formed by liquid crystal display 24, crossed polarized by a second polarizer 22, focused by projection lens 98 and projected on to projection screen 18. When projection screen 18 is of front projection type the first viewer sees the image and when projection screen is of the rear projection type the second viewer sees an image. Projection screen 18 may have a polarization preserving surface such as brushed aluminum when used for 3D movies. There are many LCD projection schemes known in the art and all of them can be configured with LCD partitioned images with visible and invisible regions.
In FIGS. 10A and 10B another embodiment of the invention similiar to the first embodiment depicted by FIG. 2 where the retaining means 26 is configured using a spring return latching roller mechanism. The spring return latching roller mechanism would have mechanics known in the art of a common adjustable window shade. The movable polarizer would be attached to the spring return mechanism so that it can be deployed to completely cover the liquid crystal display 24 as depicted in FIG. 10A or can be latched to partition to screen at any desired height as depicted in FIG. 10B.
In FIGS. 11A, 11B, and 11C another embodiment of the invention similiar to the first embodiment depicted by FIG. 2 where no remote polarizer 30 is illustrated and where multiple (2) mobile polarizers 28 replace the single mobile polarizer 28 of FIG. 2. In FIG. 11A both mobile polarizers are positioned so that the entire image on the display is visible to the viewer. In FIG. 11B the bottom mobile polarizer 28 is retracted and the top mobile polarizer 28 is postioned so that the top half of the image on the display is visible to the viewer. In FIG. 11C the top mobile polarizer 28 is retracted and the bottom mobile polarizer 28 is postioned so that the bottom half of the image on the display is visible to the viewer. Both mobile polarizers can be positioned to accomplished any desired partitioning of the screen. The 2 mobile polarizers 28 illustarted here are stacked vertically, any number of polarizers can be stacked in a multitude of orientations and positions to accomplish any desired partitioning of the screen.
In FIGS. 12A, 12B, and 12C another embodiment of the invention similiar to the first embodiment depicted by FIG. 2 where no remote polarizer 30 is illustrated and transparent retaining panels 110 are used to maintain the position of mobile polarizer 28. In FIG. 12A retaining means 26 applies uniform pressure between liquid crystal assembly 24 and transparent retaining panel 110 to sandwich and secure mobile polarizer 28. By loosening the tension of retaining means 26, polarizer 28 can be repositioned, then locked into position again by retensioning retaining means 26. The transparent retaining panel 110 can be fabricated from a host of materials such as glass. The same polarizer positioning mechanism can be achieved by sandwiching mobile polarizer 28 between two transparent retaining panels 110 as illustrated in FIG. 12B. The LCD partitioning subassembly 120 includes retaining means 26, at least 1 mobile polarizer 28, and transparent retaining panels 110. In FIG. 12C the mobile polarizer has been positioned so that only the top third of the screen is visible.
In FIGS. 13A, 13B, 13C and 13D front views of LCD display assemblies depicting the image seen by the viewer in FIGS. 12B and 12C. The liquid crystal display has an electronic image of a checkerboard pattern across the entire display. When a single mobile polarizer 28, at least as large as the LCD 24 is positioned in complete alignment such as illustrated in FIG. 12B the resulting image is illustrated in FIG. 13A. As mobile polarizer 28 is displaced upward as shown in FIG. 12C the resulting image is illustrated in FIG. 13B. If multiple mobile polarizers 28, one shaped like a circle, one like a square, one like a rectangle, and one like a triangle are sandwiched in subassembly 120 the resulting image could look like FIG. 13C. If subassembly 120 is disassembled, the four mobile polarizers 28 moved, and subassembly 120 reassembled, the resulting image would be repartitioned to look like the image in FIG. 13D. An infinite number of shapes and sizes of mobile polarizers 28 could partition the screen in this manner.
In FIG. 14 the schematic view of a representive LCD projection system as depicted in FIG. 9 has been modified with the removal of one polarizer 22 and the addition of LCD partitioning subassembly 120 in two possible locations. With subassembly 120 positioned between the liquid crystal display 24 and the screen 18 the projected image is partitioned according to the positioning of the polarizers within subassembly 120 where all viewers of the screen 18 can see an image where the subassembly 120 provides cross polarization. Alternately, if the LCD partitioning subassembly is located between the screen 18 and the viewer only the viewers that have polarizers aligned with the image on the projection screen can see a partitioned image. Relative partitioning of the screen depends on the viewers proximity to the subassembly 120. Any of the partitioning embodiments disclosed can be utilized within any LCD projection scheme.
It will thus be seen that the objects set forth above, and those made apparent from the preceding descriptions, are effectively attained and since certain changes may be made in the above construction without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings, shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all generic and specific features of the invention herein described and all statements of scope of the invention which as a matter of language, might be said to fall therebetween. | An apparatus to display images with partitionable regions allowing visible, invisible, and narrow field of view of displayed information includes a polarizing means to form a plane polarized light background from incident light, a liquid crystal panel capable of forming cross-polarized images against a plane polarized background, and a proximal movable polarizing means to distinguish images on liquid crystal panel from its plane polarized background. Linear translation of the movable polarizer partitions the liquid crystal panel into regions that are visible where there is optical alignment of the liquid crystal panel, background polarizer, and movable cross-polarizer. An optional remote polarizer complements the movable polarizer and provides a narrow viewing angle of images not visible on the liquid crystal panel. By creating a user defined visible, invisible, and narrow field of view of displayed information on an LCD assembly, electronic devices incorporating such a display can be made to provide computing privacy, accessibility to the device, strategic information separation, and information separation to multiple users. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Patent Application No. 60/297,380, filed Jun. 11, 2001.
FIELD OF THE INVENTION
The present invention relates generally to a method and system for predicting mechanical failures in machinery driven by an induction motor, and particularly for detecting, during machinery operation, the occurrence of minor mechanical disturbances as reflected in fluctuations of induction motor torque. This is useful for scheduling machinery down-time and/or maintenance at an early stage before the mechanical disturbances become mechanical failures rendering the machinery inoperable.
BACKGROUND OF THE INVENTION
A need exists for a cost-effective approach to predictive maintenance of electro-mechanical rotary equipment, such as pumps, compressors, mixers, mills, refrigeration equipment and the like. A significant disadvantage of traditional predictive maintenance practice is the significant cost of a monitoring system. A common method for predicting mechanical failures in motor-driven machinery is measuring and analyzing the machinery's vibration spectrum (vibration signature). This method requires continuous or periodic installation of special vibration sensors and/or signal analyzers and is therefore complicated and/or expensive. For many types of machinery, and especially for machinery operating in hazardous or relatively inaccessible environments, provision and/or monitoring of such sensors can be particularly complicated and/or expensive.
Various attempts to use the induction motor itself as a tool for diagnosis of mechanical failures, rather than such sensors, are known in the art. For example, U.S. Pat. No. 5,754,450 to Solomon, et al. discloses an apparatus for diagnosing certain faults in refrigeration or air conditioning systems by comparing the motor current in a normal operating mode to the motor current in failure mode. This and other techniques are inadequate for detecting mechanical failures such as misalignment, mechanical looseness, bearing failures and other typical mechanical failures.
U.S. Pat. No. 4,965,513 to Haynes, et al. discloses use of a motor's current signatures for the detection of abnormalities of motor driven machinery, especially motor-operated valves. The Haynes approach uses a demodulator of an analog signal of AC current. The output of the demodulator is a DC signal proportional to the RMS of the AC current. The demodulated signal is further processed by a low-pass filter, which deletes all frequencies below a main frequency of the supplied voltage (50 or 60 Hz). After the filter, the signal is passed through a Fast Fourier Transform processor. The frequency spectrum (digital signature) thus obtained reflects the condition of the machinery driven by an induction motor.
A principal disadvantage of the Haynes approach is the use of analog signal measurement facilities that are less accurate and more expensive than digital signal processing.
Another problem with the Haynes approach is the influence of fluctuations in the induction motor frequency and voltage. This introduces noise into the current signature and makes it difficult to detect minor disturbances in motor current signatures caused by mechanical disturbances in machinery driven by an induction motor. Accordingly, use of motor current signatures for detecting mechanical failures in motor-driven machinery is associated with certain inaccuracies that limit the possibility of using motor current signature analysis for detection of minor early-stage disturbances in machinery driven by an induction motor. This fact is known to those skilled in the art.
To partially overcome these limitations, U.S. Pat. No. 5,461,329 to Linehan, et al. discloses use of an adjustable frequency clock generator that adjusts its input frequency with the frequency variations of a non-stationary analog carrier wave. This method and circuitry makes a data acquisition and signal analyzing system more complicated and more expensive and fails to completely eliminate the influence of supply energy harmonics noise on a current signature.
The phase angle of a motor, in other words the angle between current and voltage zero crossings, is presently used for motor power calculations, current measurement compensation and motor performance evaluation, as disclosed, for example, in U.S. Pat. No. 6,144,924 to Dowling, et al. U.S. Pat. No. 5,548,197 to Unsworth, et al. discloses a method for using phase angle for calculation of rotation speed of an induction motor.
Prior art methods for load torque evaluation and analysis are mostly based on the direct measurement by strain gauges and other sensors. Such torque measuring sensors are usually installed on a coupling placed between the motor and driven machine shafts. It is often complicated, expensive and sometimes impossible to use such kinds of torque measuring devices.
Applicants have recognized that mechanical disturbances of machinery driven by an induction motor cause fluctuations in the motor's torque that influence easily measurable parameters of an electrical motor. Such parameters include, for example, current phase angle, motor slip, and motor torque. These motor operation parameters are widely known but have not been used for detection of mechanical failures. Applicants have recognized that, to be effective, the detection of minor mechanical disturbances based on analysis of an induction motor during operation should be based not on current analysis but on such other motor parameters, which are not influenced by voltage amplitude, frequency and high harmonics. Monitoring of such motor parameters is therefore useful for remote detection of disturbances, in and prediction of mechanical failures, in machinery driven by an induction motor.
SUMMARY OF THE INVENTION
The present invention provides a simple and inexpensive system and method for remote detection of mechanical disturbances in machinery driven by an induction motor, and for thereby predicting mechanical failures of the machinery. Conceptually, the present invention provides a method of using an induction motor as a diagnostic tool for predicting incipient failures and/or recognizing present disturbances in machinery driven by the motor.
The present invention provides for measurement of only motor torque and current, which may be measured during operation of the motor and machinery, with non-intrusive techniques using relatively inexpensive sensors, and avoiding the need for expensive and unstable A/D converters. From these measurements, motor phase angle and motor slip may be derived. Motor torque is proportional to the slip of the induction motor. Accordingly, motor torque may be thereby sensed indirectly by deriving motor torque from the direct measurement of only motor current and motor voltage.
The method includes monitoring operation of the induction motor and comparing easily-measurable parameters of the induction motor during operation with baseline (reference) characteristics of the induction motor for known normal operation. Deviations of the motor's characteristics from the known baseline indicate an actual mechanical disturbance and an approaching mechanical failure. Mechanical disturbances of the machinery are reflected in fluctuations in the load torque of the machinery. Therefore, motor torque fluctuations are analyzed to detect present mechanical disturbances that are indicative of early-stage mechanical failures in the machinery driven by the motor. Fluctuations of motor torque are analyzed by Fast Fourier Transform (FFT) analysis. A system in accordance with the present invention may operate in conjunction with a process control system that stops and starts the system apparatuses according to starts and stops of the monitored machinery and supplies the current values of process parameters. Optionally, machinery-specific characteristics may be learned by automated creation of a model correlating diagnostic parameters with machinery process parameters such as pressures, temperatures, flow rates, capacities, etc. A machinery-specific baseline (reference) profile of the monitored machinery may thereby be produced.
The present invention also provides a method for monitoring machinery for disturbances and/or failures by building and analyzing objects referred to herein as “Experimental Fractals” that reflect a current state of the monitored machinery. A current state of the machinery may be analyzed using Experimental Fractals in the coordinates rotor angle/B torque.
The state of machinery is evaluated by statistical evaluation of Experimental Fractal parameters, such as envelope parameters. Machinery failures may be diagnosed by combining evaluation of the FFT and Experimental Fractal diagnostic indicators. Experimental Fractal graphical images may be used to visually represent a machinery state.
Failure forecasting for machinery is provided by automatic modeling of a derivation trend by extrapolating the trend into the future.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a system in accordance with an exemplary embodiment of the present invention;
FIG. 2 shows a time diagram of a pulse generator operation;
FIGS. 3A, 3 B, 3 C, 3 D are the pulse generator block schemas;
FIG. 4 is a data block diagram;
FIG. 5 shows a time series of relative phase angle;
FIG. 6 is a plot in frequency versus amplitude coordinates of a motor torque spectrum for an exemplary petrochemical mixed reactor;
FIG. 7A is a plot of an exemplary Experimental Fractal for a vertical pump with proper fastening to a base;
FIG. 7B is an exemplary Experimental Fractal for the vertical pump of FIG. 7A, showing improper fastening to the base;
FIG. 8A shows an exemplary Experimental Fractal associated with a rolling bearing in a normal condition;
FIG. 8B shows an exemplary Experimental Fractal envelope of the rolling bearing of FIG. 8A, with the bearings in a worn condition;
FIG. 9 illustrates an exemplary Experimental Fractal associated with a failure of a capacity control system in one cylinder of a reciprocating refrigeration compressor;
FIG. 10 shows a flow chart for failure trend analysis; and
FIG. 11 illustrates an example of trend analysis with forecasting of future failure development.
DETAILED DESCRIPTION
The present invention relates to a system and method for remote detection of mechanical disturbances in machinery, such as rotary machinery, driven by an induction motor for the purpose of predicting incipient failures in the machinery. The foregoing summary, as well as the following detailed description of preferred embodiments of the invention, will be better understood when read in conjunction with the appended drawings.
Reference is now made to FIG. 1, which illustrates an exemplary system for detecting mechanical disturbances in induction motor-driven machinery in accordance with a preferred embodiment of the present invention. The exemplary system 10 of FIG. 1 includes components for carrying out the inventive method, as discussed further below. FIG. 1 shows an exemplary three phase induction motor 12 driving a piece of the rotary machinery 14 , such as a pump, compressor, mixer, mill, refrigeration/air conditioning unit, etc.
The induction motor 12 is supplied with electric power from a remote electrical board 16 of the system 10 . In accordance with the present invention, a data acquisition system, that may be placed near or integrated into the electrical board 16 , includes current sensors 18 , voltage sensors 20 , and a pulse generator apparatus 22 . The current and voltage sensors may be provided for one or more phases of the induction motor 12 . In the embodiment shown in FIG. 1, a current-measuring transformer 18 a , 18 b , 18 c and a voltage-measuring transformer 20 a , 20 b , 20 c is provided for each of the three phases (R, S and T) of the motor 12 .
Pulse generator 22 is provided to transform analog signals from the current and voltage sensors 18 , 20 to a time series of pulses having leading and trailing edges related to current and voltage zero crossings, i.e. changes in polarity from negative to positive. The time series of pulses is represented as a digital signal, as discussed in greater detail below with reference to FIG. 2 .
Digital signals from the pulse generator 22 enter the Digital Input/Output Board 28 of a computer 24 through multiplexor 26 . The operation of the pulse generator 22 is supported by signals coming from the computer 24 . The computer 24 is configured for performing signal processing and may be embodied in an embedded, desktop, handheld or other commercially available general purpose computer, or any specialized device with a microprocessor, RAM and ROM memories, long term data storage such as a hard disk drive, and communication facilities such as serial and parallel ports, an Ethernet card, wireless communication card, control bus communication card, etc.
In addition to the above-described computer 24 , pulse generator 22 and sensors 18 , 20 for measuring current and voltage, the system 10 optionally includes mechanical sensors such as vibration, acoustical, shaft position, phase markers, etc. The details of the structure and operation of such mechanical sensors is well known in the art and is not necessary for a complete understanding of the present invention.
Exemplary operation of the pulse generator 22 is illustrated by the time diagram 30 shown in FIG. 2, which illustrates the voltage and current for one phase of the induction motor 12 stator winding (not shown). In the example of FIG. 2, point A indicates the instant of voltage zero crossing related to the change in polarity from negative to positive. Point B indicates the instant of current zero crossing related to the change in polarity from negative to positive.
Accordingly, the pulse generator 22 generates two series of rectangular pulses, namely, a first series (series AB) including pulses with a leading edge at point A and a trailing edge at point B, and a second series (series BA) including pulses with a leading edge at point B and a trailing edge at point A.
An exemplary block schematic of the pulse generator 22 is shown in FIG. 3A, which illustrates the pulse generation and data acquisition arrangement for the three-phase induction motor of FIG. 1 . As shown in FIG. 3A, analog signals from the current-measuring and voltage-measuring transformers 18 , 20 are processed by zero crossing detectors 32 , 34 . For example, a suitable commercially available zero crossing detector is model number LM 339 manufactured by National Semiconductor. Other suitable detectors are well known in the art. Output signals from the zero crossing detectors 32 , 34 enter electronic flip flop circuits 36 and 38 . For example, suitable flip flop circuitry is embodied in commercially available chip model number 74LS112 manufactured by National Semiconductor. Referring now to FIGS. 2 and 3A, flip flop circuit 36 provides the rectangular pulse defined above as the AB series pulse, and flip flop circuit 38 provides the rectangular pulse defined above as the BA series pulse.
Prediction of mechanical failures in rotary machinery can be improved if diagnostic signals are associated with the angular position of a rotor of a motor. As known in the art, the mechanical rotational speed of the induction motor's rotor is a function of the electromagnetic field speed and the number of pole pairs that it has. Rotor speed can be calculated by dividing the electromagnetic field speed by the number of pole pairs, as is known in the art. Accordingly, the number of voltage zero crossings occurring during one rotor revolution is equal to the number of pole pairs (P 0 ) possessed by the motor.
To correlate the AB series pulses to rotor position it is necessary to detect a motor pole pair to which each pulse corresponds. For this purpose, a software-based pole counter is used. The pole counter's value is increased each time a voltage zero crossing occurs (from negative to positive) in one of the phases, for example phase R. Accordingly, the time series of counter values looks like: 1, 2 . . . P 0 , 1, 2 . . . P 0 .
The leading edges of the AB series pulses correspond to a specific value of the pole counter that serves as an indicator of a specific angular zone of rotation of the rotor.
According to the present invention, a plurality of pulse generators, for example eight, 22 a , 22 b , 22 c , 22 d , 22 e , 22 f , 22 g and 22 h , can be connected to one multiplexor 26 , as shown in FIG. 3 B. Therefore, the inventive data acquisition system can serve a corresponding plurality of induction motors, 12 a , 12 b , 12 c , 12 d , 12 e , 12 f , 12 g and 12 h . The multiplexor 26 of FIG. 3B is based on electronic circuitry well known in the art such as, for example, the commercially available chip model number 74LS151 manufactured by National Semiconductor. The AB and BA series pulses come through a buffer, as shown in FIG. 3C, such as, for example commercially available chip model number 74LS244 manufactured by National Semiconductor, for each phase of each induction motor 12 a , 12 b , etc., and are switched by a corresponding circuit of the multiplexor 26 . The pulse duration is obtained by an oscillator such as, for example, a 5 MHz oscillator, as shown in FIG. 3 C.
FIG. 3D shows a block schematic of an exemplary prior art Digital Input/Output 28 board of FIG. 1. A commercially available Digital Input/Output board may be used, such as Digital Input/Output board model number PCI-703 manufactured by Eagle Corporation of South Africa. This board has one 24 bit IN port and one 24 bit OUT port. The IN port receives the digital values of pulse duration. The 24 bit counters provide the values of pulse duration. The OUT port provides the pulse generators with information such as the number of pole pairs in each of the served motors, and sends reset signals. It should be noted that the disclosed functionality can be accomplished by any other suitable electronic circuitry and with other configurations of hardware components, as will be understood by those skilled in the art.
Reference is now made to FIG. 4, which shows a logic diagram of an exemplary system for detecting mechanical failures in rotary machinery driven by an induction motor by on-line processing of induction motor torque fluctuations.
In FIG. 4, blocks 50 - 69 represent the logical signal processing functions that are performed by the computer 24 of FIG. 1 . Referring now to FIG. 4, block 50 designates the calculating means providing induction motor torque fluctuations.
The method for detecting induction motor torque fluctuations is illustrated in FIG. 2 . The time interval between point A and point B of FIG. 2 is proportional to the angle between current and voltage zero crossings, which is referred to herein as phase angle. The interval A-B is constant for a given voltage supply, as a function of the voltage supply's period.
In accordance with the present invention, the phase angle time series Ang(I), namely the series AB and series BA pulses of FIG. 2, obtained as described above is used for calculation of motor slip S(I) and torque M(I).
The motor slip is derived as it follows: S ( I ) = R2 ′ * lim ( U 1 * tan Ang ( I ) ) = C 1 tan Ang ( I ) ( 1 )
where R 2 ′ designates rotor resistance related to the stator, lim is the reactive component of stator current, U 1 is phase voltage, and C 1 is a constant derived from nominal parameters of the induction motor. For example, such a constant may be obtained by the formula:
C 1 =S nom * tan(arccos( Fi nom )) (2)
where S nom is the nominal value of the induction motor's slip and arccosFi nom is a nominal value of the induction motor's power factor, which is a known characteristic of the motor and which is typically available from the motor's manufacturer.
In the normal load range, the torque varies with the motor slip as follows: M ( I ) = 2 * S ( I ) * M max * ( 1 + S m ) S m ( 3 )
where M max represents pullout torque and S m represents B slip value related to pullout torque. M max and S m are constant for a specific induction motor, as is well known in the art.
Mathematically substituting expression (1) for expression (3) above, provides: M ( I ) = 2 * C 1 * M max * ( 1 + S m ) ( S m * tan Ang ( I ) )
or : ( 4 ) M ( I ) = C 2 tan Ang ( I )
where : ( 5 ) C 2 = 2 * C1 * M max * ( 1 + S m ) S m ( 6 )
Accordingly, Expression (5) provides the relationship of torque M(I) to motor phase angle Ang(I), and torque may be thereby sensed indirectly by deriving motor torque from the measurements of only motor current and motor voltage, which may be measured during operation of the motor, and with non-instrusive techniques using relatively inexpensive sensors.
Detection of mechanical disturbances in machinery may be satisfactorily achieved by obtaining torque fluctuations only; it is not necessary to obtain the absolute values of the torque fluctuations. Therefore, the method described above can be applied in accordance with the present invention without knowing the specific values of these constants, namely S nom and Fi nom .
FIG. 5 illustrates an exemplary time series of motor slip time obtained as discussed above with reference to Expressions (1)-(6). The time series illustrated in FIG. 5 is the output of block 50 of FIG. 4, and provides a motor torque spectrum.
Block 52 of FIG. 4 represents the signal processor providing the Fast Fourier Transform (FFT) of the torque fluctuations obtained by block 50 . The FFT is executed on data batches. The number of elements in the batch is defined to insure the requested accuracy of the FFT. The time interval between processing of data batches selected to be suitable to the type of machinery being monitored. The same processor can serve various machines of different types. This batch processing is performed periodically, as desired.
The output of the FFT block 52 , which performs an FFT analysis in a traditional manner, represents a large number of spectral amplitudes corresponding to frequencies of the motor torque spectrum frequency domain. The FFT Indicators block 54 decomposes the motor torque spectrum to select the lines that are informative, e.g. statistically significant, for a specific application.
The motor torque spectrum reflects the specific structure of monitored machinery, i.e. it provides a unique motor torque signature. For example, the motor torque spectrum of machinery having roller bearings includes lines with frequencies related to the specific number of rollers, ring diameters, etc. By way of further example, the motor torque spectrum of a motor driving a gear reflects the number of gear teeth, etc. Therefore, the automated analysis of an induction motor torque spectrum should be based on knowledge of characteristics of the particular machinery being monitored.
The inventive method for analyzing an induction motor's current spectrum uses a predetermined profile of such frequencies. This definition is prepared for the specific type of machinery. A database of informative frequencies is stored in the knowledge base (database) 56 of FIG. 4 . According to the inventive method, a software module 58 is provided for automatically comparing the amplitudes of the lines associated with failures in the monitored machinery.
An exemplary torque spectrum is shown in FIG. 6, which illustrates a torque spectrum for an exemplary petrochemical rotation-based mixed reactor. The mechanical speed of this reactor is relatively uniform. The fluctuations in the torque mostly reflect the fluctuations in the friction moment of the reactor's roller bearings. Two magnitudes are prominent in the spectrum shown in FIG. 6 . These magnitudes show that the most informative diagnostics indicators are the frequencies corresponding to the pronounced peaks (3.3 and 5.85 Hz). To identify the kind of mechanical failure being experienced by the reactor, relationships from rolling bearing theory can be implemented when the number of rotor shaft revolutions (RPM) is substituted for the nominal slip value in the same units (RPM) in the expression above.
For such a determination, for example, inner bearing race frequency can be calculated as: BPFI = ( N 2 + 1.2 ) * RPM
In accordance with the inventive method, inner bearing race frequency can be calculated as: BPFI = ( N 2 + 1.2 ) * slip
By way of example, the plot in FIG. 6 has two peak lines at frequencies of 3.3 Hz and 5.85 Hz. For the reactor of FIG. 6, the nominal slip is equal to 25 RPM or 0.417 Hz. The number of bearing rollers N=15, and thus the BPFI=3.6 Hz. This value is very close to the frequency of 3.3 Hz of FIG. 6 . The second line (5.85 Hz) is associated with specific structure of the bearings and the reactor.
The side bands near these lines are associated with bearing cage frequency. The calculation of this frequency can be based on the same principle as the inner bearing race frequency calculated above. Specifically, FTF = ( 0.5 - 1.2 N ) * slip
For the spectrum in FIG. 6, FTF=0.17 Hz. This value is close to the side band width in FIG. 6 .
Referring again to FIG. 4, Block 54 represents a software implementation for performing automatic processing of the motor torque spectrum, in accordance with the present invention, to select informative diagnostic indicators from the various of lines of frequency spectrum, e.g. by selecting those with prominent peaks of magnitude.
The method of selection of the diagnostic indicators consists of the following steps. First, an overall value of spectrum line amplitudes is calculated. For example, this may be calculated as: O v = Sum ( A ( I ) ) n
where A(I) is an amplitude of a harmonic in the frequency spectrum, and n is the number of lines in the spectrum.
Next, the spectrum line amplitude standard deviation is calculated. For example, this may be obtained as follows: D = ( Sum ( A ( I ) B O v ) 2 ) n
Significant spectrum lines, i.e. those informative for diagnostic purposes, may then be detected as those having an amplitude exceeding the standard deviation. For example, spectrum lines may be selected as significant if they have amplitude greater than an overall value plus 3 measures of standard deviation. Spectrum lines with frequencies associated with machine structure are then identified, e.g. by referencing the knowledge base 56 .
Spectrum lines having frequencies close to these lines (side bands) are then identified and their amplitudes are obtained. Selected spectrum lines may then be removed (or ignored) from the spectrum, as discussed in the preceding paragraphs.
The spectral moment for the remaining spectrum is then obtained. For example, this may be obtained as follows: SM = Sum ( F ( I ) * A ( I ) ) ( F max - F min )
where F max is the B maximum frequency in the motor torque spectrum, and F min is the minimum frequency in the spectrum.
Block 60 of FIG. 4 represents a database for storage of the FFT diagnostic indicators in real time database, e.g. in the computer's long term storage, such as a hard disk.
The present invention may use a construct referred to herein as Experimental Fractals. The concept of fractals is generally known in the art. Generally speaking, a fractal may be a graphical image that illustrates a set of points corresponding to differential equation solutions over some period of time. The Experimental Fractal disclosed by the present invention is a set of points associated with data measured over a certain period of time.
For rotary machinery, the period for fractal building is associated with a number of shift revolutions. Therefore, every point of an Experimental Fractal reflects corresponding measured data for a specific value of motor shaft angle. The number of points that is added to an Experimental Fractal during one revolution is equal to the number of a pole pairs of the induction motor. The Experimental Fractal is built over a selected number of revolutions, for example 256 revolutions. For example, the Experimental Fractal may be defined as a set of points plotted on coordinates torque-rotor angle. The entity of points in these coordinates represents the distribution of the torque values versus shaft angular position.
The creation of Experimental Fractals is performed by blocks 64 , 66 of FIG. 4 . In accordance with the present invention, block 64 provides a transform of torque values from time to rotor angle dependent coordinates. The torque values are taken from the array shown in the plot 1 , FIG. 5 and a related angle value is taken from the array shown on plot 2 , FIG. 5 . Therefore, every point of the Experimental Fractal reflects a torque value for a corresponding value of shaft angular position.
The Experimental Fractal angle coordinates may be obtained as follows: FractalAng ( I ) = FractalAng ( I - 1 ) + 6.28 P 0 * ( 1 - S ( I ) ) ( 7 )
where P 0 is number of pole pairs and S(I) is the slip time series value from equation (1) above.
It will be noted that if FractalAng(I) is greater than or equal to 6.28 then FractalAng(I) equals FractalAng(I)−6.28.
FractalAng(I) is one of two the Experimental Fractal coordinates for the instant at angular position “I”. This parameter reflects the rotor angle position. The second Experimental Fractal coordinate is the torque value M(I) from equation (5) above. Accordingly, an Experimental Fractal is a graphic image or a numerical entity in polar coordinates. Typically it is built as M(I) versus FractalAng(I). In accordance with the present invention, Experimental Fractal graphical images can serve as a visualization means helpful for visual monitoring of the state of monitored machinery as well as for automatic diagnostics.
Experimental Fractals for exemplary types of rotary machinery are shown in FIGS. 7-9. The Experimental Fractals in FIGS. 7A, 7 B relate to two examples of a vertical pump fastened to a base. The Experimental Fractal in FIG. 7A corresponds to normal operation of a properly fastened pump. The Experimental Fractal in FIG. 7B indicates a looseness, or improper fastening of the pump to the base, as can be observed in the irregularities of the Experimental Fractal of FIG. 7B as compared to the Experimental Fractal of FIG. 7 A.
FIGS. 8A and 8B illustrate Experimental Fractal envelopes relating to different states of an exemplary stirred reactor's roller bearings. The Experimental Fractal of FIG. 8A corresponds to normal operation of the reactor when every roller is properly rotating in its bed. The Experimental Fractal of FIG. 8B shows irregularities reflecting deviations from the Experimental Fractal of FIG. 8B, and indicates a mechanical failure of the reactor, specifically, a worn bearing with rollers that are not properly fixed in their beds.
FIG. 9 shows an Experimental Fractal illustrating a mechanical failure in a cylinder of a reciprocating refrigeration compressor. The number of protuberances in the fractal image relates to the number of cylinders. The fluttering form of one of the protuberances (shown generally at X on FIG. 9) represents the improper operation of the capacity regulating mechanism in the one of cylinders.
The above-referenced examples demonstrate how Experimental Fractals can be used to visually represent the status and condition of monitored machinery, and can thereby help to identify mechanical failures. Use of Experimental Fractal graphical images makes it possible to diagnose the health of monitored machinery in a simple and relatively inexpensive way, facilitating predictive maintenance practice by identifying mechanical disturbances before mechanical failure in which the machinery may be rendered inoperable. Advantageously, the monitoring can be performed during operation of the machinery so equipment down-time can be planned, avoided and/or minimized.
In accordance with the present invention, Experimental Fractal entities are automatically processed to obtain fractal diagnostic indicators that are useful for failure monitoring and diagnostics. The fractal processing includes calculation of maximum and minimum envelope, i.e., boundary, sizes, their standard deviations, etc. These parameters serve as the fractal diagnostics indicators. For example, the difference in the inside and outside envelope diameters in the Experimental Fractals shown in FIGS. 7A, 7 B shows the degradation due to this specific failure.
The time dependent values of Experimental Fractal indicators are stored in real time in a database, block 60 of FIG. 4 .
Block 62 of FIG. 4 relates to the failure monitoring technique and provides automated failure trend analysis. The FFT and Experimental Fractal diagnostic parameters depend not only on machinery conditions but also on operation parameters. For example, increasing the number of revolutions or process pressures, temperatures, etc. influences the magnitude and frequencies of the FFT spectrum lines and the Experimental Fractal envelope parameters. Therefore, to detect incipient failures and present disturbances, it may be advantageous to reduce or eliminate the influence of process parameters.
An exemplary flow chart 70 of a failure trend analysis process is shown in FIG. 11 . As shown in FIG. 11, the process of failure trend analysis may be accomplished as follows. First, a baseline operation model is built to reflect normal operation, as shown at step 72 . In this step, a statistical model of the machine is created in the baseline condition, that is, normal machine state conditions. The model may be built by methods well known in the art, such as Back Propagation Artificial Neural Network (ANN). For machinery model building, various commercially available software packages may be used. In accordance with the present invention, machine performance parameters such as the number of revolutions, process pressures and temperatures, machine capacity, etc. can be used. The specific set of ANN inputs depends on the type of monitored machinery, as will be appreciated by those skilled in the art. Preferably, recommended input sets may defined initially by a system integrator and be stored in the system's database 60 , shown in FIG. 4 .
As ANN outputs, the time series of the FFT and Experimental Fractal diagnostic parameters in the initial mode of system operation, considered here as baseline parameters, are used. As a result of the ANN training, a statistical model providing correlation between machine process parameters (ANN inputs) and diagnostic parameters is obtained. The correlation coefficients (ANN weights) are preferably stored by in the system database 60 of FIG. 4 .
Next, current machinery performance is evaluated while the machinery is on-line, i.e. operating, as shown at step 74 . The same ANN monitoring is run during operation. The machinery's health is checked (i.e. to detect mechanical failures) as disclosed by the present invention by calculating the Euclidean distance between the vector of ANN weights obtained in the baseline condition training and the vector of ANN weights obtained during system operation. By way of example, Euclidean distance may be calculated as:
D ( I )={square root over (( B ( I )− A ) 2 )}
where A is an ANN weight vector obtained by training under baseline conditions, B(I) is an operating ANN weight vector for moment of time “I,” and D(i) is a Euclidean distance between two vectors for moment of time “I.”
The time series of the D(I) values is continuous analyzed, as shown at steps 76 and 78 of FIG. 11 . For example, the forecasted value of Euclidean distances FD(I) for next time step may be calculated as:
FD ( I )= FD ( I− 1)+ DER ( I− 1)
where DER(I−1)=(D(I−1)−FD(I−1))*TimeConst, and TimeConst is a constant, usually equal to approximately 0.2.
The mean value of DER(I), referred to as MeanDER(I), is next calculated for the “K” last time moments as follows: MeanDER ( I ) = SUM ( DER ( I - K ) + DER ( I - K + 1 ) + … + DER ( I ) ) K
The situation defined as Abs(MeanDER(I))>Threshold is considered a disruption situation associated with beginning of mechanical failure, which is used to determined whether a failure exists in step 78 . When a failure is detected, the related alarm is generated, as shown at step 80 .
Failure development trend modeling is then performed, as shown at step 82 . The forecasted Euclidean distance values for “K” next time steps may be calculated as:
NextKStepsForecast= FD ( I )+ K *MeanDER( I )
Extrapolation of this model to provide future data points allows forecasting of an expected time of mechanical failure. This is used for corrective maintenance timing forecasting, as shown at step 84 . A threshold level may be predetermined to reflect a tolerance for deviations such that the situation defined as NextKStepsForecast>Threshold is considered as a dangerous situation in which mechanical failure is likely. This allows for prediction of a time of machinery failure.
The expected time to the dangerous situation can be calculated as: ( Threshold - FD ( I ) ) MeanDER ( I ) * UpdateTime
where, UpdateTime is a time increment between two evaluations of failure status.
In this way, the motor's torque fluctuations are used as an indicator of early-stage mechanical failures in the machinery for predictive maintenance purposes, to avoid machinery inoperability. | A system and method for predicting mechanical failures in machinery driven by induction motors by using the motor as a diagnostic tool to detect present mechanical disturbances. The motor is monitored during operation to avoid down-time. The motor's torque fluctuations are used as an indicator of early-stage mechanical failures in the machinery. The motor's torque fluctuations are determined using indirect sensing techniques that are less expensive and less intrusive than previously known. More specifically, torque is derived from easily and inexpensively measurable parameters, such as motor slip and phase angle. Current operation is compared to known normal operation. Variations of the motor's characteristics from the known baseline indicate an actual or approaching mechanical failure. “Experimental Fractals” are disclosed that visually represent a current state of the monitored machinery and allow for visual comparison to a baseline for detection of mechanical failures. Future failures are forecasted by extrapolating a derived trend. | 7 |
This application is a continuation of U.S. patent application Ser. No. 941,090, filed Dec. 12, 1986, now abandoned.
FIELD OF THE INVENTION
This invention relates to hangers for articles and particularly to hangers designed for both transport and display of garments or similar products. The hanger is of the article clamping type and is designed to be molded of plastic.
BACKGROUND OF THE INVENTION
Many types of articles and, particularly, clothing come in various sizes and weights requiring hangers to be of a variety of widths, if the article is to be properly suspended or draped. Particularly is this true of garment hangers of the laterally spaced clamp type frequently used for transport and display purposes. To eliminate the necessity for manufacturing and stocking garment hangers in a range of sizes, hangers have been developed provided with clamps slidably mounted on the garment body making it possible to adjust the spacing between the clamps. Providing adjustability has introduced a new problem under certain circumstances of hanger use, that being clamp creep, that is, the tendency of the clamps to shift toward each other due to garment weight during transport and handling and, in some cases, even without the intervention of these factors.
To stabilize the clamp's position on the body, the clamps have been designed to have a firm frictional engagement with the clamp body. This has been found to work satisfactorily with lighter weight and smaller garments that do not require a wide and thus heavy quantity of fabric to be suspended between the clamps. However, with garments of heavier fabrics, such as winter wear, the weight of the panels of fabric suspended between the clamps is sufficient to pull the clamps toward each other despite the frictional resistance. This is particularly undesirable in the retail display of garments when it is desirable to display the garments with some degree of applied tension so that they are displayed to their best advantage. In the case of garments of the heavier fabrics, it is not practical to increase the frictional engagement between the clamps and the hanger body to a point sufficient to eliminate this type of creep because this all but eliminates the adjustability of the clamps and thus the practicality of the hanger. To add locking mechanisms to the clamps is not practical because of cost. It also complicates the hanger's operation. This latter is important because, in many retail operations, the customer must, or at least will, manipulate the hanger. If it is difficult or clumsy to use, the result could be loss of sales due to customer frustration and/or damage to the garment. Providing a practical and inexpensive solution to this problem is the purpose of this invention.
BRIEF DESCRIPTION OF THE INVENTION
The invention provides a means for preventing clamp creep along the hanger body without the necessity for providing a high degree of frictional engagement between the clamp and the hanger body, particularly when the clamp is in release or open position. The invention provides a means of utilizing garment to hanger body engagement when the clamp is closed to provide the necessary frictional resistance to creep to stabilize the position of the clamps. The invention also provides a means for materially increasing the clamp to hanger body resistance to movement when the clamp is closed, yet entirely releasing this additional resistance upon opening the clamp.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation view of the hanger of this invention with the clamps illustrated in closed position;
FIG. 2 is a rear elevation view of the hanger illustrated in FIG. 1;
FIG. 3 is a end elevation view of one of the clamps illustrated in open position;
FIG. 4 is a fragmentary front elevation view of one of the clamps in open position;
FIG. 5 is a fragmentary, rear, oblique view of one of the clamps in open position;
FIG. 6 is a sectional elevation view taken along the plane VI--VI of FIG. 1, illustrating the clamp in closed article gripping position;
FIG. 7 is a sectional elevation view taken along the plane VII--VII of FIG. 1;
FIG. 8 is a sectional elevation view of the rear leg only of the clamp taken along the same plane as FIG. 6;
FIG. 9 is an enlarged, fragmentary, sectional view taken along the plane IX--IX of FIG. 1;
FIG. 10 is a fragmentary front elevation view of a modified construction for the hanger of this invention;
FIG. 11 is a fragmentary rear elevation view of the hanger shown in FIG. 10;
FIG. 12 is a view of the hanger illustrated in FIG. 10 shown in open position;
FIG. 13 is a bottom view of the hanger illustrated in FIG. 10;
FIG. 14 is a top view of the hanger illustrated in FIG. 10; and
FIG. 15 is an oblique view of the hanger illustrated in FIG. 10, shown in open position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 of the drawings, the numeral 10 indicates a hanger having a body 11. The center of the body is vertically enlarged and provides a boss 12 for mounting the support hook 13. In the particular construction illustrated, the hook 13 is of wire and is secured to the boss in such a manner that the body and the weight of whatever garments are secured to the hanger will be supported from the hook. The body 11 is molded of plastic of a suitable type such as styrene or polypropolyene. It will be recognized that instead of a wire hook the hanger body could be designed with a molded plastic hook integral with the body. Such constructions have long been used in the molded plastic hanger art.
The hanger body 11, except in the central area of the boss 12, is in effect an elongated beam of rectangular cross section having arms 14 extending from both sides of the central boss. The arms 14 are identical in length and cross section. Preferably, the beam has a greater vertical dimension than front to back dimension as is best seen in FIG. 7 to resist bending due to the weight of the garments. For purposes of rigidity, it is of I-beam cross section construction having an upper flange 15 and a lower flange 16 interconnected by a vertical web 17.
Extending from the web 17 forwardly to the front edge of the flanges 15 and 16 are a plurality of vertical ribs 18 which are integral with and extend vertically between the flanges 15 and 16 and are also integral with the central web 17. The ribs are equally spaced along the front face of the beam, except that they are omitted in the general area of the central boss 12 for reasons which will become obvious subsequently. The ribs create a plurality of forwardly opening pockets 19 along that portion of each of the arms where the garment clamps can be expected to be located when the hanger is in use (FIG. 9). No ribs are provided along the back face of the body. Each end of the body is closed by an end web 20. Immediately adjacent each end web a stop 21 is provided on the rear face of the body which is integral with the central web 17 and has an outwardly facing and rearwardly extending inclined surface 22 which extends beyond the plane of the rear face of the body 11 (FIG. 9). The materials used for molding the body 11 and its dimensions are such that it will remain rigid and basically undeflected by the weight of any of the articles which might reasonably be expected to be suspended from the hanger.
Articles are supported from the hanger by means of a pair of clamps 30. Each of the clamps has a front leg 31 and a back leg 32, which legs are integrally joined together at their upper ends by a web forming a hinge 33. The front and rear legs and the hinge are integral and are molded as a single piece from a suitable plastic material such as polypropylene. The back or rear leg 32 has a pair of spaced side members 34, the upper ends of which extend forwardly and are integral with the hinge 33 (FIGS. 5 and 8). The side members 34 extend downwardly and at their lower ends terminate in forwardly directed article gripping teeth 35. Between the hinge 33 and the lower end of the side members, the side members are joined together by a guide bar 36, a panel 37 and a cross member 38 (FIGS. 5 and 8). They are also connected by a cross bar 36a. As shown in FIG. 8, the panel 37 is L-shaped with a short leg extending forwardly at the top of the panel. Vertically elongated openings 39 are provided in each of the side members 34. The openings provide means for a mold insert to extend through the side members to form the inwardly extending U-shaped straps 40. The size and shape of the straps 40 is such as to form a rectangular shaped track or passage 41 between the straps and the side members 34 of a size and shape to closely seat around the arms 14 of the hanger body 11 and, thus, slidably support the clamps on the hanger body. The shape of the passage is such as to positively hold the clamps against pivotal movement around the arms. The back leg is open from the ends of the straps to its lower end, thus, forming a generally upwardly directed U-shaped opening 42. The area between the bottom of the panel 37 and the cross member 38 is also open, providing an aperture 43 which extends between the side members 34 and is basically of the same vertical height as the passage 41. The functional importance of this opening will be explained subsequently.
The front leg 31, at its upper end, is of the same width as the rear leg 32. However, the lower portion of the front leg is tapered so that its lower end is of a width which will pass through the opening 42. The central portion of the front leg 31 is recessed at 45 throughout most of its height (FIG. 5). The upper portion 46 of this recess forms a guide track for the U-shaped spring clip 47 which, when the clamp is closed, seats down over both the front and rear legs. Where the guide track 46 merges into the lower portion of the recess 45, a rearwardly offset step 48 is provided in the face of the recess which cooperates with the inwardly extending flange 49 on the clamp 47. The engagement between the step and flange provides a hold down for the spring clip when it is fully seated.
The rear leg of the clip passes between the guide bar 36 and the rear face of the panel 37 in the track defined between the inner edges of the side members 34. The lower end of the spring clamp has an outwardly offset stop 50 designed to engage the guide bar 36 to prevent the spring clip from being inadvertently detached from the clamp. The rear leg of the spring clip is substantially longer than the front leg and, thus, when the clamp is fully depressed or seated, the lower portion extends almost entirely across the rear face of the aperture 43. Thus, it engages and by reason of its resilience, presses firmly against the top flange of the arm portion 14 of the body 11. The concept of the spring clip 47 and of utilizing it to resiliently hold a pair of clamping jaws of a article hanger in closed position and being mounted in a track to guide its vertical movement between clamped and released positions is disclosed in U.S. Pat. No. 3,767,092 issued Oct. 23, 1973 to J. F. Garrison et al. However, utilizing the spring clip to engage the support for the clamp is new.
To assemble the clamps to the hanger body, the end of one of the arms 14 is threaded through the passages 41 created by the straps 40 and, as this is done, the stop 21 is forced past the side members 34. This is possible because the clamps having been molded of a plastic material having a limited degree of resilience can be sufficiently deflected to enlarge the passages 41 enough to allow the side members to flex to pass over the stop 21. This is repeated on each end of the hanger body 11. This is done while the spring clip 47 is in raised or released position. Once the clamps have been mounted on the bar, because the stops 21 have an inwardly directed face which is basically perpendicular to the central web 17 the clamps cannot readily be made to disengage the bar.
So long as the spring clip 47 remains in raised or release position, the clamps can be moved reasonably freely lengthwise of the arms 14. However, when the spring clip is pushed down into clamp closing position, the rear leg of the clip passes over and presses tightly against the upper flange of the arm on which the clamp is mounted. Since the spring clip is resilient and is biased to press inwardly, this creates frictional resistance to movement of the clamp lengthwise of the bar. Thus, this is an important and very useful in contribution to stabilizing the position of the clamp once the garment has been secured to the hangers.
Even with the resistance created by the spring clip 47 bearing against the back face of the top flange of the body or bar, particularly in the case of garments which are wide and, therefore, have a central portion of substantial width, the weight of the garment between the clamps can be sufficient to cause the clamps to creep toward each other even though such movement is resisted by the engagement between the spring clip and the back of the arms. This is particularly true when the hangers are used for transport. The ribs 18 are provided to overcome this problem. When a garment is placed with its upper end, normally the waistband, seated in the chamber 58 created between the legs of the clamp when it is closed, the garment is not only gripped between the teeth 35 and 44, it is also squeezed against the front face of the body 11 that is exposed to the chamber 58 between the straps 40 (FIG. 6). The squeezing action is created not only by the fact that the exposed face of the body 11 extends a substantial distance into chamber 58, but also by the fact that the central portion of the front leg 31 which lies behind the recess 45 is curved inwardly toward the body 11 and, thus, squeezes the garment firmly against the front face of the body. Portions of the garment are forced to protrude into the pockets or spaces 19 between the ribs 18. Thus, the garment's engagement with the ribs provides a positive interference resistance to the movement of the clamps 30 lengthwise of the body. In this manner, the spring clip's engagement with the back face of the body and the garment engagement of the ribs 18 cooperate to prevent lateral movement of the clamps along the body, even though the garment may be heavy and tensioned between the clamps so that the garment presents a neat and pleasing experience. This is very important in making the hanger acceptable to those who would use it for garment display at the retail level.
FIGS. 10-15 illustrate a modification of this invention. The clamp 60 has a pair of jaws 61 and 62 joined by an integral hinge 63 whereby the clamp can be opened and closed. Closure of the clamp is effected by a U-shaped spring clip 64 which preferably is of the same design and functional characteristics as the spring clip 47. Garment hangers with this type of clamp are disclosed in the previously mentioned U.S. Pat. No. 3,767,092. When the spring clip 64 is in the raised position the clamp is released and can be opened and when depressed, the clamp is closed.
The rear jaw 62 at its lower end has a pair of laterally spaced forwardly extending straps 65 which form a pair of rectangular passages of a size and shape to closely fit around and embrace one of the arms 14 of a hanger. These straps serve the same function as the straps 40 but they are positioned adjacent the lower ends of the jaws 61 and 62. Thus, the front face of the arm 14 passing through the passage 66 created by the straps is vertically aligned with the lower end of the jaw 61. This arrangement provides positive pressure against the garment, forcing it into engagement with the front face of the body and in the case of the body 14 against the ribs 18. Since most of the chamber 70 is above the body 14, the waist band of the garment may be entirely above the body 14 or the front jaw will clamp against the waist band. In either case, the clamp will provide a positive grip against release of the garment. It will also provide a positive anti-creep engagement with the body 14.
FIGS. 11 and 15 illustrate a modified construction for the hanger body. In this construction, the body 14a has a center flange or rib 72 on the front face. The front center rib 72 has a plurality of teeth 73 in its front face. These teeth may be pointed or rounded, as illustrated. These teeth either align with or are slightly above the gripping teeth 74 on the front jaw. They provide a positive anti-creep grip on the garment. Preferably, rear jaw 62 of the clamp 60 has a central elongated opening 75 between the lower end of the panel 76 and the base tie bar 77 connecting the sides of the rear jaw together at the rear end of the straps 65. This opening permits the lower end of the spring clip 64 to frictionally engage the top flange and rear center rib of the body providing a positive resistance to creep when the clamp is closed (FIG. 11).
It will be recognized that the main body of the hanger can be molded in relatively simple molds and, thus, both its mold cost and the actual manufacturing process is materially simplified and the cost reduced. In addition, only a single type of mold cavity is needed to make all of the necessary clamps, since all of the clamps are identical. Further, since the clamps are molded separately from the body of the hanger, the cost of the necessary molds is substantially reduced, since both the size and the complexity of the molds is materially lessened. This is accomplished without adversely affecting the functional characteristics of the hanger.
Having described the invention and its operation, it will be recognized that various modifications of the invention can be made without departing from the principles of the invention. Such modifications are to be considered as included in the hereinafter appended claims, unless these claims by their language expressly state otherwise. | An article hanger particularly useful for clothing has an elongated, non-circular, beam-like body along which article gripping clamps are slidably mounted for adjustment in spacing. The beam-like body passes through the article receiving chamber formed between the jaws of the clamps. The clamps have spaced strap-like members which extend around and embrace the beam-like body. The face of the body directed into the chamber is exposed between the straps and has an irregular or unsmooth surface against which the article is pressed by the clamps to create a frictional grip resisting creep of the clamp lengthwise of the body. Also the spring clip holding the clamp closed engages the back face of the body to further resist creep. | 0 |
TECHNICAL FIELD
This disclosure relates to the field of automatic transmissions for motor vehicles. More particularly, the disclosure pertains to an arrangement of gears, clutches, and the interconnections among them in a power transmission.
BACKGROUND
Many vehicles are used over a wide range of vehicle speeds, including both forward and reverse movement. Some types of engines, however, are capable of operating efficiently only within a narrow range of speeds. Consequently, transmissions capable of efficiently transmitting power at a variety of speed ratios are frequently employed. When the vehicle is at low speed, the transmission is usually operated at a high speed ratio such that it multiplies the engine torque for improved acceleration. At high vehicle speed, operating the transmission at a low speed ratio permits an engine speed associated with quiet, fuel efficient cruising. Typically, a transmission has a housing mounted to the vehicle structure, an input shaft driven by an engine crankshaft, and an output shaft driving the vehicle wheels, often via a differential assembly which permits the left and right wheel to rotate at slightly different speeds as the vehicle turns.
Some vehicles are equipped with a two speed secondary transmission such that a driver can select a high range and a low range. The high range may be selected for on-road transportation while the low range may be used to provide higher speed ratios for off-road use. In some situations, such as transitioning from on-road to off-road or from off-road to on-road conditions, it is desirable to shift between high and low range while the vehicle is moving, preferably without interrupting the flow of power to the vehicle wheels.
SUMMARY OF THE DISCLOSURE
A transmission gearing arrangement includes a range selection clutch and five other clutches. The transmission is operated in high range by engaging the range selection clutch and in low range by disengaging the range selection clutch. The transmission can shift from the fourth low range ratio to the third high range ratio while the vehicle is in motion.
In one embodiment, a transmission includes input and output shaft and first, second, third, fourth, and sixth rotating elements. A first gearing arrangement fixedly constrains the speed of the input shaft to be between that of the first and second elements. The first gearing arrangement may be, for example, a simple planetary gear set with the sun gear as the first element, the ring gear as the second element, and the carrier fixedly coupled to the input shaft. A second gearing arrangement fixedly constrains the speed of the output shaft to be between that of the third and fourth elements. The second gearing arrangement may be, for example, a simple planetary gear set with the sun gear as the third element, the ring gear as the fourth element, and the carrier fixedly coupled to the output shaft. A third gearing arrangement fixedly constrains the speed of the fourth element to be between zero and the speed of the sixth element. The third gearing arrangement may be, for example, a simple planetary gear set with the sun gear as the sixth element, the ring gear fixedly held against rotation, and the carrier fixedly coupled to the fourth element. A fourth gearing arrangement selectively constrains the speed of the output shaft to be between that of the second and third elements. The fourth gearing arrangement may be, for example, a simple planetary gear set with the sun gear selectively coupled to second element, the ring gear fixedly coupled to the third element, and the carrier fixedly coupled to the output shaft. A range clutch selectively couples the sixth element to the input shaft. The third element is selectively coupled to the second element by a second clutch and to the input shaft by a third clutch. The first element is selectively coupled to the sixth element by a fourth clutch and held against rotation by a brake.
In another embodiment, a transmission includes input and output shaft and first, second, third, fourth, fifth, and sixth rotating elements. A first gearing arrangement fixedly constrains the speed of the input shaft to be between that of the first and second elements. The first gearing arrangement may be, for example, a simple planetary gear set with the sun gear as the first element, the ring gear as the second element, and the carrier fixedly coupled to the input shaft. A second gearing arrangement fixedly constrains the speed of the third element, the output shaft, the fourth element, and the fifth element to be linearly related. The second gearing arrangement may be, for example, two simple planetary gear sets with the first sun gear as the fifth element, the two carriers fixedly coupled to one another and to the output shaft, the second ring gear as the fourth element, and first ring gear fixedly coupled to the second sun gear as the third element. A third gearing arrangement fixedly constrains the speed of the fourth element to be between zero and the speed of the sixth element. The third gearing arrangement may be, for example, a simple planetary gear set with the sun gear as the sixth element, the ring gear fixedly held against rotation, and the carrier fixedly coupled to the fourth element. A range clutch selectively couples the sixth element to the input shaft. The third element is selectively coupled to the second element by a second clutch and to the input shaft by a third clutch. The first element is selectively coupled to the sixth element by a fourth clutch and held against rotation by a brake. A fifth clutch selectively couples the second element to the fifth element.
In another embodiment, a vehicle having a transmission with a range selection clutch and five other clutches is operated in high range with the range selection clutch disengaged and operated in a low range with the range selection clutch engaged in response to a driver selection. In the high range, the transmission is operated in up to eight distinct forward speed ratios and one reverse speed ratio by selective engagement of the five other clutches in combinations of three. In the low range, the transmission is operated in up to five distinct forward speed ratios by selective engagement of the five other clutches in combinations of two. A transition from low range to high range can be accomplished by sequentially engaging a third of the other five clutches and then disengaging the range clutch. A transition from high range to low range can be accomplished by sequentially engaging the range clutch and then disengaging one of the other five clutches. These transitions can be accomplished while the vehicle is moving in response to a change in range selection by a vehicle driver.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a transmission gearing arrangement;
FIG. 2 is a lever diagram corresponding to the gearing arrangement of FIG. 1 ;
FIG. 3 is a clutch application chart indicating the state of each clutch in the gearing arrangement of FIG. 1 and the resulting speed ratios when operated in a high range;
FIG. 4 is a clutch application chart indicating the state of each clutch in the gearing arrangement of FIG. 1 and the resulting speed ratios when operated in a low range;
FIG. 5 is a flow diagram illustrating the steps required to transition between low range and high range; and
FIG. 6 is a clutch application chart indicating the state of each clutch in the gearing arrangement of FIG. 1 and the resulting speed ratio when operated in a combined low and high range.
DETAILED DESCRIPTION
Embodiments of the present disclosure are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodiments may take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures may be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.
A gearing arrangement is a collection of rotating elements and clutches configured to impose specified speed relationships among elements. Some speed relationships, called fixed speed relationships, are imposed regardless of the state of any clutches. A gearing arrangement imposing only fixed relationships is called a fixed gearing arrangement. Other speed relationships are imposed only when particular clutches are fully engaged. A gearing arrangement that selectively imposes speed relationships is called a shiftable gearing arrangement. A discrete ratio transmission has a shiftable gearing arrangement that selectively imposes a variety of speed ratios between an input shaft and an output shaft.
A group of elements are fixedly coupled to one another if they are constrained to rotate as a unit in all operating conditions. Elements may be fixedly coupled by spline connections, welding, press fitting, machining from a common solid, or other means. Slight variations in rotational displacement between fixedly coupled elements can occur such as displacement due to lash or shaft compliance. In contrast, two elements are selectively coupled by a clutch when the clutch constrains them to rotate as a unit whenever the clutch is fully engaged and they are free to rotate at distinct speeds in at least some other operating condition. Clutches include actively controlled devices such as hydraulically or electrically actuated clutches and passive devices such as one way clutches. A clutch that holds an element against rotation by selectively connecting the element to the housing may be called a brake.
Shifts among speed ratios may be performed without interrupting the flow of power from the input shaft to the output shaft by carefully coordinating the engagement of one clutch with the disengagement of another clutch. During the transition, one of both of these clutches must transmit torque between elements moving at different speeds. In such a condition, heat is absorbed and dissipated by the clutch. The amount of energy absorbed is larger when the ratio of the two speed ratios involved, called the step size, is higher. Sometimes, providing a clutch with enough energy absorption capability dictates the sizing of the clutch and increases the amount of parasitic drag the clutch causes when disengaged. Also, shifts with very large step sizes are difficult to perform without generating large torque disturbances at the output shaft which may be uncomfortable for vehicle occupants.
Typical secondary transmissions have step sizes exceeding 2:1 . In order to minimize the parasitic drag associated with the secondary transmission, the secondary transmission is often configured such that shifting between the low range and high range is only possible when the vehicle is stationary. If range shifts are allowed while the vehicle is moving, it may be necessary to interrupt the flow of power by putting the primary transmission in neutral while shifting the secondary transmission.
An example transmission is schematically illustrated in FIG. 1 . The transmission utilizes four simple planetary gear sets 20 , 30 , 40 , and 50 . A simple planetary gear set is a type of fixed gearing arrangement. A planet carrier 22 rotates about a central axis and supports a set of planet gears 24 such that the planet gears rotate with respect to the planet carrier. External gear teeth on the planet gears mesh with external gear teeth on a sun gear 26 and with internal gear teeth on a ring gear 28 . The sun gear and ring gear are supported to rotate about the same axis as the carrier. A simple planetary gear set imposes the fixed speed relationship that the speed of the carrier is between the speed of the sun gear and the speed of the ring gear. (This relationship is defined to include the condition in which all three rotate at the same speed.) More specifically, the speed of the carrier is a weighted average of the speed of the sun gear and the speed of the ring gear with weighting factors determined by the number of teeth on each gear. Similar speed relationships are imposed by other known types of fixed gearing arrangements. For example, a double pinion planetary gear set constrains the speed of the ring gear to be a weighted average between the speed of the sun gear and the speed of the carrier. A suggested ratio of gear teeth for each planetary gear set in FIG. 1 is listed in Table 1.
TABLE 1
Ring 28/Sun 26
2.12
Ring 38/Sun 36
2.14
Ring 48/Sun 46
1.73
Ring 58/Sun 56
3.56
Input shaft 10 is fixedly coupled to carrier 32 . Output shaft 12 is fixedly coupled to carrier 42 and carrier 52 . Ring gear 28 is fixedly held against rotation by transmission case 14 . Carrier 22 is fixedly coupled to ring gear 58 . Ring gear 48 is fixedly coupled to sun gear 56 . Sun gear 36 is selectively coupled to sun gear 26 by clutch 62 and selectively held against rotation by brake 64 . Input shaft 10 and carrier 32 are selectively coupled to sun gear 26 by range clutch 70 and selectively coupled to ring gear 48 and sun gear 56 by clutch 66 . Ring gear 38 is selectively coupled to sun gear 46 by clutch 60 and selectively coupled to ring gear 48 and sun gear 56 by clutch 68 .
FIG. 2 describes the transmission of FIG. 1 in the form of a lever diagram. Gear elements which rotate about a common axis and have speeds with a fixed linear relationship are shown along a lever according to their relative speeds. The two elements that have the most extreme speeds are shown at the endpoints of the lever. The remaining elements are shown at intermediate points. The 1st through 6th rotating elements each correspond to one or more planetary gear elements. Gear sets 20 and 30 correspond directly to three node levers with the sun gear at one endpoint, the ring gear at the opposite endpoint, and the carrier at an intermediate point. Specifically, the 1st element corresponds to sun gear 36 , the 2nd element corresponds to ring gear 38 , the 4th element corresponds to carrier 22 , and the 6th element corresponds to sun gear 26 . Four node lever 72 corresponds to gear sets 40 and 50 , with the 3rd element corresponding to ring gear 48 and sun gear 56 , the 4th element corresponding to ring gear 58 , and the 5th element corresponding to sun gear 46 . Any four element fixed gearing arrangement that imposes the designated speed relationships with appropriate weighting factors may be substituted for gear sets 40 and 50 of FIG. 1 without impacting the transmission speed ratios. Any combination of two planetary gear sets with two elements of each fixedly connected to two elements of the other forms a four element fixed gearing arrangement. Some fixed gearing arrangements will be preferable to others in terms of packaging, efficiency, and planet gear speeds.
The clutches and brakes may be hydraulically actuated multi-plate clutches or other types of clutches that are actively engaged and disengaged by a controller. As discussed below, it is possible to operate the transmission such that the controller does not need to accurately modulate the torque capacity of range clutch 70 and range clutch 70 does not absorb appreciable energy during shifts. Consequently, the design of range clutch 70 can be optimized for very low parasitic drag. Also, brake 64 can be a combination of a controllable friction clutch and a passive one way clutch. Such a combination may be engaged either actively by the controller or as a result of the one way clutch resisting rotation in a reverse direction.
As shown in FIGS. 3-5 , engaging the clutches in combinations of three establishes a variety of forward and reverse speed ratios between input shaft 10 and output shaft 12 . An X indicates that the clutch is engaged to establish the speed ratio. When the gear sets of FIG. 1 have tooth numbers as indicated in Table 1, the speed ratios have the values indicated in FIGS. 3-5 .
FIG. 3 indicates which clutches are applied during high range operation. Range clutch 70 is disengaged in all high range gear states. All shifts between adjacent speed ratios can be accomplished by the coordinated release of one clutch and the engagement of one other clutch. Similarly, all two-step shifts and many of the three step shifts can be accomplished by the coordinated release of one clutch and engagement of one other clutch. If the transmission is equipped with a launch device such as a torque converter or launch clutch, then the transmission is prepared for forward driving by engaging clutches 62 and 66 and brake 64 . Alternatively, brake 64 can be utilized as a launch clutch. For reverse driving, clutch 60 is engaged instead of clutch 66 . FIG. 4 indicates which clutches are applied during low range forward operation. Range clutch 70 is engaged in all low range gear states.
FIG. 5 illustrates a process for transitioning between low range and high range in response to a driver changing the selected range. Operation in high range is shown at 80 . Two sequences of clutch transitions effect the change from high range to low range. The controller selects between these two sequences at 82 based on vehicle speed. If the vehicle is stopped or nearly stopped, the controller disengages all currently engaged clutches except clutch 64 at 84 , placing the transmission in neutral. Then, clutch 70 is engaged at 86 . The only energy absorbed by clutch 70 during this engagement is the energy associated with the inertia of transmission components, which is small because all transmission components are rotating slowly if at all. Because the transmission is still in neutral even after clutch 70 is engaged, very little torque disturbance is transmitted to the output shaft. At 88 , clutch 60 is engaged. At that point, the transmission in is Low 1, and operation in low mode commences at 90 . If the vehicle is moving, a different sequence of transitions is selected at 82 . At 92 , the transmission is shifted to 3rd gear if it was in some other gear. If this shift is not allowed due to excessive vehicle speed, the controller waits until vehicle speed decreases and then shifts into 3rd gear. At 94 , clutch 70 is engaged. In 3rd gear, sun gear 26 and the input shaft, the two elements coupled by clutch 70 , rotate at the same speed. Consequently, engaging clutch 70 does not change the speed of any elements or cause any output torque disturbance. Then, clutch 62 is disengaged at 96 , placing the transmission in Low 4, and operation in low mode commences at 90 . The transmission continues to transmit power from the input shaft to the output shaft throughout the transition from high mode to low mode by this later sequence.
Similarly, two sequences of clutch transitions effect the change from low mode to high mode. The controller selects between these two sequences at 98 based on vehicle speed. If the vehicle is stopped or nearly stopped, the controller disengages all currently engaged clutches except clutch 64 at 100 , placing the transmission in neutral. Then, clutches 60 and 62 are engaged at 102 placing the transmission in 3rd gear. Operation in high mode commences at 80 . If the vehicle is moving, a different sequence of transitions is selected at 98 . At 104 , the transmission is shifted to Low 4 if it was in some other gear. At 106 , clutch 62 is engaged. Then, clutch 70 is disengaged at 108 , placing the transmission in 3rd gear, and operation in high mode commences at 80 . The transmission continues to transmit power from the input shaft to the output shaft throughout the transition from high mode to low mode by this later sequence.
FIG. 6 is a clutch application chart for a combined low and high range mode of operation. In this mode of operation, the transmission is automatically shifted between low range and high range based on vehicle speed or other factors like accelerator pedal position. At low speed, the transmission operates in low range, utilizing Low 1 through Low 4 speed ratios. If a further upshift is indicated, the transmission first shifts into 3rd gear by engaging clutch 62 and then disengaging clutch 70 . At higher speeds, the transmission operates in high range, utilizing 3rd through 8th gears. If a further downshift is indicated while operating in 3rd gear, the transmission first shifts into low range by engaging clutch 70 and then releasing clutch 62 .
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments may be combined to form further embodiments of the invention that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics may be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. These attributes can include, but are not limited to cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. As such, embodiments described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications. | A transmission gearing arrangement includes four simple planetary gear sets, a range selection clutch, and five other clutches including one brake. The transmission is operated in high range by engaging the range selection clutch and in low range by disengaging the range selection clutch. In high range, the transmission produces eight forward speed ratios and one reverse speed ratio by selective engagement of various combinations of three of the five other clutches. In low range, the transmission produces five forward speed ratios by selective engagement of various combinations of two of the other five clutches. The transmission can shift from the fourth low range ratio to the third high range ratio while the vehicle is in motion. | 5 |
FIELD OF THE INVENTION
This invention relates to a fluid operated disconnect coupling, and more specifically, such a coupling that may be utilized for coupling or uncoupling a power takeoff shaft in a power train.
BACKGROUND OF THE INVENTION
A large number of power trains associated with, for example, motors or engines, include provision for operating auxiliary devices via a power take-off. Frequently, the power take-off is in the form of a shaft connected to the auxiliary devices.
Depending upon the system, any number of a large variety of reasons may exist that require occasional decoupling of the power take-off from the power train and a variety of proposals of coupling and decoupling mechanisms have been made. By way of example, attention may be directed to the following U.S. Pat. Nos. 2,784,822 issued Mar. 12, 1957 to Heiser; 3,835,722 issued Sept. 17, 1974 to Bertram, et al; and 4,482,039 issued Nov. 13, 1984 to Harris.
While such couplings may operate generally satisfactorily for their intended purpose, the same generally fail to provide for positive latching of the coupling in either the coupled or decoupled state. The failure to provide such means can result in operational difficulties in the case of system failures. For example, unintentional attempts to couple or decouple during operation of the power train may cause damage to the coupling and/or provide undesirably high loads elsewhere in the system.
The present invention is directed to overcoming the above problems.
SUMMARY OF THE INVENTION
It is the principle object of the invention to provide a new and improved fluid operated disconnect coupling. More particularly, it is an object of the invention to provide such a coupling wherein the coupling is positively maintained in either a coupled or an uncoupled state, as desired. Preferably, provision is made for positively, alternatively maintaining the coupling in both a coupled state and a decoupled state.
An exemplary embodiment of the invention achieves the foregoing objects in a structure including first and second power train elements mounted for movement relative to each other between a coupled, power transmitting position and a decoupled non-transmitting position. Means are connected to at least one of such elements for effecting the relative movement between the positions and include a first fluid cylinder. Fluid operated latch means are provided for latching the effecting means in at least one of the two positions and include a moveable latch for latchingly engaging or releasing the effecting means, a second fluid cylinder for moving the latch and a valve operable with the latch to establish fluid communication between the fluid cylinders when the moveable latch was released the effecting means. A control means is provided for selective directing fluid under pressure to the second cylinder.
As a consequence of this construction, the latching means will positively latch the movement effecting means in a desired one of the positions. When it is desired to shift to the other position, the control means provides fluid under pressure first to the second fluid cylinder to release the latch. When the latch is released, the establishment of fluid communication by the valve between the fluid cylinders results in the application of fluid under pressure to the first cylinder to provide the desired change in state.
In a preferred embodiment, the second cylinder is a spring loaded, single acting cylinder which operates to bias the latch into engagement with the effecting means.
The second cylinder may have a rod mounting the latch and the rod further defines part of the valve.
In a highly preferred embodiment, the second cylinder is mounted on the first cylinder and the latch enters the first cylinder for latching engagement with a piston rod therein. The valve includes a port into the first cylinder and the rod of the second cylinder extends through the port.
The invention contemplates the first cylinder be a double acting cylinder and that there be two of the latch means. One of the latch means latchingly engages the piston rod at the coupled position and the other latchingly engages the piston rod at the decoupled position. The control means is selectively operable to direct fluid under pressure to one or the other of the latch means. In a highly preferred embodiment, there is further included a means for detecting a condition indicative of the operation of one of the elements for disabling the effecting means. As a consequence, coupling or uncoupling is precluded from occurring during operation of a power train with which the mechanism may be associated.
Other objects and advantages will become apparent from the following specification taken in connection with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of a coupling system made according to the invention with parts shown schematically; and
FIG. 2 is an enlarged fragmentary view of a portion of a latching mechanism utilized in connection with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An exemplary embodiment of the invention is illustrated in the drawing and with reference to FIG. 1 is seen in connection with a power train, shown schematically by the general designation 10, which may be, for example, the gear box on a turbine engine.
Within the power train 10 are first and second rotatable gears 12 and 14 journaled by conventional means (not shown). The gear 14 includes internal gear teeth 16 which are chamfered as shown at 18 at their ends facing the gear 12. The gear 12 has chamfered ends 20 and is axially moveable towards and away from the gear 14. When moved toward the gear 14, the chamfers 18 and 20 serve to align the gears 12 and 14 so that the gear 12 enters the gear 14 to engage the teeth 16. Thus, if the gear 14 is a drive gear within the power train 10, the gear 12 will be driven thereby when axially moved into coupling engagement therewith. To decouple the gears 12 and 14, the latter is moved axially away from the former to the position illustrated in FIG. 1.
The gear 12 is moved between coupled and uncoupled positions by one end 22 of a piston rod 24 of a double acting, double rod ended, fluid cylinder, generally designated 26.
Within the cylinder 26 the rod 24 mounts a piston 28 and annular grooves 30 and 32 are located in the rod 24 on each side of the piston 28.
As viewed in FIG. 1, when the lower side of the piston 28 is subjected to fluid under pressure, the gear 12 will be moved into engagement with the gear 14 as shown by the arrow bearing the legend "couple."
Conversely, when the upper side of the piston 28 is pressurized, the latter will move in the direction indicated by the arrow bearing the legend "decouple" to move the gear 12 out of engagement with the gear 14.
Latch means are provided for holding the rod 24 in either of two positions, one position corresponding to a coupled position of the gears 12 and 14 and the other position corresponding to a decoupled position of the gears 12 and 14. A first latch unit, generally designated 34, is operable to latch the rod 24 in a decoupled position while a second latch 36 is operable to latch the rod 24 in a position corresponding to a coupled position.
The latches 34 and 36 are identical structurally to each other so only the latch 34 will be described in detail. The same includes a single acting, spring biased cylinder, generally designated 38 which is mounted on the cylinder 26. The cylinder 38 includes an internal bore 40 reciprocally receiving a piston 42 on a rod 44. A spring 46 is located within the bore 40 and is operable to bias the piston 42 to the left as viewed in FIGS. 1 and 2.
The rod 44, at its end adjacent the rod 24, mounts a latch 48 which can enter the groove 30 of the rod 24 to mechanically latch the rod 24 against movement. In the usual case, the bias provided by the spring 46 is sufficient to cause introduction of the latch 48 into the groove 30.
A fluid port 50 opens to the bore 40 on the side of the piston 42 opposite the spring 46. By introducing fluid under pressure into the port 50, the piston 42 may be moved against the bias of the spring 46 to withdraw the latch 48 from the groove 30.
It will be observed that the rod 44 and the latch 48 enter the cylinder 26 via a port 52 in the wall thereof. The port 52 along with a shoulder 54 on the rod 44 act as a valve for controlling fluid communication between the bore 40 of the cylinder 38 and the interior of the cylinder 26 on the side of the piston 28 adjacent the groove 30. When the piston 42 is moved to its full left position as viewed in FIG. 2 under the influence of the biasing spring 46, it will be appreciated that the port 52 is sealed by the presence of the shoulder 54 therein. Consequently, there will be no fluid communication between the bore 40 and the cylinder 26 during such occurrence, which will always be the case so long as the latch 36 is partly or wholly within the groove 30.
The latch 36 operates in the same fashion but cooperates with the groove 32 and the associated side of the piston 28. The rods 44 of the latches 34 and 36 also operate respective electrical switches 58 and 60 of the multiple contact variety.
The system includes a supply of fluid under pressure shown schematically at 62 which provides, for example, pressurized air to a reservoir 64. The air reservoir 64 is connected in parallel to solenoid operated valves 66 and 68. The valves 66 and 68 are three-way valves and connect respective conduits 70 and 72 to the reservoir 64 when the associated solenoid is energized or to a vent 74 when the associated solenoid is de-energized.
The conduit 70 is connected to the port 50 associated with the first latch 34 while the conduit 72 is connected to the corresponding port associated with the second latch 36.
The system also includes an activating switch 76 which may be closed via a contact 76D to cause decoupling of the gears 12 and 14 or through a contact 76C to cause coupling of the gears 12 and 14. Wired into the circuit are indicator lights 78C to indicate coupling of the gears and 78D to indicate decoupling.
The system also includes a power source and a detecting switch in the form of a pressure switch 82 which is open when subjected to pressure. Typically, the pressure switch 82 will be located in the lubricant system of the power train 10, which, of course, will contain lubricant at an elevated pressure whenever the power train is operative. Conversely, when the power train is not operative, the lubricant system will be at ambient pressure and the switch 82 will close.
Operation of the system is as follows. As illustrated, the components are in a decoupled position. Assuming that the detecting switch 82 is closed, indicative of the fact that the system is not operative, the moving of the switch 76 to a closed position via the contact 76C will result in power being applied through the closed set of contacts of the switch 60 to the solenoid valve 66. The solenoid will be energized with the consequence that the air reservoir 64 will be connected to the line 70. Fluid under pressure will be applied to the left hand side of the piston 42 to move the same to the right against the bias of the spring 46. This will result in the latch 48 being withdrawn from the groove 30 freeing the rod 24 for movement toward the coupling position.
When the shoulder 54 clears the port 52, the lower side of the piston 28 will be in fluid communication with the interior of the bore 40 and the pressurized fluid therein will act against the piston 28 to move the same upwardly to cause engagement of the gear 12 with the gear 14. At this time the solenoid valve 68 will be de-energized since it can only be energized when the switch 76 is closed via the contact 76D. As a consequence, as the piston rod 24 moves up within the cylinder 26, the groove 32 will align with the latch associated with the latch 36 and the biasing spring 46 of the latch 36 will result in positive latching by entry into the groove 32 when the gears 12 and 14 are aligned and engaged. This, in turn, will cause the opening of the closed contact of the switch 60 de-energizing the solenoid valve 66. It will also cause the open contact of the switch 60 to be closed to illuminate the indicator light 78C indicating a coupled position.
Furthermore, the withdrawal of the latch 48 associated with the latching mechanism 34 from the groove 30 will change the condition of the contacts of the switch 58. The open contact will become closed thereby conditioning the circuit for operation to cause decoupling upon a change in the condition of the switch at 76. In addition, the closed contact of the switch 56 will have opened to de-energize the indicator light 78D.
A similar but opposite operation occurs in the system in switching from a coupled to a decoupled condition.
From the foregoing, it will be appreciated that the coupling system of the invention provides positive retention of the shiftable element responsible for coupling and uncoupling in either a coupled or a decoupled position, and then by mechanical latches unaffected by system failures as, for example, the loss of air pressure, sticky valves or the like. The unique arrangement of system components utilizes air under pressure only under a coupling or decoupling operation and constant air pressure is not required to maintain a coupled or a decoupled operation.
Stress on system components is further eliminated by the unique arrangement of the latches 34 and 36 with respect to the cylinder 26 and the valving function provided by the shoulders 54 with respect to the ports 52. Simply stated, unlatching of the mechanical latches must be effected before the piston 28 can be pressurized. Thus, stresses on the latches that could result from early pressurization of the pistion 28 are avoided. | Positive retention of a power train coupling in either a coupled or decoupled position is achieved in a structure including first and second power train elements 12 and 14 mounted for movement relative to each other between a coupled power transmitting position and a decoupled non-transmitting position by the provision of a pair of fluid operated latches 34 and 36 engageable with a double acting piston 28 and cylinder 26 which is operable to move one of the elements 12,14 relative to the other. Each latch includes a moveable latch element 48 for latchingly engaging a groove 30, 32 in the rod 24 mounting the pistion 28, a second fluid cylinder 38 for moving the latch element 48, and a valve 52, 54 for establishing fluid communication between the second cylinder 36 and the double acting cylinder 26. | 5 |
FIELD OF THE INVENTION
The present invention relates to a cap for a condiment container.
BACKGROUND OF THE INVENTION
Condiment containers such as salt shakers traditionally have caps with dispensing openings provided therein to allow the escape of condiments through the cap when the container is inverted. The condiment container can thus be used to spread condiments over, e.g., a meal by inverting the container over the meal to allow the condiment from escaping through the cap onto the plate.
With condiment containers that have exposed dispensing openings, condiments may escape accidentally if the container is tilted or tipped unwillingly. Furthermore, the open dispensing openings allow the entry of humidity, dust and other impurities into the condiment container which may soil the condiments. As such, caps for condiment containers that provide a closing mechanism are preferred to those that do not.
U.S. Pat. No. 5,597,096 provides a shaker for condiments with a cap that can open and close. The cap has an arcuate form and can be opened by a user by pressing on the apex of the form. When opened, the cap arches upwards and reveals dispensing openings. This cap, however, suffers from multiple drawbacks. For example, it is only mountable on a shaker having an integral mounting bead along the mouth.
In the context of the above, it can be appreciated that there is a need in the industry for an improved cap for a condiment container.
SUMMARY OF THE INVENTION
In accordance with a first broad aspect, the present invention provides a cap for a container defining an interior for storing condiments for human consumption and having an upper portion defining a mouth. The cap comprises a member having a top portion with a peripheral wall extending downwardly for covering the mouth of the container, the peripheral wall having means for retaining the cap onto the container, the top portion having a plurality of dispensing openings for allowing passage of the condiments. The cap further comprises a seal having a top portion comprising a central portion, a flange portion extending around the central portion for overlapping the dispensing openings of the member, and a central peripheral wall extending downwardly from said top portion and having a lower end mounted to the member. In use, the seal is moveable between a closed position, wherein the central portion is above the flange portion and the flange portion covers the dispensing openings of the member for preventing passage of the condiments outwards from the interior of the container, and an open position, wherein the central portion is below the flange portion and the flange portion frees the dispensing openings of the member for allowing passage of the condiments outwards from the interior of the container.
In accordance with a second broad aspect, the present invention provides a cap for a container defining an interior for storing condiments for human consumption and having an upper portion defining a mouth. The cap comprises a member having an inner portion and an outer portion, the inner portion having a top portion with a peripheral wall extending downwardly for covering the mouth of the container, the peripheral wall of the inner portion having means for retaining the cap onto the container, the top portion of the inner portion having a plurality of openings for allowing passage of the condiments, the outer portion having a top portion with a peripheral wall extending downwardly for covering at least partially the peripheral wall of the inner portion, the top portion of the outer portion having a plurality of dispensing openings for allowing passage of the condiments outwards from the interior of the container. The cap further comprises a seal having a top portion comprising a central portion, a flange portion extending around the central portion for overlapping the dispensing openings, and a central peripheral wall extending downwardly from said top portion and having a lower end mounted to the member. In use, the seal is moveable between a closed position, wherein the central portion is above the flange portion and the flange portion covers the dispensing openings of the outer portion for preventing passage of the condiments outwards from the interior of the container, and an open position, wherein the central portion is below the flange portion and the flange portion frees the dispensing openings for allowing passage of the condiments outwards from the interior of the container.
In accordance with a third broad aspect, the present invention provides a cap for a container defining an interior for storing condiments for human consumption and having an upper portion defining a mouth. The cap comprises a member having an inner portion and an outer portion, the inner portion having a top portion with a peripheral wall extending downwardly for covering the mouth of the container, the peripheral wall of the inner portion having means for retaining the cap onto the container, the top portion of the inner portion having a plurality of openings for allowing passage of the condiments, the outer portion having a top portion with a peripheral wall extending downwardly for covering at least partially the peripheral wall of the inner portion, the top portion of the outer portion having a central opening encircling a vertical axis of the cap and a plurality of dispensing openings for allowing passage of the condiments outwards from the interior of the container. The cap further comprises a seal having a top portion comprising a central portion, a flange portion extending around the central portion for overlapping the dispensing openings, and a central peripheral wall extending downwardly from a peripheral live hinge, passing through the central opening of the outer portion and having a lower end mounted to the member, the seal being in a closed position when the flange portion covers the dispensing openings of the outer portion for preventing passage of the condiments outwards from the interior of the container and the seal being in an open position when the flange portion frees the dispensing openings of the outer portion for allowing passage of the condiments outwards from the interior of the container; wherein, in use, when the seal is in the closed position and a user presses on the central portion, downward movement of the central portion below the peripheral live hinge imparts upward movement of the flange portion above the peripheral live hinge such that the seal is in the open position and the central portion is at least partially located within the central peripheral wall, and when the user presses afterwards on the flange portion, downward movement of the flange portion below the peripheral live hinge imparts upward movement of the central portion above the peripheral live hinge such that the seal returns in the closed position.
These and other aspects and features of the present invention will now become apparent to those of ordinary skill in the art upon review of the following description of specific embodiments of the invention and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
A detailed description of examples of implementation of the present invention is provided hereinbelow with reference to the following drawings, in which:
FIG. 1A is a side elevation view of a cap in accordance with an embodiment, the seal being shown in a closed position;
FIG. 1B is a cross-sectional view of the cap shown in FIG. 1A ;
FIG. 2A is a side elevation view of the cap shown in FIG. 1A , the seal being shown in an open position;
FIG. 2B is a cross-sectional view of the cap shown in FIG. 2A ;
FIG. 3 is a top perspective view of the cap shown in FIG. 1A , the seal being shown in the closed position;
FIG. 4 is a top perspective view of the cap shown in FIG. 1A , the seal being shown in the open position;
FIG. 5 is a bottom perspective view of the cap shown in FIG. 1A ; and
FIG. 6 is a cross-sectional of the seal of the cap shown in FIG. 1A .
In the drawings, embodiments of the invention are illustrated by way of example. It is to be expressly understood that the description and drawings are only for purposes of illustration and as an aid to understanding, and are not intended to be a definition of the limits of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
FIG. 1A shows a cap 10 for a condiment container such as a salt shaker. In a non-limiting example, the cap is suitable for fastening to a container having an upper portion with a peripheral wall defining a mount and an interior for receiving condiments.
Unless explicitly or implicitly suggested otherwise, the various elements described herein are described from the perspective of a condiment container, such as a salt shaker, that is standing upright on a flat surface and onto which the cap is affixed at a top portion. As such, orientationally descriptive terms such as ‘upward’, ‘top’, ‘vertical’ or ‘upper’, will generally refer to this particular frame of reference. However, it should be understood that this orientation is used only as an example to facilitate understanding of the invention, but that the invention is not limited to any particular orientation of its elements. For example, although the mouth of the container described above is described as being defined at an upper portion of the container, it should be understood that the container could be reoriented or otherwise shaped such that the portion defining the mouth is no longer “up” without departing from the intended scope of the invention.
The cap 10 comprises a seal 12 and a member 14 . The member 14 comprises a top portion 16 and a peripheral wall 18 extending downwardly from the top portion 16 . In this exemplary view, the peripheral wall 18 is circular in cross-section; however it should be understood that the peripheral wall 18 of the member 14 , and indeed, all parts of the cap 10 and the cap 10 itself may vary in shape and size and that the invention is not intended to be limited to the particular shape shown in the figures. The cap 10 is suited for attachment to a condiment container at a mouth of the condiment container by any appropriate retaining mean. When the cap is attached to the container, the peripheral wall of the member is said to cover the mouth of the container. In a non-limiting example, the peripheral wall of the member has threads 92 and can be twisted onto a suitably threaded container, however the particular retaining means used is not meant to limit the invention and in any arrangement when the mouth of the container is covered by the cap, it is said that the peripheral wall of the member covers the mouth of the container.
The seal 12 comprises a top portion 20 , which is the only portion of the seal 12 visible in FIG. 1A . The top portion 20 comprises a central portion 22 and an annular flange portion 24 extending around the central portion 22 . As best seen in FIG. 3 , in this particular example, the seal 12 has a substantially circular circumference.
The central portion 22 is substantially circular and is surrounded by the flange portion 24 . FIGS. 1A , 1 B and 3 show the seal 12 in a closed position. In the closed position, the seal 12 adopts a substantially convex form, so called because from a perspective outside of the cap 10 and the container, the seal 12 swells outwards. At least an area 28 within the top portion 16 of the member 14 is covered by the seal 12 when the seal 12 is in the closed position.
As seen in FIG. 4 , the area 28 is a peripheral surface which surrounds a central opening 40 provided in the member. The peripheral surface comprises a plurality of dispensing openings 30 . The dispensing openings 30 can be located anywhere on the member 14 but are preferably on the top portion 16 thereof and preferably still on the peripheral surface. When not blocked, the dispensing openings 30 allow the passage of condiments through the member 14 , for example from the interior of a container attached to the cap 10 outwards. The peripheral surface comprises a flat section 34 , an inclined section 36 and a crest 38 . The inclined section 36 extends upwardly from the flat section to the crest 38 . Although the flat section 34 , inclined section 36 and crest 38 are shown here as three discrete section, they can be merely portions of a continuum, and even infinitesimal such portions. For example, the flat section 34 and the inclined section 38 could form a continuous curve from the central opening 40 up to the crest 38 . Also, while the crest 38 is shown here as a circular peak, it should be understood that it could be any section of any shape located upwardly from the flat section 34 , such as a flat section extending outward from the inclined section 36 or even an inclined continuation of the inclined section 36 .
The area 28 is said to be covered or overlapped by the seal 12 because the seal 12 blocks it and makes it inaccessible. In this non-limiting example, the top portion 20 forms a seal around this area. It should be understood that it is not necessary for there to be direct contact between the seal and the area 28 for it to be considered covered. Rather, it must merely be blocked e.g. in such a manner that condiments cannot exit to the exterior through the dispensing openings 30 . As seen in FIG. 1B , the top portion 20 rests against the crest 38 but leaves an open gap 42 above the inclined section 36 and the flat section 34 . Nevertheless, the gap 42 , flat section 34 , inclined section 36 and dispensing openings 30 are considered covered by the seal 12 , since they are blocked. For example, condiments such as salt cannot pass through the dispensing openings 30 and out away from the cap when the seal is in the closed position. Alternatively, the seal 12 could lay physically on the covered area 28 , leaving no gap between the seal 12 and the member 14 at the area 28 .
The flange portion 24 of the seal 12 comprises a lower peripheral end wall 80 for abutting against the member 14 . As shown in FIG. 1B , when the seal 12 is in the closed position, the lower peripheral end wall 80 is generally horizontally flat, or aligned perpendicularly with a longitudinal axis 72 of the cap 10 and rests against the crest 38 for forming a seal for preventing exit of the condiments. As shown in FIG. 2B , when the seal is in the open position, the lower peripheral end wall 80 is, along with the rest of the flange portion 24 , moved upwards from its closed-position location and no longer prevents passage of condiments outwards. The lower peripheral end wall 80 is aligned transversely with respect to the vertical axis 72 of the cap 10 , not perpendicularly but rather obliquely.
The flange portion 24 comprises on its lower surface an annular indentation 82 located radially interiorly of the lower peripheral end wall 80 . The annular indentation 82 is adjacent the lower peripheral end wall 80 . The annular indentation 82 may reduce resilience in the material in the flange portion 24 , which resilience may otherwise impede the seal 12 from adopting the closed position or the open position.
FIGS. 2A , 2 B and 4 show the seal 12 in an open position. Here, the seal 12 adopts a substantially concave form, so called because it defines a depression visible from a perspective outside of the cap 10 and the container. When the seal 12 is in the open position, the area 28 of the top portion 16 of the member 14 is considered uncovered even though part of the seal 12 may lie physically above it because it is not blocked.
As mentioned above, the top portion 16 of the member 14 has the dispensing openings 30 located in the section 28 that is covered by the seal 12 when the seal 12 is in the closed position. As best seen in FIG. 4 , grooves 32 are provided adjacent the dispensing openings 30 . The dispensing openings 30 are each located inside a respective groove 32 , each groove 32 extending outwards into the inclined section 36 . When the seal 12 is in the open position, and the container is tilted, condiments contained in the container escape through the dispensing openings 30 and are guided by the grooves 32 such that they flow directly outwards. When the container is returned to the upright position, any condiment remaining on the inclined section 36 is guided by the groove 32 back into the dispensing opening 30 , thus preventing the unsightly accumulation of condiment along the flat section 34 . While in this example each dispensing opening 30 is located in a respective groove 32 , it should be noted that many other configurations of grooves 32 and dispensing openings 30 are possible. For example, the dispensing openings 30 may be near, but not in, the grooves 32 and there may be multiple dispensing openings 30 to a groove 32 .
As best seen in FIG. 2B , the seal 12 comprises a central peripheral wall 44 extending downwardly from the top portion 20 of the seal 12 at a peripheral live hinge 46 . In the example shown, the central peripheral wall 44 has a generally cylindrical shape however, other shapes are possible. The central peripheral wall 44 has a lower end 66 to be mounted to the member 14 . The peripheral live hinge 46 allows movement of the top portion 20 of the seal 12 with respect to the central peripheral wall 44 . The peripheral live hinge 46 defines an area of reduced thickness with respect to the central peripheral wall 44 , although any configuration providing adequate hinging could be used. The live hinge 46 connects the central peripheral wall 44 to the underside of the top portion 20 of the seal 12 around the periphery of central portion 22 .
As mentioned above, the top portion 20 of the seal 12 adopts a substantially concave form when in the closed position and a substantially concave form when in the open position. As seen in FIGS. 1A and 1B , when the seal 12 is in the closed position, the flange portion 24 extends downwardly from the central portion 22 . As best seen in FIG. 2B , when the seal 12 is in the open position, the flange portion 24 extends above the central portion 22 and the central portion 22 is located within the central peripheral wall 44 .
When a user presses on the central portion 22 , the central portion 22 moves downwards below the level of the live hinge 46 . As best seen in FIG. 2B , the central portion 22 moves into the cylindrical form defined by the central peripheral wall 44 of the member. When the central portion 22 is pushed downwards, resilience in the material of the top portion 20 of the seal 12 causes the flange portion 24 to move upwards above the live hinge 46 . As a result, the top portion 20 of the seal 12 adopts the convex form characteristic of the open position of the seal 12 . In order to return the seal 12 to the closed position, a user moves the flange portion 24 downwards towards its closed-position arrangement. Resilience in the material of the top portion 40 of the seal 12 causes the central portion 22 to move upwards above the live hinge 46 and return to the open-position arrangement.
It should be noted that the central peripheral wall 44 and the peripheral live hinge 46 can be made of any suitable material and do not need to be of the same material as the top portion 20 of the seal 12 . For example, the central peripheral wall 44 and/or the peripheral live hinge 46 could be made of different materials, e.g. by overmolding. However, in the example shown here, the central peripheral wall 44 , live hinge 46 and top portion 20 of the seal 12 together form an integral piece made of a soft single flexible material with a good shape memory. For example, the seal can be made of injection molded silicone, compression molded silicone, thermoplastic rubber (TPR) or natural rubber.
The lower end 66 of the central peripheral wall 44 is affixed to the member 14 in an area adjacent the central opening 40 . Preferably, the central peripheral wall 44 may be affixed to the member 14 in such a way as to block or seal the central opening 40 , if present, such that condiments cannot pass through the central opening 40 . In the example shown, the central peripheral wall 44 passes through at least a part of the central opening 40 and the lower end 66 is held against a bottom surface of the member 14 such that condiment cannot escape through the central opening 40 . In this example, condiments can enter the cylindrical form of the central peripheral wall 40 , but then find no opening through which to escape to the exterior. The central peripheral wall 44 can be affixed to the member 14 by any suitable means. For example, the lower end 66 of the central peripheral wall 14 can be glued to the member 14 or held by friction.
The member 14 may be a single integral piece or may be made of two or more pieces. As best shown in FIGS. 1B , 2 B and 5 , the member 14 is made up of an inner portion 50 and an outer portion 52 . The inner portion 50 has a top portion 54 and a peripheral wall 56 that extends downwardly from the top portion 50 . In a non limiting example, the peripheral wall 56 of the inner portion 50 comprises threads 92 disposed on the inside thereof that match treads on the outside surface of the container for attaching the cap 10 thereto.
The outer portion 52 has a top portion 58 and a peripheral wall 60 that extends downwardly from the top portion 58 and may make up a portion of the peripheral wall 18 of the member 14 . In a non-limiting example, the peripheral wall 60 of the outer portion 52 covers at least partially the peripheral wall 56 of the inner portion, as shown in FIGS. 1B and 2B .
The outer portion 52 comprises the dispensing openings 30 , the area 28 having the peripheral surface, the grooves 32 and the central opening 40 . As seen in FIG. 5 , in order for condiments to be able to exit through member 14 at the dispensing openings 30 , the inner portion 50 comprises a plurality of openings 62 adjacent with the dispensing openings 30 of the outer portion 52 . It is not necessary for the openings 62 of the inner portion 50 to be similar in shape, size or quantity as the dispensing openings 30 of the outer portion, rather it is merely necessary for at least a portion of the dispensing openings 30 to be aligned with at least a portion of the openings 62 such that condiments can flow out through the member 14 . As seen in FIG. 5 , the openings 62 of the inner portion 50 are much larger than the dispensing openings 30 of the outer portion, each being aligned with four dispensing openings 30 .
In the example where member 14 is made of the inner and outer portions 50 , 52 , a central opening 64 could be provided in the inner portion 50 , as shown in FIGS. 1B and 2B . The central opening 64 is generally circular and encircles the vertical axis 72 of the cap 10 . The central opening 64 may allow passage of air downward into the container and out through the dispensing openings 30 . Thus, as the central portion 22 of the seal 12 is being pushed downwards to move the seal 12 from the closed position to the open position, the air occupying the space enclosed between the central portion 22 , the central peripheral wall 44 and the member 14 can escape through the central opening 64 , thus avoiding an increase in pressure that would resist the downward motion of the central portion 22 . Likewise, the air flow enabled by the central opening 64 also facilitates movement of the seal 12 from the open position to the closed position by preventing a decrease of pressure that would result from moving the central portion 22 upwards and increasing the volume of space between the central portion 22 , the central peripheral wall 44 and the member 14 , which decrease in pressure would resist the movement of the central portion 22 upwards. It should be appreciated however, that it is not necessary to provide central opening 40 , and that other means could be provided for allowing airflow. For example, holes in the top portion of the seal could be provided.
The central peripheral wall 44 passes through the central opening 40 of the outer portion 52 . The central peripheral wall 44 has a peripheral ring 68 at the lower end 66 . The peripheral ring 68 can be a simple enlargement of the diameter of the central peripheral wall 44 or any other form that projects radially outwards therefrom. The term peripheral “ring” is used here because in this non-limiting example the central peripheral wall 44 is cylindrical and the peripheral ring 68 follows the contour of the central peripheral wall 44 , thus defining a ring-like shape. However it should be understood that the peripheral ring 68 can be any form that projects outwards from the central peripheral wall 44 , not necessarily following the shape of the central peripheral wall 44 which in any case does not necessarily have to be cylindrical in form. While the peripheral ring 68 is disposed around the periphery of central peripheral wall 44 at the lower end, it does not necessarily need to follow the entire periphery of central peripheral wall 44 , and may be present only on a section or sections thereof.
As shown in FIGS. 1B and 2B , the central peripheral wall 44 passes through the central opening 40 of the outer portion 52 and rests against the inner periphery of the central opening 40 . The peripheral ring 68 is below the outer portion 52 and projects radially outwards beyond the central opening 40 . As such, the peripheral ring 68 abuts against a bottom surface 70 of the top portion 58 of the outer portion 52 and prevents movement of the seal 12 . In addition, the top portion 54 of the inner portion 50 rests against the peripheral ring 68 from beneath, such that the peripheral ring 68 is sandwiched between the bottom surface 70 of the top portion 58 of the outer portion 52 and the top portion 54 of the inner portion 50 . The seal 12 is thus securely held in place with respect to the member 14 .
As seen in FIGS. 1B , 2 B and 6 , the peripheral ring 68 can include one or more projection 90 with a hole 86 . The projection 90 may project radially outwards beyond the rest of the peripheral ring 68 and may receive within the hole 86 a pin 88 projecting downwardly from the outer portion 52 . Where the peripheral ring 68 is sandwiched between a bottom surface 70 of the top portion 58 of the outer portion 52 and the top portion 54 of the inner portion 50 , the hole 86 receives the pin 88 projecting downwardly from the bottom surface 70 . Four projections 90 can be included in the peripheral ring 68 located at four equidistant points on the peripheral ring 68 ; although more or less projections 90 could be provided. For each projection 90 , a pin 88 is provided on the outer portion 52 so as to align with the projection 90 . Optionally, in the top portion 54 of the inner portion 50 , holes 84 are provided to accommodate the respective pins 88 , such that each pin 88 can pass through the respective holes 86 , 84 (see FIGS. 1B , 2 B and 5 ). Although the pin 88 was described as projecting downwards from the bottom surface 70 of the top portion 58 of the outer portion 52 , it will be readily appreciated that the pin 88 could equally project upwards from the top portion 54 of the inner portion 50 and that accordingly, corresponding hole could be located in the outer portion 52 . Alternatively in the non-limiting embodiment where the member 14 is made of a single piece, pins projecting downwardly from the bottom surface of the member 14 can be received in the respective holes 86 of the seal 12 . Advantageously, the projection 90 and pin 88 combination impedes rotational motion of the seal 12 relative to the member 14 .
The central opening 40 of the outer portion 52 overlaps at least partially the central opening 64 of the inner portion 50 so that air can flow as described above. Optionally, the top portion 54 of the inner portion 50 comprises a projection 74 extending upwardly inside the volume enclosed by the central peripheral wall 44 of the seal 12 . Preferably, the projection 74 follows at least partly the inner contour of central peripheral wall 44 . The projection 74 may rest against the interior surface of central peripheral wall 44 and so hold the central peripheral wall 44 against the inner periphery of central opening 40 of the outer portion 52 , as best shown in FIGS. 1B and 2B . The projection 74 extends upwards past the top portion 58 of the outer portion 52 and supports the central peripheral wall 44 .
The inner portion 50 and the outer portion 52 can be connected in any suitable manner. Their connection can be permanent or releasable. For example, they can be glued together. In another example, the inner portion 50 and the outer portion 52 are held together by friction-fit arrangement.
A protrusion and a complementary recess combination can be provided on the inner portion and outer portion to prevent movement of the inner portion and outer portion relative to one another in the vertical direction. The protrusion and complementary recess can follow the curvature of the inner and outer portions 50 , 52 respectively and impede translational movement of the inner portion 50 relative to the outer portion 52 along the vertical axis. Additional protrusions and complementary recesses can be provided to prevent other motion between the inner and outer portions 50 , 52 . Vertical protrusions extending vertically along the interior surface of the outer portion and complementary vertical recesses extending vertically along the exterior surface of the inner portion can be provided. Four such vertical protrusions and corresponding complementary recess combinations can be provided along the contour of the respective inner and outer portions 50 , 52 , each of which can be aligned with the hole 84 of the inner portion 50 which may facilitate visual alignment of the inner portion 50 with the outer portion 52 for insertion therein. Vertical protrusions and corresponding complementary recesses may prevent rotational motion of the inner portion 50 relative to the outer portion 52 , particularly when twisting the cap 10 on or off a container. It will be appreciated that these protrusions and complementary recesses could be inverted, the protrusions being on the inner portion 50 and the complementary recesses on the outer portion 52 .
FIG. 6 is a cross-sectional view of a seal 12 with various thicknesses of materials indicated. The table below indicates the values of dimensions referred to by the variables in FIG. 6 . The entries in the table indicate a range of possible values for each variable and at least one preferred value.
Range
Preferred
Variable
Lower End (mm)
Upper End (mm)
Value (mm)
A
4.70
5.80
5.25
B
3.00
5.00
3.53
C
1.30
1.65
1.48
D
3.29
4.00
3.65
E
4.00
5.00
4.54
F
1.20
1.50
1.35
G
2.45
3.05
2.75
H
1.35
1.75
1.55
I
1.10
1.35
1.20
J
0.35
0.45
0.40
K
12.55
15.40
13.97
L
11.10
13.55
12.3
M
9.65
11.85
10.73
N
7.55
9.35
8.46
O
7.20
8.80
8
P
0.70
0.90
0.80
Q
8.30
10.20
9.25
R
21.05
25.80
23.43
S
21.5
27.5
24.04
T
20.85
25.55
23.22
U
0.60
0.80
0.70
Note that the seal can have an external diameter of between 30 millimeters and 60 millimeters. These dimensions are in no way intended to limit the invention.
Although various embodiments have been illustrated, this was for the purpose of describing, but not limiting, the invention. Various modifications will become apparent to those skilled in the art and are within the scope of this invention, which is defined more particularly by the attached claims. | The invention provides a cap for a container for storing condiments for human consumption. The cap comprises a member having a top portion with a peripheral wall that has means for retaining the cap onto the container extending downwardly for covering the mouth of the container, the top portion having dispensing openings for allowing passage of the condiments. The cap comprises a seal having a top portion comprising a central portion, a flange portion extending around the central portion for overlapping the dispensing openings of the member and a central peripheral wall extending downwardly from the top portion and having a lower end mountable to the member. In use, the seal is moveable between a closed position, wherein the flange portion covers the dispensing openings for preventing passage of the condiments outwards from the interior of the container, and an open position, wherein the flange portion and the flange portion frees the dispensing openings for allowing passage of the condiments outwards from the interior of the container. | 1 |
FIELD OF INVENTION
This invention relates to asphaltic compositions, such as asphaltic concretes, blacktops, pavements and the like, and asphaltic compositions made from recycled materials. More particularly, this invention relates to asphaltic materials, pavements made there from, and to methods for making paving materials and pavements having recycled or waste building materials as a component of the asphaltic composition.
BACKGROUND OF THE INVENTION
Paving materials such as asphaltic concretes that are used for roadways, parking areas, walkways and other traffic surfaces have been the subjects of much recent research. Some of these efforts have involved the addition of polymers, including plastics, in attempts to improve the flexibility, strength and life of the paving material. Other efforts have centered on recycling roadway asphalts in an effort to lower costs and reduce the environmental impacts such roadways have on our surroundings.
The increasing need to dispose of or find new uses for used or waste building materials (such as concrete, brick, gravel, rock and other debris) has led to growing costs and increased environmental concerns in the disposal of these materials.
DETAILED DESCRIPTION
The present invention provides for asphaltic compositions, such as an asphaltic concrete, blacktop, pavement or other similar composition. Such compositions include an aggregate and a binder to hold the aggregate in place upon curing of the composition to form, e.g., a roadway.
Aggregates
The aggregates of the present invention may be made from one or more recycled materials (referred to herein as “recycled aggregates”). For example, the recycled materials may be obtained from recovered waste, scrap or debris building materials obtained from demolition, remodeling or building sites. These recycled materials may include a wide variety of granulated, crushed or pulverized materials. For example, such materials may include the following: concrete, rock, stone, stone aggregates, sand, brick or material derived from masonry units. Mixtures of one or more of these materials may also be used to form the recycled aggregate of the present invention. For example, the recycled aggregate may be a mixture of rock, brick and concrete. In an embodiment of the present disclosure, and without limiting the scope of the disclosure herein, an asphaltic composition may include at least 5% by weight of recycled aggregate. In additional embodiments, the recycled aggregate may include at least 1% by weight of recycled brick. In yet another embodiment, an asphaltic composition of the present disclosure may include at least 15% by weight of recycled aggregate.
The recycled aggregates of the present invention may further include other aggregate materials, traditionally used to form aggregates for asphaltic compositions, in conjunction with the above mentioned recycled materials. Such traditional materials include virgin rock, stone or concrete, crushed gravel or crushed slag and may also include asphaltic materials or bitumen.
Other recycled materials may also be included in the recycled aggregates of the present invention. For example, roofing material such as shingles, plastics or recycled asphalt or asphalt waste and the like.
To maintain the desired properties of the asphaltic cement, the size distribution of the recycled aggregate may be controlled. In this manner, the recycled aggregate may be produced so as to conform to, e.g., a particular state highway standard for aggregates used in asphaltic cements. Generally, this process of creating a recycled aggregate with a controlled particle size distribution may be accomplished as follows, although other suitable processes for preparing aggregates for asphaltic materials may be employed.
For example, larger recycled materials are first broken up, crushed, pulverized or otherwise mechanically granulated to form a particulate. The resulting particulate is then passed through several screens so that as a result, individual particles are separated by size in particle fractions. From the sorted materials, a recycled aggregate can then be produced by mixing the desired portion of each sized particle fractions. For example, an aggregate may include from five to seven sieve sizes ranging from no. 40 to three-fourths inch in size, or preferably from no. 200 to one inch in size.
For example, using the above technique a given recycled aggregate may be formed in accordance with a particular state highway standard for asphaltic compositions. One such suitable mix is, for example, shown in Table 1, and represents formulation parameters for bituminous plant mixtures according to the standards of New York State.
TABLE 1
New York State Standard of Bituminous Plant Mixtures
Mixture
Base
Binder
Shim
Top 2
Requirements 1
Type 1
Type 2
Type 3
Type 5
Type 6, 6F
Type 7, 7F
General
Job
General
Job
General
Job
General
Job
General
Job
General
Job
Limits %
Mix
Limits %
Mix
Limits %
Mix
Limits %
Mix
Limits %
Mix
Limits %
Mix
Screen Sizes
Passing
Tol. %
Passing
Tol. %
Passing
Tol. %
Passing
Tol. %
Passing
Tol. %
Passing
Tol. %
50.0 mm
100
—
100
—
—
—
—
—
—
—
—
37.5 mm
90-100
—
75-100
±7
100
—
—
—
—
—
—
25.0 mm
78-95
±5
55-80
±8
95-100
—
—
—
100
—
—
12.5 mm
57-84
±6
23-42
±7
70-90
±6
—
—
95-100
—
—
6.3 mm
40-72
±7
5-20
±6
48-74
±7
100
—
65-85
±7
—
3.2 mm
26-57
±7
2-15
±4
32-62
±7
80-100
±6
36-65
±7
±6
850 μm
12-36
±7
—
—
15-39
±7
32-72
±7
15-39
±7
±7
425 μm
8-25
±7
—
—
8-27
±7
18-52
±7
8-27
±7
±7
180 μm
4-16
±4
—
—
4-16
±4
7-26
±4
4-16
±4
±4
75 μm
2-8
±2
—
—
2-8
±2
2-12
±2
2-6
±2
±2
Asphalt
4.0-6.0
±0.4
5.2-4.5
±0.4
4.5-6.5
±0.4
7.0-9.5
±0.4
5.8-7.0
±0.4
6.0-8.0
±0.4
Content, % 3,4
Description and
Dense base
Open base
Dense
Dense, smooth
Dense, granular
Dense, gritty
Typical Uses
course with
course with
intermediate
texture sand
texture for rural
texture for
relatively low
relatively high
course with
asphalt for
suburban, and
single course
permeability
permeability
relatively low
leveling where
urban arterial
resurfacing of
permeability
feathered edge
roadways
rural, suburban,
is required
and urban
arterial
Notes:
1 All aggregate percentages are based on the total weight of the aggregate. The asphalt content is based on the total weight of the mix.
2 The “F” designation in the mix type indicates that high friction coarse aggregates are required.
3 When slag aggregates are used in the mix, the asphalt content shall be increased accordingly minimum 25 percent for all slag mix.
4 The asphalt content job mix tolerance of ±0.4% shall not apply to Marshall Design mixtures.
By way of another example, the size distribution of the recycled aggregate may be prepared in accordance to the Texas Master Gradation Bands as shown in Table 2.
TABLE 2 Texas Master Gradation Bands (% Passing by Weight or Volume) and Volumetric Properties of Aggregates Used in Hot-Mix, Cold-Laid Asphaltic Concretes. C D F A B Coarse Fine Fine Sieve Size Coarse Base Fine Base Surface Surface Mixture 1½″ 98.0-100.0 — — — — 1″ 78.0-94.0 98.0-100.0 — — — ¾″ 64.0-85.0 84.0-98.0 95.0-100.0 — — ½″ 50.0-70.0 — — 98.0 — ⅜″ — 60.0-80.0 70.0-85.0 85.0-100.0 98.0-100.0 #4 30.0-50.0 40.0-60.0 43.0-63.0 50.0-70.0 80.0-86.0 #8 22.0-36.0 29.0-43.0 32.0-44.0 35.0-46.0 38.0-48.0 #30 8.0-23.0 13.0-28.0 14.0-28.0 15.0-29.0 12.0-27.0 #50 3.0-19.0 6.0-20.0 7.0-21.0 7.0-20.0 6.0-19.0 #200 2.0-7.0 2.0-7.0 2.0-7.0 2.0-7.0 2.0-7.0 Design VMA 1 , % Minimum — 12.0 13.0 14.0 15.0 16.0 Plant-Produced VMA 1 , % Minimum — 11.0 12.0 13.0 14.0 15.0 Note: 1 Voids in mineral aggregates.
Binder
To form an asphaltic composition, such as an asphaltic concrete, blacktop, pavement or other similar such material, the recycled aggregate of the present invention may be combined with a suitable binder. Many such binders will be known to one of skill in the art. For example, such binders may include tars. Binders in accordance with the present invention may also take the form of asphalt emulsions such as asphalt/water or asphalt/naphthalene binders, such as, for example, the binders referred to as MS2 and HMFS-64.
The binders may also be polymeric materials. In one embodiment the polymeric materials may be obtained or recycled from at least one of various waste sources. Any waste source is suitable. Examples of such sources are municipal solid waste, industrial waste and household waste. Any single or combination of multiple polymeric materials may be used such as thermosets, elastomers, and thermoplastics. Non-limiting examples of such materials are: acetals, acrylics, amino resins, cellulosics, phenolics, polyamides, polyesters, polyolefins, polyethers, styrenes, vinyls, polyurethanes, ketone-formaldehydes, polycarbonates, epoxy resins, polyethylene terphtalates, polyethylenes (including high and low density), polypropylenes, polyvinyl chlorides, polystyrenes, melamine-fomaldehyde resins, urea-fomaldehyde resins, acyrlonitrile butadiene styrene copolymers, blends, mixtures, and other copolymers (including terpolymers, etc.). Preferred examples of such materials include polyethylene terphthalate, high density polyethylene, styrene (including styrene-butadiene rubber, styrene-butadiene-styrene block copolymer) and polystyrene. Non-limiting common examples of recyclable items comprising such materials may include tools, gears, bearings, pumps, valves, screws, containers, bottles, fans, paint sprayers, shower heads, tool handles, dishes, molded products, switch cover plates, buttons, electric mixer housings, cabinets, coffee makers, door knobs, adhesives, laminates, coatings, fabric, shoe heels, eyeglass frames, toothbrush handles, pen and pencil barrels, piano keys, beads, toys, fishing tackle, cutlery handles, combs, steering wheels, veneers, automotive parts, pulleys, washing machines, detergent dispensers, telephones, food containers, ashtrays, croquet balls, roof panels, windshield wipers, football helmets, inks, clothing, cellophane, boat hulls, vehicle bodies, wash tubs, luggage, costume jewelry, fan blades, pie fittings, surgical implants, insulation, drink containers, trash can liners, bags, rug backing, canteens, gaskets, tires, sponges, furniture, and utensils, and the like. Preferably these items may be recyclable drink bottles, such as water bottles or soda bottles, for example polyethylene terephthalate containers.
The binders of the current invention may be used alone or in combination. For example the binders may be combinations of polymeric materials, or combinations of tars and polymeric materials, or combinations of asphalt emulsions and polymeric materials, or combinations of tars and asphalt emulsions, or combinations of tars, asphalt emulsions, and polymeric materials, or any other combination of binders. Furthermore, the binders of the present disclosure may include virgin binders (i.e. binders not made from waste sources or recycled materials), recycled binders, or any combination thereof. In an embodiment of the present disclosure, and without limiting the scope of the disclosure herein, an asphaltic composition may include 80% by weight of binder. In an additional embodiment, an asphaltic composition may include 85% by weight of binder.
One method of forming the asphaltic composition of the present invention includes the steps of mixing the recycled aggregate with the binding agent. The recycled aggregate may be heated to an elevated temperature prior to mixing with the binder. For example, the recycled aggregate may be heated to greater than 100° F., for example, to greater than 120° F., for instance, to greater than 130° F., such as greater than 150° F. The recycled aggregate may be heated to less than 400° F., for example, to less than 350° F., such as less than 300° F. or less than 250° F., such as less than 230° F.
The heated recycled aggregate may then be mixed with a binder. The binder may also be an elevated temperature. For example, the binder may be heated to a temperature greater than 100° F., for example, to greater than 120° F., for instance, to greater than 130° F., such as greater than 150° F. It is also possible for both the binder and the recycled aggregate to be at the same temperature when they are mixed.
Heater
As described above, the recycled aggregate of the present invention may be heated to an elevated temperature prior to mixing with the binder. For example, the aggregates of the present invention, including the recycled aggregates, may be heated with a radiant heater, subjected to microwave irradiation to heat it, or a combination of radiant heating and heating through microwave irradiation may be used. Preferably a radiant heater is used. | Asphaltic compositions that are made from recycled waste building materials may include recycled plastics, provide reduced environmental impact and may be formed to meet state standards for aggregates used in asphaltic cement and other paving and construction standards. | 4 |
TECHNICAL FIELD
[0001] The present invention generally relates to steering systems of motor vehicles. More particularly, the invention provides a push member device for a motor vehicle rack-and-pinion steering assembly. Still more particularly, this is a so-called <<eccentric>> push member device.
BACKGROUND
[0002] It is recalled that in most present steering systems of motor vehicles, a steering pinion is linked in rotation with a steering column, maneuvered by means of the steering wheel of the vehicle, the pinion being engaged with a rack which is slideably mounted in the longitudinal direction in a steering gearbox. Both ends of the rack, outside the gearbox, are respectively coupled with two steering connecting rods, which are then themselves respectively associated with the left and right steered wheels of the vehicle. Thus, rotation of the steering wheel in one direction or in the other, transmitted by the steering column to the pinion, is converted into a corresponding translation of the rack which, via connecting rods, causes orientation of the steered wheels for steering right or left.
[0003] In such a steering system, the rack-and-pinion mechanism, linked to the front running gear of the vehicle via connecting rods, is subject to load transfers, to impacts and vibrations, depending on the condition of the road covered by the vehicle. Because of the angle formed by the connecting rods with the rack, a load may then occur on the rack which risks moving it away from the pinion. For this reason, the rack is customarily applied permanently against the pinion by a so-called “push member” device elastically acting on the back of the rack in the region of the pinion in order to strongly press the gear teeth of this rack against the pinion. Thus the push member limits the play between the respective teeth of the pinion and of the rack, and this push member also allows control of the sliding force of the rack in the gearbox. Further the action of the push member allows compensation of the alignment defects of the rack.
[0004] In its most current embodiment, the pusher member device comprises the pusher member strictly speaking, which is a rigid part mounted so as to be translationally mobile in a direction substantially perpendicular to the longitudinal axis of the rack, and urged towards the back of the rack by spring means also positioned along a direction substantially perpendicular to the longitudinal axis of the rack.
[0005] On the contrary, in the case of an eccentric push member device as described for example in U.S. Pat. No. 6,247,375 B1 (or patent documents FR 2219868 A and EP 0770538 A2), a rotary mounting comprising an off-center portion which pushes the rack towards the pinion, the rotary mounting being rotatably mounted in a housing, such as the housing of a pinion, around an axis parallel to the longitudinal axis of the rack. The inner circumference of said mounting is off-center with respect to its outer circumference, so that when it rotates in the housing, its off-center portion is applied against the back of the rack and pushes the latter towards the teeth of the pinion, so as to keep them engaged. The mounting is rotationally biased in one direction by a spring (in particular see aforementioned document FR 2 219 868A), so as to make up for the play caused by the inaccuracies of the mounting and by the wear between the teeth of the rack and the teeth of the pinion.
[0006] In the case of the aforementioned U.S. Pat. No. 6,247,375 B1, the inner portion of the rotary mounting includes a recess in which is mounted a leaf spring, which will bear upon the rack and thereby allow a slight radial movement in order to compensate for the alignment defects of the rack.
[0007] The advantages of a resident eccentric push member device, in particular, lie in the compactness of such a device, and in the fact that it may be made irreversible, any backward return of the rotary mounting (from a certain angular position reached) being made impossible.
[0008] However, in the arrangement according to US Pat. No. 6,247,375 B1, the fact of placing the leaf spring between the rotary mounting and the rack has the consequence that, when the rack is urged by variable forces, the latter does not always bear upon the spring in the same way, which may cause losses of contact between said spring and the rack. Further, the leaf spring changes position over time, considering the gradual rotation of the mounting, which causes a change in the orientation and in the intensity of the forces applied on the rack. All this may strongly degrade the function fulfilled by the eccentric push member device.
BRIEF SUMMARY
[0009] The present invention aims at finding a remedy to these drawbacks, therefore at improving the operation of an eccentric push member device for a rack-and-pinion steering system, by better control over the movements and positions of the members of the push member device.
[0010] For this purpose, the invention comprises an eccentric push member device for a rack-and-pinion steering assembly of a motor vehicle, a device which comprises in a known way per se, a rotary mounting, the inner circumference of which is off-center relatively to the outer circumference, said support being rotationally biased in one direction by spring means, and being provided so as to be applied by its off-center inner circumference against the back of the rack in order to push the latter back towards the teeth of the steering assembly pinion, this eccentric push member device being essentially characterized by the fact that the rotary mounting is rotatably mounted in a housing, itself slideably mounted substantially perpendicularly to the plane of the teeth of the rack, other damping spring means being positioned between the sliding housing and a fixed member, such as the steering gearbox, in order to act on said housing along its sliding direction.
[0011] Thus the principle of the invention comprises separating the function of making up for the plays due to the assembling and to wear, which is achieved by the eccentric mounting itself, on the one hand, and the function of absorbing alignment defects of the rack and optionally geometrical defects of the pinion, which is achieved by the translational movement of the housing, subject to the action of damping spring means themselves bearing upon the housing, on the other hand. This association of both functions in particular gives the possibility of having proper guiding of the rack which directly rests on a rigid support with an off-center portion. It also allows limitation of the degradation causes of irreversibility of the push member device, by stabilizing the supports of the rotary mounting. The absorption of the alignment defects of the rack is better controlled because of the guiding of the sliding housing in a slide made in the steering gearbox.
[0012] The spring means, which urge into rotation the mounting with an off-center portion, are here positioned between this rotary mounting and the sliding housing; these means may be formed by at least one compression or traction spring, or by at least one torsion spring, or by at least one leaf spring or further by at least one coil spring.
[0013] The damping spring means, placed between the sliding housing and the steering gearbox, may be formed by at least one leaf spring or by at least one block in elastomer, or by at least one O-ring gasket, or by at least one compression spring.
[0014] In a particular embodiment, these damping spring means comprise two O-ring gaskets, respectively placed at both ends of the sliding housing, around this housing.
BRIEF DESCRIPTION OF THE FIGURES
[0015] The invention will be better understood with the description which follows, with reference to the appended schematic drawing illustrating as an example an embodiment of this eccentric push member device for a motor vehicle rack-and-pinion steering assembly.
[0016] FIG. 1 is a block diagram of an eccentric push member device according to the present invention;
[0017] FIG. 2 is a diagram illustrating the irreversibility condition of the push member device;
[0018] FIG. 3 is another explanatory diagram, illustrating an aspect of the operation of this push member device;
[0019] FIG. 4 is a sectional view passing through the axis of the rack, of a practical exemplary embodiment of the eccentric push member device according to the invention;
[0020] FIG. 5 is a cross sectional view of this push member device, along V-V of FIG. 4 , more particularly showing the making of the slide for translationally guiding the sliding housing.
DETAILED DESCRIPTION
[0021] First with reference to FIG. 1 , the push member device designated as a whole by the mark 1 is associated with a rack 2 of a motor vehicle steering assembly. The rack 2 , the longitudinal axis of which is indicated by A, has teeth 3 , the plane of which is indicated in P. The push member device 1 is placed at a small distance from the steering pinion (not shown here) which will engage with the teeth 3 of the rack 2 .
[0022] The push member device 1 comprises, as a main component, an eccentric mounting 4 which is a rigid part with a general annular conformation, but including a circular inner circumference 5 which is off-center relatively to its circular outer circumference 6 . The eccentric mounting 4 is crossed by the rack 2 , its circular inner circumference 5 is applied against the back of the rack 2 i.e. against the outer region of this rack 2 opposite to the teeth 3 of the latter.
[0023] The eccentric mounting 4 is rotatably mounted in a housing 7 of corresponding shape, in other words a housing with a general cylindrical aspect, which is itself guided in translation in the direction of an axis B, orthogonal to the plane P of the teeth 3 of the rack 2 . The guiding in translation of the housing 7 is ensured by a connection of the “slide” type with the steering gearbox, a gearbox which is symbolized in 8 as a fixed portion, the connection of the slide type being itself schematized in 9 .
[0024] A first elastic element 10 mounted between the eccentric mounting 4 and the sliding housing 7 , urges this eccentric mounting 4 into rotation in a given direction. A second elastic element 11 , with damping properties, is mounted between the sliding housing 7 and the steering gearbox 8 and acts parallel to the connection of the slide type 9 .
[0025] The rotary eccentric mounting 4 , with which is associated the elastic element 10 , is dimensioned so that it is irreversible and driven into rotation by sliding by means of the elastic element 10 , in order to press on the back of the rack 2 , while compensating for the assembling and wear plays, the average angular position of the eccentric mounting 4 is suitably selected in order to compensate for a maximum of wear along the axis B defined earlier, while minimizing the movement of the rack 2 along the axis C perpendicular to this axis B and located in a plane normal to the longitudinal axis A of the rack 2 , in other words the plane of FIG. 1 . The second elastic element 11 , which is a damping element, allows controlled relative displacement of the teeth of the steering pinion and of the teeth 3 of the rack 2 , in order to absorb the alignment defects of this rack 2 , it being understood that the rated force, the stiffness and the damping of the second elastic element 11 are selected for obtaining such a controlled relative displacement.
[0026] As regards the rotary eccentric mounting 4 , the expression “dimensioned so that it is irreversible” means that the different dimensions observe the following condition (see FIGS. 2 and 3 ):
[0027] The ratio between the value of the eccentricity e and the radial distance between the center O of the outer circumference 6 of the eccentric mounting 4 and the point of contact between the eccentric mounting 4 and the sliding housing 7 is less than the value of the static friction co-efficient between the eccentric mounting 4 and the sliding housing 7 for low eccentricity values.
[0028] In the previous formulation, “by value of the eccentricity” is meant the minimum distance between the longitudinal axis of the inner circumference 5 and the longitudinal axis of the outer circumference 6 of the eccentric mounting 4 .
[0029] This irreversibility condition may be written generally as:
[0000] e/R .cos(α))< f
[0000] i.e. for an angle α for which the value is close to zero:
[0000]
e/R<f
[0000] formula in which:
[0030] e is the value of the eccentricity,
[0031] R is the contact radius, in other words the distance between the center O of the outer circumference 6 of the eccentric mounting 4 and the point of contact,
[0032] f is the static friction co-efficient between both surfaces in contact.
[0033] The formulation according to which << the average angular position of the eccentric mounting is suitably selected in order to compensate a maximum of wear along the axis B defined earlier, while minimizing the movement of the rack 2 along the axis C perpendicular to this axis B and located in a plane normal to the longitudinal axis A of the rack 2 >> is explained by the diagram of FIG. 3 . It means that the angle α, formed by the straight line passing through the center of the off-center inner circumference 5 and through the center O of the outer circumference 6 of the eccentric mounting 4 , on the one hand and through the straight line normal to the plane P of the teeth 3 of the rack 2 , on the other hand, is an angle for which the value should vary in a reduced interval and be centered on an average value equal to 90°.
[0034] Now referring to FIGS. 4 and 5 , a practical embodiment of the push member device 1 will be described herein below, corresponding to the principles discussed earlier.
[0035] The eccentric mounting 4 here has a corner shape, and is rotationally biassed by a compression spring 10 which follows a curved path as a circular arc, inside the housing 7 which itself has a general cylindrical aspect. The whole is mounted inside a steering gearbox portion 8 , surrounding the rack 2 and located in proximity to the steering pinion (not shown). As shown by FIG. 5 , the slide connection 9 between the housing 7 and the gearbox 8 is achieved with flats 9 a and 9 b parallel to each other and perpendicular to the plane P of the teeth 3 of the rack 2 .
[0036] Again referring to FIG. 4 , the elastic member 11 having damping properties here comprises two O-ring gaskets 11 a and 11 b , which are mounted in annular grooves respectively made towards both ends of the housing 7 . Positioned in this way, both O-ring gaskets 11 a and 11 b allow the sliding of the housing 7 in the direction of the link of the slide type 9 , while damping this sliding.
[0037] One would not depart from the scope of the invention, as defined in the appended claims:
[0038] by changing shape details of the components of the device, such as the eccentric mounting and the sliding housing,
[0039] by resorting to any equivalents of the described means, notably by replacing the compression spring, acting on the eccentric mounting, with a spring of another type, such as a traction spring or a torsion spring, or a leaf spring or a coil spring,
[0040] also, by replacing the double O-ring gasket with any other elastic element having damping properties, such as a spring leaf in a suitable material, or a block in elastomer, or a compression spring,
[0041] by dedicating this push member device to steering systems of any types, which may be manual steering assemblies or electric or hydraulic assisted steering assemblies. | The push member device ( 1 ) of the present invention includes a rotatable mounting ( 4 ), the inner circumference ( 5 ) of which is eccentric relative to the outer circumference ( 6 ). The mounting ( 4 ) is rotationally biased in a direction by a spring ( 10 ) and is placed against the back of the rack ( 2 ) that is thus pushed against the teeth of the steering pinion. The rotatable mounting ( 4 ) is rotatably mounted in a housing ( 7 ), itself being slidably mounted in the steering gearbox. A shock absorbing spring means ( 11 ) is arranged between the sliding housing ( 7 ) and the steering gearbox to absorb the alignment defects of the rack ( 2 ). | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is related to five co-pending and commonly-owned application filed on even date herewith, the disclosure of each is hereby incorporated by reference in its entirety:
“Anastomosis Wire Ring Device”, Ser. No. ______ to Don Tanaka, Mark Ortiz and Darrell Powell; “Applier For Fastener For Single Lumen Access Anastomosis”, Ser. No. ______ to Mark Ortiz; “Single Lumen Access Deployable Ring for Intralumenal Anastomosis”, Ser. No. ______ to Mark Ortiz; and “Single Lumen Anastamosis Applier for Fastener”, Ser. No. ______ to Mark Ortiz, Robert McKenna, Bill Kraimer, Mike Stokes, and Foster Stulen.
FIELD OF THE INVENTION
[0006] The present invention relates, in general, to devices and methods for surgically modifying organs and vessels. More particularly, it relates to anastomosis devices for joining two organs such as, for example, two separate lengths of small bowel to each other, a section of small bowel to the stomach, or the common bile duct to the duodenum in a procedure called a choledochoduodenostomy. Vascular anastomosis could be performed as well.
BACKGROUND OF THE INVENTION
[0007] Creating an anastomosis, or the surgical formation of a passage between two normally distinct vessels, is a critical step of many surgical procedures. This is particularly true of gastric bypass procedures in which two portions of small intestine are joined together and another portion of small intestine is joined to the stomach of the patient. This is also true of surgery to alleviate blockage in the common bile duct by draining bile from the duct to the small intestine during surgery for pancreatic cancer.
[0008] The percentage of the world population suffering from morbid obesity is steadily increasing. Severely obese persons are susceptible to increased risk of heart disease, stroke, diabetes, pulmonary disease, and accidents. Because of the effect of morbid obesity to the life of the patient, methods of treating morbid obesity are being researched.
[0009] Numerous non-operative therapies for morbid obesity have been tried with virtually no permanent success. Dietary counseling, behavior modification, wiring a patient's jaws shut, and pharmacologic methods have all been tried, and though temporarily effective, failed to correct the condition. Further, introducing an object in the stomach, such as an esophago-gastric balloon, to fill the stomach have also been used to treat the condition; however, such approaches tend to cause irritation to the stomach and are not effective long-term.
[0010] Surgical treatments of morbid obesity have been increasingly used with greater success. These approaches may be generalized as those that reduce the effective size of the stomach, limiting the amount of food intake, and those that create malabsorption of the food that it is eaten. For instance, some patients benefit from adjustable gastric bands (AGB) that are advantageously laparoscopically placed about the stomach to form a stoma of a desired size that allows food to fill an upper portion of the stomach, causing a feeling of satiety. To allow adjustment of the size of the stoma after implantation, a fluid conduit communicates between an inwardly presented fluid bladder of the AGB to a fluid injection port subcutaneously placed in front of the patient's sternum. A syringe needle may then inject or withdraw fluid as desired to adjust the AGB.
[0011] Although an effective approach to obesity for some, other patients may find the lifestyle changes undesirable, necessitated by the restricted amount of food intake. In addition, the medical condition of the patient may suggest the need for a more permanent solution. To that end, surgical approaches have been used to alter the portions of the stomach and/or small intestine available for digesting food. Current methods of performing a laparoscopic anastomoses for a gastric bypass include stapling, suturing, and placing biofragmentable rings, each having significant challenges. For instance, suturing is time consuming, as well as being technique and dexterity dependent. Stapling requires placement of an anvil, which is a large device that cannot be introduced through a trocar port. Having to introduce the port through a laparotomy presents an increased incidence of wound site infection associated with intralumenal content being dragged to the laparotomy entry site.
[0012] As an example of the latter approach, in U.S. Pat. No. 6,543,456 a method for gastric bypass surgery includes the insertion of proximal and distal anastomosis members (e.g., anvils) transorally with grasping forceps. The stomach and the small intestine are transected endoscopically by a surgical severing and stapling instrument to create a gastric pouch, a drainage loop, and a Roux limb. An endoscopically inserted circular stapler attaches to the distal anastomosis member to join the drainage loop to a distal portion of the intestine, and the circular stapler attaches to the proximal anastomosis member to join the Roux limb to the gastric pouch. Thereafter, the anastomosis members are removed to create an orifice between joined portions of the stomach and intestine. This method reduces the number of laparoscopic ports, avoids a laparoscopic insertion of an anastomosis instrument (e.g., circular stapler) into an enlarged surgical port, and eliminates the need for an enterotomy and an enterotomy closure.
[0013] For many anastomoses, surgeons use circular staplers, linear staplers, or manual sutures. However, to reduce incision size and to make the surgical process less technically demanding and time consuming, an anastomotic device that deforms to hold tissue portions together when the device is ejected from a constraining enclosure has been described. Such an approach is described in U.S. Pat. Appl. Publ. No. US 2003/0032967 and PCT application WO 03/000142 both to Adrian Park et al, which is hereby incorporated herein by reference, describes such a device. Therein, gastrointestinal or enteric (including biliary) anastomosis is achieved by insertion of a sheath that perforates the walls of two tissue passages, such as the stomach and small intestine. A three-dimensional woven tube of wire of having a thermal shape memory effect (SME) (“generally-known nitinol ring device”) is presented by a cannula of the sheath on both sides of the openings. Deployment of the woven tube causes the outer loops or ends of the tube to fold or loop back to hold the luminal interface of the anastomosis site in apposition. Thereby, the need for a mechanical compression component in a delivery system is reduced or avoided, reducing the size and complexity of the delivery device.
[0014] The anastomotic device disclosed in WO 03/000142 is constrained by a retractable sheath to an advantageous small-diameter tubular shape. A surgeon applies the anastomotic device by maneuvering the sheath through the tissue portions requiring anastomosis and retracting the sheath. Retracting the sheath removes the constraint on the device, allowing the device to assume a roughly hourglass shape. The larger ends of the hourglass shape hold the two tissue portions together in an effective anastomosis.
[0015] The constrained anastomotic device, which may be made of a shape memory material such as nitinol, exerts a force against the inner diameter of the sheath and tends to warp towards its roughly hourglass-shaped deployed position. When the sheath is retracted proximally, the forces generated by the device in transition from a tubular shape to an hourglass shape urge the anastomotic device distally. This device movement makes surgical control harder to achieve when placing the device through the otomies of two tissue portions requiring anastomosis.
[0016] While the generally-known nitinol ring device is a significant advancement in the treatment of morbid obesity, it is believed that further improvements would be desirable. For instance, the continuous interlocking petals are difficult to manufacturer, especially since the depicted woven tube is of a continuous wire loop bent into a pattern of interlocking triangles that are hand woven from two wire strands and the four free ends connected to one another.
[0017] Consequently, there is a general need for an approach to making an anastomosis ring device that can be used in existing trocar ports (e.g., 12 mm size) and that reliably and effectively creates an anastomotic attachment between lumens, eliminate the need for surgical stapling and suturing to form an anastomosis.
BRIEF SUMMARY OF THE INVENTION
[0018] The invention overcomes the above-noted and other deficiencies of the prior art by providing a method of making an anastomotic ring device of interlocking sinusoidal members in a cylindrical shape (undeployed) that readily converts to a hollow rivet shape (deployed), or “hour glass shape”, for endoscopic surgical procedures. In particular, each anastomotic ring device is assembled from a plurality of “points”, or arcuate members. These components allow for a proximal and distal longitudinal halves (i.e., “crowns”) of the ring device to be assembled individually and joined together, which lends itself for simplified manufacture.
[0019] In one aspect of the invention, a longitudinally bisected ring device is assembled from arcuate members of a deformable material (e.g., nitinol or other alloy). Each arcuate member is of identical or similar points (e.g., two diverging legs joined at an acutely bent radius). One crown is formed by placing half of the arcuate members (e.g., 10) in cylindrical configuration, overlapping each leg with the leg of an adjacent arcuate member. The crown may be held in a fixture until mated to another crown that is inverted to the first. The longitudinally bisected ring device thus formed in its undeployed, cylindrical shape may receive further processing to impart an ability to actuate to a hollow rivet shape to hold two tissue lumens at an anastomotic attachment.
[0020] In another aspect of the invention, such a method of implanting the longitudinally bisected ring device includes not having to rely solely or at all upon an intrinsic actuation potential. Instead, an actuator member of an applier is capable of receiving the cylindrical, undeployed shape of the ring device. When inserted across the anastomotic attachment site, the applier actuates the actuator member by compressing the ring device into a hollow rivet shape.
[0021] In yet another aspect of the invention, a longitudinally bisected ring device is formed from molded arcuate members assembled into interlocking cylindrical sinusoids that hingedly attach with adjacent arcuate members in their same longitudinal half of the ring device and rigidly attach to inverted arcuate members in the other longitudinal half. These molded arcuate members advantageously lend themselves to assembly in a deployed configuration. The ability for the interlocking sinusoids to hinge, allowing overlapping petals to move between cylindrical orientation and hollow rivet shape, lend themselves to implantation at an anastomotic surgical site, such as with the afore-described applier.
[0022] These and other objects and advantages of the present invention shall be made apparent from the accompanying drawings and the description thereof.
BRIEF DESCRIPTION OF THE FIGURES
[0023] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention, and, together with the general description of the invention given above, and the detailed description of the embodiments given below, serve to explain the principles of the present invention.
[0024] FIG. 1 is perspective view of an anastomotic ring device assembled from a plurality of arcuate petals.
[0025] FIG. 2 is a perspective view of one longitudinal half, or “crown” of the anastomotic ring device of FIG. 1 being assembled onto a fixture.
[0026] FIG. 3 is a perspective view of the two halves, or a crown and mirrored or inverted crown prior to attachment one to the other.
[0027] FIG. 4 is a perspective view of an applier capable of implantation, actuation and deployment of an anastomotic ring device of FIG. 1 , which is retained in an unactuated, cylindrical shape.
[0028] FIG. 5 is a detail view of the distal tip including an actuating member and piercing tip of the applier of FIG. 4 retaining the anastomotic ring device of FIG. 1 by gripping each point of each respective petal.
[0029] FIG. 6 is a perspective the applier of FIG. 4 actuating with opposing, compressive longitudinal actuation motions the anastomotic ring device of FIG. 1 into an actuated hollow rivet, or hour glass, shape to form an anastomotic attachment.
[0030] FIG. 7 is a detail view of the distal tip of the applier of FIG. 6 , depicting the actuated anastomotic ring device having been released from the actuating member in preparation for deployment from the applier.
[0031] FIG. 8 is a perspective view of hinged anastomotic ring device assembled in an actuated condition from a plurality of molded arcuate petals.
[0032] FIG. 9 is a perspective view of one molded arcuate petal.
[0033] FIG. 10 is a perspective view of one half of the hinged anastomotic ring device of FIG. 8 assembled into hinged petals.
[0034] FIG. 11 is a perspective view of the applier of FIG. 4 actuating to implant the hinged anastomotic ring device of FIG. 8 .
[0035] FIG. 12 is a detail view of the distal tip of the applier of FIG. 11 depicting the actuated hinged anastomotic ring device having been released from the actuating member in preparation for deployment from the applier.
DETAILED DESCRIPTION OF THE INVENTION
[0036] Turning to the Drawings, wherein like numerals denote like components throughout the several views, FIG. 1 depicts an anastomotic ring device 10 in its generally cylindrical, unactuated condition, with its woven tube of strands resembling the interweaving of a chain link fence. In the illustrative embodiment, a plurality of arcuate members, or petals, 12 are assembled in a longitudinal half, or crown 14 , intended to be on one side of an anastomotic attachment site, with a similar but inverted or mirrored crown 16 , intended to be on the other side of the anastomotic attachment site.
[0037] Both halves or crowns 14 , 16 are attached at a circular midpoint 18 such that the plurality of arcuate members 12 resemble a plurality woven sinusoids. At the midpoint 18 , attachments 20 respectively between pair of end 22 , 24 from an arcuate member 12 in the top crown 14 is made to a respective end 22 , 24 of an arcuate member 12 in the bottom crown 16 . A non-exclusive list of couplings 20 include snap fits, glue, ultrasonic welding, thermal adhesives, etc.
[0038] In the illustrative ring device of FIG. 1 , ten arcuate members 12 are included in each crown 14 , 16 . Each arcuate member is woven with two arcuate members to each side and attached to two arcuate members in the other half. For instance, for arcuate member 12 a , a left end 22 a passes in front (outside) of a right end 24 b of a left adjacent arcuate member 12 b and then passing behind a right end 24 c of a farther left arcuate member 12 c , with the pattern repeated about the circumference of the crown 14 . It should be appreciated that this number of arcuate members and this degree of interweaving is illustrative and that other patterns consistent with aspects of the invention may be used.
[0039] In FIG. 2 , assembly of the crown 14 is depicted, illustrating how the plurality of arcuate members 12 facilitates economical manufacture that may be performed by automated mechanisms. In this depiction, a fixture, or disk, 26 holds the plurality of arcuate members 12 until the crown 14 is complete, specifically locating each pair of ends 22 , 24 of each arcuate member 12 for attachment to the other crown 16 (shown in FIG. 3 ). Moreover, the fixture 26 , ensures that each curved point 28 , from which each end 22 , 24 diverges, is equidistantly spaced about the crown 14 and evenly extending for engagement by an applier.
[0040] Anastomotic Ring Device Applier.
[0041] In FIGS. 4-7 , an illustrative applier 30 has the anastomotic ring device 12 advantageously retained in a generally cylindrical shape ( FIGS. 4-5 ) distal to an outer tube 32 upon a molded actuation member 34 forming a cannula 36 that distally terminates in a flared tip 38 . This flared tip 38 presents a distal piercing surface 40 to form an anastomotic opening 42 through apposite tissue walls 44 , 46 of two gastrointestinal passages.
[0042] With particular reference to FIG. 6 , a handle 48 , proximal to the cannula 36 , includes a pair of longitudinally aligned triggers 50 , 52 . The proximal trigger 50 , shown at its most proximal, unfired position, is coupled to proximal leaves 54 of the molded actuation member 34 via an intermediate tube 56 of the cannula 36 . Distal movement of the proximal trigger 50 thus causes longitudinal distal movement of the intermediate tube 56 and proximal leaves 54 , which outwardly actuate like an umbrella by a hinged relationship to a central portion 58 of the molded actuation member 34 . (Unlike an umbrella, the “top” is brought toward the center rather than the converse.)
[0043] Similarly, the distal trigger 42 , shown at its most distal, unfired position, is coupled to distal leaves 60 of the molded actuation member 34 via an internal rod 62 that is coupled for movement within the intermediate tube 56 . Proximal movement of the distal trigger 38 causes longitudinal proximal movement of the rod 62 and distal leaves 64 of the molded actuation member 34 , which outwardly actuate by a hinged relationship to the central portion 58 .
[0044] In FIGS. 6-7 , the triggers 50 , 52 have been slid toward one another to actuate the molded actuating member 34 . Specifically, the distal trigger 52 has been moved proximally, causing similar distal movement of the internal rod 62 , the distal terminating end of the latter being attached to flared tip 38 . The flared tip 38 thus moves toward the distal end of the intermediate tube 56 . The proximal trigger 50 has been moved distally, moving intermediate tube 56 also distally. The molded actuating member 34 is compressed between the inwardly moving flared tip 38 and intermediate tube 56 . The distal leaves 64 actuate lateral to the longitudinal axis, and move toward and interdigitate with the proximal leaves 54 . This movement expedites actuating of an anastomotic ring device 10 .
[0045] In use, the flared tip 24 of the applier 30 is inserted through a trocar port into a tissue passage that has been placed proximate to another tissue passage that are to be anastomotically joined (See FIGS. 4-5 ). The flared tip 38 and a distal half of the molded actuating member 34 and anastomotic ring device 12 are inserted through an anastomotic opening 42 formed therebetween and then the applier 30 is actuated. With particular reference to FIGS. 6-7 , the proximal and distal leaves 54 , 64 are shown as having gripping slots 66 that grip respective curved points 28 of each arcuate member or petals 12 of the anastomotic ring device 12 , especially in its unactuated, generally cylindrical shape. These gripping slots 66 assist in preventing the anastomotic ring device 12 from slipping off of the applier 30 or being inappropriately placed thereon for actuation until fully actuated, forming the anastomotic ring device 12 into a hollow rivet shape or hourglass shape to form the anastomotic attachment between tissue walls 44 , 46 . The fully actuated proximal and distal leaves 54 , 64 cause the curved points 28 to disengage from the gripping slots 66 . Thereafter, the applier 30 is returned to an unactuated condition and the actuated anastomotic ring device 12 deployed by withdrawing the flared tip 38 from the anastomotic opening 42 and ring device 12 .
[0046] It should be appreciated that the unactuated anastomotic ring device 10 may be formed from nitinol and temperature treated to create a Shape Memory Effect that would cause self-actuation after implantation to a hollow rivet or hourglass shape, thus allowing generally known appliers to be used. However, as described above and in more detail in the above-referenced co-pending application entitled “Single Lumen Anastamosis Applier for Self-Deploying Fastener” to M. Ortiz, such actuation is enhanced or performed entirely by the applier 30 capable of causing the rapid actuation of the anastomotic ring device 10 , thus allowing other materials to be used as well as nitinol. Moreover, the ability to cause actuation with an applier 30 enables the use of ring devices with no inherent actuating ability.
[0047] Hinged Anastomotic Ring Device.
[0048] For instance, in FIGS. 8-10 , another anastomotic ring device 110 is formed from molded arcuate members 112 that show further advantages of forming two crowns 114 , 116 with attachments 120 at a circular midpoint 118 . With particular reference to FIG. 9 , each arcuate member 112 has a first end 122 and a second end 124 convergingly joined at a curved point 128 . Each first end 122 , 124 bends perpendicularly to their respective elongate shafts 130 , 132 presenting respectively pin hinge receiving surface 134 and a pin hinge surface 136 . The pin hinge receiving surface 134 includes a lateral half cylinder recess 138 interposed between a distally presented female attachment feature 140 and a proximally disposed male attachment feature 142 . The pin hinge surface 136 includes a half pin 144 interposed between a distally disposed female attachment feature 146 and a proximally disposed male attachment feature 148 .
[0049] These first and second ends 122 , 124 of the arcuate member 112 in one crown 114 facilitate a rigid attachment at attachment 120 to rotated identical arcuate members of the other crown 116 . The joined first ends 122 between the two arcuate members 112 forms a through hole of the two half cylinder recesses 138 that receive a pin hinge formed from two half pins 144 formed from two second ends 124 . Thus each arcuate member 112 is interwoven with its two adjacent arcuate members 112 , moves in concert with its two attached arcuate members 112 in the other crown 116 and is hingedly connected to arcuate members 112 that are on the other side to the adjacent arcuate members 112 .
[0050] Sufficient friction exists in the hinged connection between arcuate members at the midpoint 118 that when placed in position, such as depicted in FIGS. 11-12 by an applier 30 , the anastomotic ring device 110 tends to stay in its actuated position. Alternatively, the anastomotic ring device 110 is intended to maintain the anastomotic opening and requires a secondary fastening element to remain in the actuated position, such as sutures fastening arcuate members 112 to the tissue and to one another.
[0051] Although such molded arcuate members 112 may be assembled in an unactuated, cylindrical fashion as previously described above for the wire anastomotic ring device 10 , in FIG. 9 , it is shown how one crown 114 may be formed in an actuated configuration, readily prepared to accept individual arcuate members 112 of the other crown or a fully assembled bottom crown 116 .
[0052] Each molded arcuate member may be formed from a bioabsorbable material, such as a biofragmentable polymer mixture that eventually passes out of the digestive tract.
[0053] While the present invention has been illustrated by description of several embodiments and while the illustrative embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications may readily appear to those skilled in the art.
[0054] For example, a molded arcuate member consistent with aspects of the invention may form a hinged relationship rather than a rigid attachment to respective arcuate members of the inverted crown.
[0055] As a further example, an anastomosis ring device may include a circular fixture or band at its midpoint for attaching the arcuate members that remains part of the anastomosis ring device, intended to sit at a tissue juncture of the anastomosis. | An anastomotic ring device for forming a hollow rivet (ring) attachment between tissue lumens facilitates laparoscopic or endoscopic implantation by including features that facilitate assembly, specifically by forming from constituent arcuate members or petals that join with one another at a circular midpoint. Automated assembly is thereby facilitated with each longitudinal half including a “crown” of these arcuate members arranged in a cylindrical pattern with equally spaced curved points and overlapping ends. Molded arcuate members with integral hinges further enhance assembly and provide other advantages, especially when implanted with an applier capable of actuating the anastomotic ring device. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to portable structures and particularly multi-level portable structures.
2. Description of Related Art
Tents have been used for centuries as temporary shelters for travelers or for semi-permanent housing units in warmer climates. Tents have been designed in many styles and with many features. However, virtually all tents have been designed as single-story structures. This makes living in tents uncomfortable at best and miserable at worst. All sleeping, eating and cooking must be carried out at the same level.
BRIEF SUMMARY OF THE INVENTION
The invention is a large multi-level tent that has an interior divided into two levels. A platform system is included within the tent to divide it into the levels. The tent is built up around the platform. The tent has an outer covering made of canvas and a set of frame elements that make assembly of the tent easy. The tent is a ¾ sphere that is supported by shaped tubes, a set of braces, and a top band.
The platform is a combination of wood, metal and plastic. Polyvinylchloride (PVC) posts are used to secure the platform to the ground. They have an auger base to anchor then securely. Each post extend upward to the full desired height for a two level living space. Metal brackets are secured to the vertical posts at each floor location. These brackets hold 2×4 horizontal wooden frame members. The frame members are reinforced with additional wood framing, similar to deck construction. Each deck is then covered with plywood sheathing to form a “floor” surface.
After the platform is built, the tent is constructed around it. The tent has a number of lower frame elements, a number of vertical elements and a top ring. The lower frame elements are joined in a circle. The vertical elements are attached to the lower frame elements at the connection joints. These vertical elements are secured by the top ring to form a semi-spherical frame. This frame is covered by a canvas outer covering that is attached to all the tent frame elements. Stakes are used to secure the tent to the ground. The tent has openings for doors and ventilation. The top ring is also fitted with a cover to prevent water from entering the tent.
Once assembled, the structure has two living levels. The upper level can be used for sleeping and the lower level can be used for living. In this way, bedding and other supplies do not have to be moved or stored while doing different activities.
Thus, this tent system makes a comfortable long term camp for doing fieldwork of any kind.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cut-away view of the tent showing the interior two-level platform in place.
FIG. 2 is a perspective view of the invention with the tent fully closed.
FIG. 3 is a detail view of a vertical support post, showing the auger base.
FIG. 3 a is a detail view of the vertical support and auger base, showing a threaded connection.
FIG. 4 is a detail view of a vertical support post with the base plate, and corner brackets installed, and showing two 2×4 frame members in the lower corner bracket.
FIG. 4 b is a detail of an alternative base plate connection.
FIG. 5 is a top view of a corner bracket.
FIG. 6 is a side view of a spacer portion of the corner brackets.
FIG. 7 is a perspective view of the corner brackets showing the 2×4 framing in place.
FIG. 8 is a top view of a platform showing the placement of the vertical posts, the corner brackets, the 2×4 framing and the plywood decking.
FIG. 9 is a detail view of the top ring showing four vertical elements in place.
FIG. 10 is a detail view of the lower frame members being temporarily assembled with the vertical elements.
FIG. 11 is a detail view showing the frame in place around the platform and the tent covering being installed.
FIG. 12 is a detail view showing the final assembly of the frame elements and the tent fabric.
FIG. 13 is a side view of a tent stake.
FIG. 14 is a detail view showing a stake being positioned in a lower frame element.
FIG. 15 is a side view of a vertical frame element.
FIG. 16 is a top view of a lower frame element.
FIG. 17 is an outside view of the first section of canvas covering.
FIG. 18 is an inside view of a typical section of canvas covering.
FIG. 19 is an inside view of the final canvas section.
FIG. 20 is a bottom view of the canvas top cap.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, the tent 1 and platform 2 are shown. In the preferred embodiment, the tent has an overall diameter of 16 feet and a height of 10 feet. The internal platform is 12 feet long by 8 feet wide. The lower floor 3 of the platform is designed to lie about 1 foot above the ground. The upper floor 4 of the platform is designed to be five feet above the top of the lower floor 3 .
FIG. 2 shows the tent fully assembled and closed. The platform 2 is entirely within this tent structure.
The platform is installed using four vertical members 5 . FIG. 3 shows one form of the vertical members. Each vertical member has a number of components. The bottom 6 of each vertical member 5 has an auger portion 7 . This portion is used to screw the vertical member into the ground. In the preferred embodiment, the auger portion 7 is approximately 1 foot long. The vertical members are made of 4-inch pipe. In the preferred embodiment, the vertical members are made of schedule 40 Polyvinylchloride (PVC) pipe. A number of holes are drilled in this pipe. A lower set of holes 8 and an upper set of holes 9 are used to secure the floor brackets (discussed below). A center hole 10 is used to pass a rod through. The rod is used to help screw the vertical member into the ground.
FIG. 3 a shows an alternative form of the vertical member 5 and auger portion 7 . Here, the vertical member and auger portion are made in two pieces. The auger portion has a set of female threads 7 b and the vertical member 5 has a set of male threads 7 a. In this way, the two parts can be installed separately. In this design, the center hole 10 is relocated to the auger portion 5 as shown. Four mounting holes 6 a are provided around the perimeter of the lower portion of the vertical member 6 as shown.
FIG. 4 shows the vertical member 6 with a base plate 11 placed on the bottom. This plate covers the auger portion and provides some lateral stability for the vertical members. Two floor brackets 12 are used on each vertical member. The floor brackets are made of lightweight metal. Each floor bracket has two triangular mounting plates 13 . FIG. 5 shows a top view of one mounting plate 13 . The two plates 13 are separated by a spacer 14 . The spacer has a diameter slightly larger than the diameter of the vertical member. FIG. 6 shows the spacer 14 . Note too that the mounting plates have central holes 15 of the same size as the spacer. The spacer is designed to provide room for a standard 2×4 piece of dimensional lumber. The floor brackets are place over the top of the vertical member and are slid down until they align with the holes 8 or 9 . Once aligned with the proper sets of holes, the floor brackets are bolted to the vertical member using fasteners common to the art.
With the threaded auger and vertical members, the base plate 11 can be installed with a hole to allow the auger and vertical member to be screwed together. Alternatively, The base plate 11 a of FIG. 4 b may be used. Here, two wooden blocks 11 b are attached to the base plate 11 a as shown. The auger and vertical member fit over the blocks as shown. Once in place the auger and vertical member can be secured to the blocks using the mounting holes 10 for the auger and 6 b for the vertical member 5 . In this way, it is possible to assemble the platform without the augers.
The platform requires four vertical members set in a rectangular pattern. Once the first vertical member is placed, the other members are positioned according to the steps discussed below. After the vertical members are in place, the horizontal framing can be added. This framing used standard 2×4 lumber. As shown in FIG. 5, the floor bracket plates have a number of holes 16 formed in them. These holes are used to secure the 2×4 lumber to the floor brackets. Nails or similar fasteners may be used to secure them in place. FIG. 7 shows how the 2×4s 20 and 21 are placed to align in the brackets without having to miter or cut the ends.
FIG. 8 shows the framework and the vertical members. The outer 2×4s, 20 , 21 , 22 , and 23 are placed as shown. Note how the holes 16 align with the 2×4s. Once the perimeter has been framed, addition joists 24 are placed within the frame as shown and secured with fasteners to the perimeter frame. The frame is then covered with plywood sheeting 25 . The plywood ends are notched to fit around the vertical members as shown. Typically, the plywood is cut prior to locating the unit in the field.
Both the lower and upper floors are built in the same manner. Once the platform is finished, the outer tent can be built.
The tent portion is assembled from a number of components. FIGS. 9-20 show the tent's structural components the tent framework components. The base of the tent is formed using a number of lower frame brace 30 . FIG. 16 shows a top view of a lower frame brace 30 . In the preferred embodiment, 10 of the braces 30 are used. Each frame brace 30 has a pair of eyebolts 31 secured in the ends of the brace 30 as shown. The brace is a square piece of wood. In the preferred embodiment, each brace is five feet long from eyebolt center to eyebolt center and made from 2×2 dimensional lumber. At the center of each brace is a hole 32 . The hole 32 is approximately ½-inch in diameter. However, the hole 32 can be any reasonable size. The holes 32 are used for stakes 34 , shown in FIG. 13 . FIG. 14 shows the placement of the stakes 34 in the holes 32 . This procedure is also described in more detail below. Finally, each brace 30 has a small strip of VELCRO 39 , a hook and loop fastener, attached to one side of the outer face of the brace as shown.
The tent frame has a number of bent poles 35 . The poles are shown in FIG. 15 . The poles may be made of 1-inch tubing, or may be lighter weight flexible tubing. The bent poles 35 are approximately 14 feet long. As discussed below, one end of the poles fits in the eyebolts 31 at the base of the tent. Two holes 36 are provided to secure the poles to the lower tent frame braces. This procedure is discussed below. The tops of the poles 35 have a hole 37 that is used to secure the pole into a band 40 , as shown in FIG. 15 . The band 40 , in the preferred embodiment is metal. The band 40 is approximately 2 feet long and 2 inches wide. A number of holes 41 , corresponding to the number of poles, are cut into the band as shown. The band is formed into a circle, as shown. The poles 35 pass through the holes 41 . Pins 42 are placed through the holes 37 to secure the tops of the poles within the band 40 . See FIG. 9 .
The tent material is made of canvas or other waterproof material. The tent wall 50 is made up of several tent panels 51 . The tent panels 51 have similar characteristics, except for the first and last panels. All the panels are sewn together except for the first and last panels, where one end of those panels are left open to allow the tent material to be placed over the frame. FIG. 17 shows the outer surface of the first panel 51 a . This panel is generally shaped as shown. On the right side, a strip of VELCRO 52 , a hook and loop fastener is attached as shown. At the top, a second loop of VELCRO 53 is attached as shown. Two pairs of grommets 55 are placed at the bottom corners as shown. Finally, a number of ties 56 are placed on the right side of the first panel as shown. The second panel is then sewn to the left side of the first panel (from the perspective of the outside of the panel as shown in FIG. 17 ). FIG. 18 shows the inside face of the first panel 51 a . This face has a strip of VELCRO 57 as shown. All of the remaining panels, with the exception of the last panel, have the same shape as the first panel. All the intermediate panels have a strip of VELCRO 53 secured to the outer face at the top and a second strip of VELCRO 57 at the bottom of the inner face. FIG. 19 shows the inner face of the last panel 51 b . This panel is sewn to the last intermediate panel on one side 60 . On the other side, are strips of VELCRO 61 as shown. This panel has a small slit 62 cut into the outer edge as shown. Like the other panels, this panel also has the two pairs of grommets 55 and an outer strip of VELCRO 53 .
FIG. 20 is an inner view of a top cap 70 that is used to cover the ring 40 . The top cap 70 has a continuous strip of VELCRO 71 within the inner perimeter. This strip 71 engages with the VELCRO strips 53 at the top of the tent panels to seal the top of the tent.
Referring now to FIGS. 10-12, the tent and platform are installed as follows: first, find a level ground surface. Then position the first corner post and screw it into the ground to a one-foot depth. Use a level to make sure the post is plumb. Place a platform bracket on the post and measure for the second support post location. At that location, screw in the second post. Repeat this procedure for the remaining posts, placing the posts in a rectangular pattern. Once the posts are set and plumb, secure the platform brackets to the posts using screws, nuts, bolts or other common fasteners. Next, secure the vertical and horizontal 2×4 frame members for the lower platform, securing them to the platform brackets. Once these are secure, add joists at 16 inches on center. Next place a sheet of plywood on the lower platform and secure it to the framework. Then, install a second set of platform brackets at the top of the vertical 2×4 members. Repeat the placement of horizontal members and joists, cover the top platform with plywood, and secure it to the joists as before. FIG. 8 shows this assembly.
Once the platform is completed, place the tent braces in a circle. The diameter of the preferred embodiment is sixteen feet. The platform is in the center of the circle. Assemble four vertical tent tubes and the top band on the top platform. The tubes are positioned at 90-degree increments and are installed on the top band with hardware. See FIG. 10 . The bottom end of each tube is placed through two of the eyebolts found at the ends of the braces. In this way, the braces are interlocked with the tubes. Temporarily secure the tubes to the braces using a nail 100 as shown. This step is shown in FIG. 10 . Install the remaining braces using the same techniques. Tie the end of the first panel of rolled canvas tent material to the top band, the middle of one tube and the bottom of the same tube. See FIG. 11 . Proceed to unroll the canvas around the frame. At each tube position, replace the nail with a “U” bolt that is placed through grommets 55 in the canvas. As shown in FIG. 13, a “U” bolt 70 then passed through two holes 36 in the tube (one above the eyebolts 31 and one below). The “U” bolts are secured with nuts 75 and lock washers 75 . See FIG. 12 . The VELCRO strips 57 are secured to the VELCRO strips 39 on the frame braces, as each panel is unrolled. When the entire canvas is unrolled, the last panel is mated with the first panel using the VELCRO strips, as discussed above. Finally, the tent cap is secured over the ring to seal the tent and make it weather tight.
Once the canvas is secured to the frame, a stake is driven through holes in each of the braces to secure the tent to the ground. The tent is then ready to use.
The present disclosure should not be construed in any limited sense other than that limited by the scope of the claims having regard to the teachings herein and the prior art being apparent with the preferred form of the invention disclosed herein and which reveals details of structure of a preferred form necessary for a better understanding of the invention and may be subject to change by skilled persons within the scope of the invention without departing from the concept thereof. | A large multi-level tent that has an interior divided into two levels. The tent is a ¾ sphere that is supported by shaped tubes, a set of braces, and a top band. The platform has polyvinylchloride (PVC) posts to secure the platform to the ground. Each post extends upward to the full desired height for a two level living space. Metal brackets are secured to the vertical posts at each floor location. These brackets hold 2×4 horizontal wooden frame members. The frame members are reinforced with additional wood framing, similar to deck construction. Each deck is then covered with plywood sheathing to form a “floor” surface. After the platform is built, the tent is constructed around it. The tent has frame, which is covered by a canvas outer covering that is attached to all the tent frame elements. | 4 |
CLAIM OF PRIORITY
This application claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 61/174,832, entitled “Methods and Systems using Improved ARQ Reset Mechanism” and filed May 1, 2009, which is assigned to the assignee of this application and fully incorporate herein by reference for all purposes.
TECHNICAL FIELD
Certain embodiments of the present disclosure generally relate to wireless communication and, more particularly, to automatic repeat request (ARQ) reset.
SUMMARY
Certain embodiments of the present disclosure provide a method for wireless communication. The method generally includes receiving, at a first device, a message initiating an automatic repeat request (ARQ) reset procedure transmitted by a second device, determining if both the first and second devices have initiated an ARQ reset procedure, and taking action to limit a loss of blocks of data exchanged between the first and second devices, if both the first and second devices have initiated an ARQ reset procedure.
Certain embodiments of the present disclosure provide an apparatus for wireless communication. The apparatus generally includes logic for receiving, at a first device, a message initiating an automatic repeat request (ARQ) reset procedure transmitted by a second device, logic for determining if both the first and second devices have initiated an ARQ reset procedure, and logic for taking action to limit a loss of blocks of data exchanged between the first and second devices, if both the first and second devices have initiated an ARQ reset procedure.
Certain embodiments of the present disclosure provide an apparatus for wireless communication. The apparatus generally includes means for receiving, at a first device, a message initiating an automatic repeat request (ARQ) reset procedure transmitted by a second device, means for determining if both the first and second devices have initiated an ARQ reset procedure, and means for taking action to limit a loss of blocks of data exchanged between the first and second devices, if both the first and second devices have initiated an ARQ reset procedure.
Certain embodiments of the present disclosure provide a computer-program storage apparatus for wireless communication, comprising a memory device having instructions stored thereon, the instructions being executable by one or more processors and the instructions. The storage apparatus generally includes instructions for receiving, at a first device, a message initiating an automatic repeat request (ARQ) reset procedure transmitted by a second device, instructions for determining if both the first and second devices have initiated an ARQ reset procedure, and instructions for taking action to limit a loss of blocks of data exchanged between the first and second devices, if both the first and second devices have initiated an ARQ reset procedure.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above-recited features of the present disclosure can be understood in detail, a more particular description, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, that the appended drawings illustrate only certain typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the description may admit to other equally effective embodiments.
FIG. 1 illustrates an example wireless communication system, in accordance with certain embodiments of the present disclosure.
FIG. 2 illustrates various components that may be utilized in a wireless device in accordance with certain embodiments of the present disclosure.
FIG. 3 illustrates an example transmitter and an example receiver that may be used within a wireless communication system that utilizes orthogonal frequency-division multiplexing and orthogonal frequency division multiple access (OFDM/OFDMA) technology in accordance with certain embodiments of the present disclosure.
FIG. 4 illustrates an automatic repeat-request (ARQ) transmission, in accordance with certain embodiments of the present disclosure.
FIG. 5A illustrates a transmitter (TX) initiated ARQ reset.
FIG. 5B illustrates a receiver (RX) initiated ARQ reset.
FIG. 6 illustrates a scenario in which both a TX and a RX initiate an ARQ reset within a narrow time interval.
FIG. 7 illustrates example operations for selecting a TX initiated ARQ reset when both the TX and RX initiate an ARQ reset within a narrow time interval.
FIG. 7A is a block diagram of means corresponding to the example operations of FIG. 7 .
FIGS. 8A-B illustrate example exchanges utilizing the TX initiated ARQ reset when both a TX and a RX ARQ reset have been initiated within a narrow time interval.
FIG. 9 illustrates example operations for selecting a RX initiated ARQ reset when both the TX and RX initiate an ARQ reset within a narrow time interval.
FIG. 9A is a block diagram of means corresponding to the example operations of FIG. 9 .
FIGS. 10A-B illustrate example exchanges utilizing the RX initiated ARQ reset when both a TX and a RX ARQ reset have been initiated within a narrow time interval.
FIG. 11 illustrates example operations for ignoring both a TX and a RX initiated ARQ reset when both the TX and RX initiate an ARQ reset within a narrow time interval.
FIG. 11A is a block diagram of means corresponding to the example operations of FIG. 11 .
FIGS. 12A-B illustrate example exchanges utilizing the TX initiated ARQ reset when both a TX and a RX ARQ reset have been initiated within a narrow time interval.
DETAILED DESCRIPTION
Orthogonal frequency-division multiplexing (OFDM) and orthogonal frequency division multiple access (OFDMA) wireless communication systems, such as those compliant with the IEEE 802.16 family of standards, typically use a network of base stations to communicate with wireless devices (i.e., mobile stations) registered for services in the systems based on the orthogonality of frequencies of multiple subcarriers and can be implemented to achieve a number of technical advantages for wideband wireless communications, such as resistance to multipath fading and interference. Each base station (BS) emits and receives radio frequency (RF) signals that convey data to and from the mobile stations (MS).
To improve the reliability of data transmission, some wireless systems employ an automatic repeat-request (ARQ) scheme where acknowledgments and timeouts may be used to achieve reliable data transmission over an unreliable service. A receiver (e.g., an MS) may use an acknowledgement to notify a transmitter (e.g., a BS) whether or not a packet was successfully received and decoded. If the packet was not successfully received or decoded, the receiver may signal the transmitter via a negative acknowledgment (NAK), prompting the transmitter to retransmit the packet.
Occasionally, a state associated with the ARQ scheme may be reset. The 802.16 standard specifies a set of actions taken to reset the state associated with an ARQ scheme. The standard addresses an ARQ reset initiated by a receiver and an ARQ reset initiated by transmitter, but is silent with respect to certain ARQ reset scenarios.
Embodiments of the present propose a method and apparatus for ignoring at least one of two previously initiated ARQ resets when it is determined that both the RX and TX initiated independent ARQ reset procedures. For example, a TX may initiate an ARQ reset procedure by sending a Type 0 reset message to a RX, but subsequently receive a Type 0 reset message sent by the RX. Certain embodiments of the present disclosure may enable the TX, which received the Type 0 reset message sent by the RX after initiating its own ARQ reset, to ignore the RX initiated ARQ reset continuing, instead, with the TX initiated ARQ reset.
Exemplary Wireless Communication System
The techniques described herein may be used for various broadband wireless communication systems, including communication systems that are based on an orthogonal multiplexing scheme. Examples of such communication systems include Orthogonal Frequency Division Multiple Access (OFDMA) systems, Single-Carrier Frequency Division Multiple Access (SC-FDMA) systems, and so forth. An OFDMA system utilizes orthogonal frequency division multiplexing (OFDM), which is a modulation technique that partitions the overall system bandwidth into multiple orthogonal sub-carriers. These sub-carriers may also be called tones, bins, etc. With OFDM, each sub-carrier may be independently modulated with data. An SC-FDMA system may utilize interleaved FDMA (IFDMA) to transmit on sub-carriers that are distributed across the system bandwidth, localized FDMA (LFDMA) to transmit on a block of adjacent sub-carriers, or enhanced FDMA (EFDMA) to transmit on multiple blocks of adjacent sub-carriers. In general, modulation symbols are sent in the frequency domain with OFDM and in the time domain with SC-FDMA.
One example of a communication system based on an orthogonal multiplexing scheme is a WiMAX system. WiMAX, which stands for the Worldwide Interoperability for Microwave Access, is a standards-based broadband wireless technology that provides high-throughput broadband connections over long distances. There are two main applications of WiMAX today: fixed WiMAX and mobile WiMAX. Fixed WiMAX applications are point-to-multipoint, enabling broadband access to homes and businesses, for example. Mobile WiMAX is based on OFDM and OFDMA and offers the full mobility of cellular networks at broadband speeds.
IEEE 802.16x is an emerging standard organization to define an air interface for fixed and mobile broadband wireless access (BWA) systems. These standards define at least four different physical layers (PHYs) and one media access control (MAC) layer. The OFDM and OFDMA physical layer of the four physical layers are the most popular in the fixed and mobile BWA areas respectively.
FIG. 1 illustrates an example of a wireless communication system 100 . The wireless communication system 100 may be a broadband wireless communication system. The wireless communication system 100 may provide communication for a number of cells 102 , each of which is serviced by a base station 104 . A base station 104 may be a fixed station that communicates with user terminals 106 . The base station 104 may alternatively be referred to as an access point, a Node B or some other terminology.
FIG. 1 depicts various user terminals 106 dispersed throughout the system 100 . The user terminals 106 may be fixed (i.e., stationary) or mobile. The user terminals 106 may alternatively be referred to as remote stations, access terminals, terminals, subscriber units, mobile stations, stations, user equipment, etc. The user terminals 106 may be wireless devices, such as cellular phones, personal digital assistants (PDAs), handheld devices, wireless modems, laptop computers, personal computers (PCs), etc.
A variety of algorithms and methods may be used for transmissions in the wireless communication system 100 between the base stations 104 and the user terminals 106 . For example, signals may be sent and received between the base stations 104 and the user terminals 106 in accordance with OFDM/OFDMA techniques. If this is the case, the wireless communication system 100 may be referred to as an OFDM/OFDMA system.
A communication link that facilitates transmission from a base station 104 to a user terminal 106 may be referred to as a downlink 108 , and a communication link that facilitates transmission from a user terminal 106 to a base station 104 may be referred to as an uplink 110 . Alternatively, a downlink 108 may be referred to as a forward link or a forward channel, and an uplink 110 may be referred to as a reverse link or a reverse channel.
A cell 102 may be divided into multiple sectors 112 . A sector 112 is a physical coverage area within a cell 102 . Base stations 104 within a wireless communication system 100 may utilize antennas that concentrate the flow of power within a particular sector 112 of the cell 102 . Such antennas may be referred to as directional antennas.
FIG. 2 illustrates various components that may be utilized in a wireless device 202 . The wireless device 202 is an example of a device that may be configured to implement the various methods described herein. The wireless device 202 may be a base station 104 or a user terminal 106 .
The wireless device 202 may include a processor 204 that controls operation of the wireless device 202 . The processor 204 may also be referred to as a central processing unit (CPU). Memory 206 , which may include both read-only memory (ROM) and random access memory (RAM), provides instructions and data to the processor 204 . A portion of the memory 206 may also include non-volatile random access memory (NVRAM). The processor 204 can perform operations based on program instructions stored within the memory 206 . The instructions in the memory 206 may be executable to implement what is described herein.
The wireless device 202 may also include a housing 208 that may include a transmitter 210 and a receiver 212 to allow transmission and reception of data between the wireless device 202 and a remote location. The transmitter 210 and receiver 212 may be combined into a transceiver 214 . An antenna 216 may be attached to the housing 208 and electrically coupled to the transceiver 214 . The wireless device 202 may also include (not shown) multiple transmitters, multiple receivers, multiple transceivers, and/or multiple antennas.
The wireless device 202 may also include a signal detector 218 that may be used in an effort to detect and quantify the level of signals received by the transceiver 214 . The signal detector 218 may detect such signals as total energy, pilot energy from pilot subcarriers or signal energy from the preamble symbol, power spectral density, and other signals. The wireless device 202 may also include a digital signal processor (DSP) 220 for use in processing signals.
The various components of the wireless device 202 may be coupled together by a bus system 222 , which may include a power bus, a control signal bus, and a status signal bus in addition to a data bus.
FIG. 3 illustrates an example of a transmitter 302 that may be used within a wireless communication system 100 that utilizes OFDM/OFDMA. Portions of the transmitter 302 may be implemented in the transmitter 210 of a wireless device 202 . The transmitter 302 may be implemented in a base station 104 for transmitting data 306 to a user terminal 106 on a downlink 108 . The transmitter 302 may also be implemented in a user terminal 106 for transmitting data 306 to a base station 104 on an uplink 110 .
Data 306 to be transmitted is shown being provided as input to a serial-to-parallel (S/P) converter 308 . The S/P converter 308 may split the transmission data into N parallel data streams 310 .
The N parallel data streams 310 may then be provided as input to a mapper 312 . The mapper 312 may map the N parallel data streams 310 onto N constellation points. The mapping may be done using some modulation constellation, such as binary phase-shift keying (BPSK), quadrature phase-shift keying (QPSK), 8 phase-shift keying (8PSK), quadrature amplitude modulation (QAM), etc. Thus, the mapper 312 may output N parallel symbol streams 316 , each symbol stream 316 corresponding to one of the N orthogonal subcarriers of the inverse fast Fourier transform (IFFT) 320 . These N parallel symbol streams 316 are represented in the frequency domain and may be converted into N parallel time domain sample streams 318 by an IFFT component 320 .
A brief note about terminology will now be provided. N parallel modulations in the frequency domain are equal to N modulation symbols in the frequency domain, which are equal to N mapping and N-point IFFT in the frequency domain, which is equal to one (useful) OFDM symbol in the time domain, which is equal to N samples in the time domain. One OFDM symbol in the time domain, Ns, is equal to Ncp (the number of guard samples per OFDM symbol)+N (the number of useful samples per OFDM symbol).
The N parallel time domain sample streams 318 may be converted into an OFDM/OFDMA symbol stream 322 by a parallel-to-serial (P/S) converter 324 . A guard insertion component 326 may insert a guard interval between successive OFDM/OFDMA symbols in the OFDM/OFDMA symbol stream 322 . The output of the guard insertion component 326 may then be upconverted to a desired transmit frequency band by a radio frequency (RF) front end 328 . An antenna 330 may then transmit the resulting signal 332 .
FIG. 3 also illustrates an example of a receiver 304 that may be used within a wireless communication system 100 that utilizes OFDM/OFDMA. Portions of the receiver 304 may be implemented in the receiver 212 of a wireless device 202 . The receiver 304 may be implemented in a user terminal 106 for receiving data 306 from a base station 104 on a downlink 108 . The receiver 304 may also be implemented in a base station 104 for receiving data 306 from a user terminal 106 on an uplink 110 .
The transmitted signal 332 is shown traveling over a wireless channel 334 . When a signal 332 ′ is received by an antenna 330 ′, the received signal 332 ′ may be downconverted to a baseband signal by an RF front end 328 ′. A guard removal component 326 ′ may then remove the guard interval that was inserted between OFDM/OFDMA symbols by the guard insertion component 326 .
The output of the guard removal component 326 ′ may be provided to an S/P converter 324 ′. The S/P converter 324 ′ may divide the OFDM/OFDMA symbol stream 322 ′ into the N parallel time-domain symbol streams 318 ′, each of which corresponds to one of the N orthogonal subcarriers. A fast Fourier transform (FFT) component 320 ′ may convert the N parallel time-domain symbol streams 318 ′ into the frequency domain and output N parallel frequency-domain symbol streams 316 ′.
A demapper 312 ′ may perform the inverse of the symbol mapping operation that was performed by the mapper 312 , thereby outputting N parallel data streams 310 ′. A P/S converter 308 ′ may combine the N parallel data streams 310 ′ into a single data stream 306 ′. Ideally, this data stream 306 ′ corresponds to the data 306 that was provided as input to the transmitter 302 .
Exemplary ARQ Reset
In a WiMAX network, an ARQ mechanism may be implemented as part of the Media Access Control (MAC) layer to improve data transmission reliability over an unreliable service. When implemented, ARQ may be enabled on a connection-by-connection basis and negotiated during the connection creation.
FIG. 4 illustrates a basic sequence of ARQ transmissions. A transmitter (TX) 400 , such as the base station, may broadcast a first signal s(1,t) containing an ARQ message via an antenna 402 . An antenna 404 of a receiver (RX) 406 , contained within a wireless device such as a user terminal, may receive the broadcast first signal as received signal r(1,t) with a certain power √{square root over (p(1))}.
The first received signal r(1,t) may be processed and decoded by the receiver (RX) 406 . In decoding the message, error correction bits (e.g., a checksum) generated for the data payload may be compared against error correction bits sent in the message. A match between the generated and transmitted error correction bits may indicate the decoded message is correct, while a mismatch may indicate one or more of the bits in the decoded message are not correct.
If the decoded message is not correct, the RX 406 transmits a not-acknowledged (NAK) signal back to the transmitter (TX) 400 . The TX 400 , upon receiving the NAK signal, may retransmit the same signal s(q,t) containing the ARQ message again for the qth iteration (q=2 in the illustrated example). This process is repeated until (at q=Nq) the decoded message is correct and the RX 406 transmits an ACK signal to the TX 400 , indicating successful reception and decoding of the correct ARQ message.
For ARQ-enabled connections, the TX may partition each service data unit (SDU) into a set of fragments (or blocks) for separate transmission. The size of the blocks formed for transmission may be specified by a connection tuple parameter.
After dividing the SDU into blocks, the TX may begin sending the set of blocks to the RX. If a block was not successfully received or decoded, the RX may signal the transmitter via a negative acknowledgment (NAK), prompting the transmitter to retransmit the block. To manage the transmission of one or more sets of block, a TX or RX may assign a state to each block.
The state of each block may either be “not-sent,” “outstanding,” “discarded,” or “waiting-for-retransmission.” All blocks being in the “not-sent” state. After a block is sent, it enters the “outstanding” state for a previously negotiated period of time. While the block is in the “outstanding” state, it is either acknowledged, then placed in the “discarded” state or transitioned to the “waiting-for-retransmission” state.
At times, it may be beneficial for the TX or the RX to reset the states of the set of blocks. For example, it may be beneficial for the state of blocks sent between the RX and the TX to be synchronized. Accordingly, the current version of the WiMAX standard, TX initiated ARQ resets and RX initiated ARQ resets are provided for.
FIG. 5A illustrates a transmitter (TX) initiated ARQ reset. Upon determining it is beneficial to perform an ARQ reset, the TX may initiate ARQ reset operations by sending a Type 0 reset message to the RX. The TX may also disable additional block transmissions. After receiving the Type 0 reset message, the RX may transition blocks from the “outstanding” and the “waiting-for-retransmission” to the “discarded” state. The RX may then discard blocks in the “discarded” state and respond to the TX with a Type 1 reset message. In response to receiving the Type 1 reset the TX may also transition blocks from the “outstanding” and the “waiting-message, for-retransmission” to the “discarded” state and discard blocks in the “discarded” state before enabling additional block transmissions.
FIG. 5B illustrates a receiver (RX) initiated ARQ reset. Upon determining it is beneficial to perform an ARQ reset, the RX may initiate ARQ reset operations by sending a Type 0 reset message to the TX and disable the reception of additional blocks. Upon receiving a Type 0 reset message from the RX, the TX may disable additional block transmissions and respond with a Type 1 reset message. After receiving the Type 1 reset message from the TX, the RX may transition blocks from the “outstanding” and the “waiting-for-retransmission” to the “discarded” state, discard blocks in the “discarded” state, enable reception of additional blocks, and respond to the TX with a Type 2 reset message. In response to receiving the Type 2 reset message, the TX may also transition blocks from the “outstanding” and the “waiting-for-retransmission” to the “discarded” state and discard blocks in the “discarded” state before enabling additional block transmissions.
However, the current version of the 802.16 standard does not address scenarios in which both the TX and the RX determine it is beneficial to perform an ARQ reset within a narrow time interval. Consequently, both the TX and the RX may perform the operations for a TX initiated ARQ reset and an RX initiated ARQ reset.
As illustrated in FIG. 6 , in some scenarios, this may result in the TX enabling additional block transmissions following the execution of a TX initiated ARQ reset (Reset Type 1 as shown), then receiving a Type 2 reset message from the RX. In response to receiving the Type 2 reset message, the TX may transition blocks from the “outstanding” and the “waiting-for-retransmission” to the “discarded” state and discard blocks in the “discarded” state.
As further illustrated in FIG. 6 , ARQ blocks 0-n maybe sent during the interval between the TX enabling transmissions following receiving of Reset Type 1 (TX initiated Reset) and TX enabling transmissions following receiving of Reset Type 2 (RX initiated Reset). After the 2nd TX enabling transmission, new ARQ blocks sent to the RX maybe dropped, because the RX may have received the first batch of ARQ blocks.
To prevent blocks from being discarded before they are properly received and decoded, embodiments of the present disclosure propose a method and apparatus for ignoring at least one of two previously initiated ARQ reset procedures when it is determined that both a TX and a RX initiated ARQ reset procedures.
FIG. 7 illustrates example operations 700 for ignoring an ARQ reset previously initiated by the RX when it is determined that both the RX and the TX initiated independent ARQ reset procedures. Operations 700 may be performed by either the RX or the TX when performing ARQ reset procedures.
Operations 700 begin, at 702 , with a device receiving an automatic repeat request (ARQ) Type 0 reset message. At 704 , the device may determine if both it and its compliment (i.e., both the receiver (RX) and the transmitter (TX)) have initiated ARQ reset procedures.
If both the RX and the TX have initiated ARQ reset procedures, the device, at 706 , may ignore the RX initiated ARQ reset procedures and proceed with the appropriate step of the TX initiated ARQ reset procedures.
FIG. 8A illustrates an example in which the transmitter 400 is the device employing operations 700 . As illustrated, the TX 400 initiated an ARQ reset and subsequently received a Type 0 reset message from the RX indicating the RX 406 also initiated an ARQ reset. After determining both the RX and the TX initiated ARQ reset procedures, the TX ignores the Type 0 reset message received from the RX. Afterwards, the TX receives a Type 1 reset message from the RX corresponding to the TX initiated ARQ reset and completes the TX initiated ARQ reset procedures.
FIG. 8B illustrates an example in which the receiver 406 is the device employing operations 700 . As illustrated, the RX 406 initiated an ARQ reset and subsequently received a Type 0 reset message from the TX indicating the TX 400 also initiated an ARQ reset. After determining both the RX and the TX initiated ARQ reset procedures, the RX abandons the RX initiated ARQ reset and ignores the Type 1 reset message received from the TX. The RX, then, proceeds to transmit the Type 1 reset message to the TX completing the TX initiated ARQ reset procedures.
FIG. 9 illustrates example operations 900 for ignoring an ARQ reset previously initiated by the TX when it is determined that both the RX and the TX initiated independent ARQ reset procedures. Operations 900 may be performed by either the RX or the TX when performing ARQ reset procedures.
Operations 900 begin, at 902 , with a device receiving an automatic repeat request (ARQ) Type 0 reset message. At 904 , the device may determine if both it and its compliment (i.e., both the receiver (RX) and the transmitter (TX)) have initiated ARQ reset procedures.
If both the RX and the TX have initiated ARQ reset procedures, the device, at 906 , may ignore the TX initiated ARQ reset procedures and proceed with the appropriate step of the RX initiated ARQ reset procedures.
FIG. 10A illustrates an example in which the transmitter 400 is the device employing operations 900 . As illustrated, the TX 400 initiated an ARQ reset and subsequently received a Type 0 reset message from the RX indicating the RX 406 also initiated an ARQ reset. After determining both the RX and the TX initiated ARQ reset procedures, the TX may abandon the TX initiated ARQ reset and proceeds with sending a Type 1 reset message in accordance with the RX initiated ARQ reset. Additionally, if the TX receives a Type 1 reset message from the RX indicating the continuation of the TX initiated ARQ reset, the TX may ignore the Type 1 reset message received from the RX. Afterwards, the TX may receive a Type 2 reset message from the RX corresponding to the RX initiated ARQ reset and complete the RX initiated ARQ reset procedures.
FIG. 10B illustrates an example in which the receiver 406 is the device employing operations 900 . As illustrated, the RX 406 initiated an ARQ reset and subsequently received a Type 0 reset message from the TX indicating the TX 400 also initiated an ARQ reset. After determining both the RX and the TX initiated ARQ reset procedures, the RX ignores the Type 0 reset message received from the TX. The RX, then, proceeds with the RX initiated ARQ reset receiving a Type 1 reset message from the TX and, in response, sending a Type 2 reset message to the TX.
FIG. 11 illustrates example operations 1100 for ignoring both of the ARQ resets previously initiated by the TX and the RX when it is determined that both the RX and the TX initiated independent ARQ reset procedures. Operations 1100 may be performed by either the RX or the TX when performing ARQ reset procedures.
Operations 1100 begin, at 1102 , with a device receiving an automatic repeat request (ARQ) Type 0 reset message. At 1104 , the device may determine if both it and its compliment (i.e., both the receiver (RX) and the transmitter (TX)) have initiated ARQ reset procedures.
If both the RX and the TX have initiated ARQ reset procedures, the device, at 1106 , may ignore both the TX and the RX initiated ARQ reset procedures and initiate another ARQ reset.
FIG. 12A illustrates an example in which the transmitter 400 is the device employing operations 1100 . As illustrated, the TX 400 initiated an ARQ reset and subsequently received a Type 0 reset message from the RX indicating the RX 406 also initiated an ARQ reset. After determining both the RX and the TX initiated ARQ reset procedures, the TX may abandon both the TX initiated ARQ reset and the RX initiated ARQ reset and, after an appropriate time, initiates another ARQ reset. Being a TX initiated ARQ reset, the subsequent ARQ reset procedures may include the TX sending a Type 0 reset message to the RX and receiving a Type 1 reset message from the RX in response.
FIG. 12B illustrates an example in which the receiver 406 is the device employing operations 1100 . As illustrated, the RX 406 initiated an ARQ reset and subsequently received a Type 0 reset message from the TX indicating the TX 400 also initiated an ARQ reset. After determining both the RX and the TX initiated ARQ reset procedures, the RX ignores both the TX initiated ARQ reset and the RX initiated ARQ reset and, after an appropriate time, initiates another ARQ reset. Being an RX initiated ARQ reset, the subsequent ARQ reset procedures may include the RX sending a Type 0 reset message to the TX, receiving a Type 1 reset message from the TX in response, and providing an additional message to the TX in the form of a Type 2 reset message.
The various operations of methods described above may be performed by various hardware and/or software component(s) and/or module(s) corresponding to means-plus-function blocks illustrated in the Figures. Generally, where there are methods illustrated in Figures having corresponding counterpart means-plus-function Figures, the operation blocks correspond to means-plus-function blocks with similar numbering. For example, blocks 702 - 706 illustrated in FIG. 7 correspond to means-plus-function blocks 702 A- 706 A illustrated in FIG. 7A . Similarly, blocks 902 - 906 illustrated in FIG. 9 and blocks 1102 - 1106 illustrated in FIG. 11 correspond to means-plus-function blocks 902 A- 906 A illustrated in FIG. 9A and means-plus-function blocks 1102 A- 1106 A illustrated in FIG. 11A , respectively.
As used herein, the term “determining” encompasses a wide variety of actions. For example, “determining” may include calculating, computing, processing, deriving, investigating, looking up (e.g., looking up in a table, a database or another data structure), ascertaining and the like. Also, “determining” may include receiving (e.g., receiving information), accessing (e.g., accessing data in a memory) and the like. Also, “determining” may include resolving, selecting, choosing, establishing and the like.
Information and signals may be represented using any of a variety of different technologies and techniques. For example, data, instructions, commands, information, signals and the like that may be referenced throughout the above description may be represented by voltages, currents, electromagnetic waves, magnetic fields or particles, optical fields or particles or any combination thereof.
The various illustrative logical hardware blocks, modules and circuits described in connection with the present disclosure may be implemented or performed with a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array signal (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, but in the alternative, the processor may be any commercially available processor, controller, microcontroller or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core or any other such configuration.
The steps of a method or algorithm described in connection with the present disclosure may be embodied directly in hardware, in a software module executed by a processor or in a combination of the two. A software module may reside in any form of storage medium that is known in the art. Some examples of storage media that may be used include RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, a hard disk, a removable disk, a CD-ROM and so forth. A software module may comprise a single instruction, or many instructions, and may be distributed over several different code segments, among different programs and across multiple storage media. A storage medium may be coupled to a processor such that the processor can read information from, and write information to, the storage medium. In the alternative, the storage medium may be integral to the processor.
The methods disclosed herein comprise one or more steps or actions for achieving the described method. The method steps and/or actions may be interchanged with one another without departing from the scope of the claims. In other words, unless a specific order of steps or actions is specified, the order and/or use of specific steps and/or actions may be modified without departing from the scope of the claims.
The functions described may be implemented in hardware, software, firmware, or any combination thereof If implemented in software, the functions may be stored as one or more instructions on a computer-readable storage apparatus. A storage media may be any available media that can be accessed by a computer or processor. By way of example, and not limitation, such computer-readable media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to carry or store desired program code in the form of instructions or data structures and that can be accessed by a computer. Disk and disc, as used herein, includes compact disc (CD), laser disc, optical disc, digital versatile disc (DVD), floppy disk and Blu-ray® disc where disks usually reproduce data magnetically, while discs reproduce data optically with lasers.
Software or instructions may also be transmitted over a transmission medium. For example, if the software is transmitted from a website, server, or other remote source using a coaxial cable, fiber optic cable, twisted pair, digital subscriber line (DSL), or wireless technologies such as infrared, radio, and microwave, then the coaxial cable, fiber optic cable, twisted pair, DSL, or wireless technologies such as infrared, radio, and microwave are included in the definition of transmission medium.
Further, it should be appreciated that modules and/or other appropriate means for performing the methods and techniques described herein, such as those illustrated in the Figures, can be downloaded and/or otherwise obtained by a mobile device and/or base station as applicable. For example, such a device can be coupled to a server to facilitate the transfer of means for performing the methods described herein. Alternatively, various methods described herein can be provided via a storage means (e.g., random access memory (RAM), read only memory (ROM), a physical storage medium such as a compact disc (CD) or floppy disk, etc.), such that a mobile device and/or base station can obtain the various methods upon coupling or providing the storage means to the device. Moreover, any other suitable technique for providing the methods and techniques described herein to a device can be utilized.
It is to be understood that the claims are not limited to the precise configuration and components illustrated above. Various modifications, changes and variations may be made in the arrangement, operation and details of the methods and apparatus described above without departing from the scope of the claims. | Systems and methods for handling automatic repeat request (ARQ) resets are described. A first device may receive a message initiating an ARQ reset procedure transmitted by a second device. The first device may determine if both the first and second devices have initiated an ARQ reset procedure. The first device may take action to limit a loss of blocks of data exchanged between the first and second devices, if both the first and second devices have initiated an ARQ reset procedure. | 7 |
BACKGROUND
1. Field
Embodiments of the invention relate to the field of digital camera modules; and more specifically, to structures for setting the initial focus position during factory assembly.
2. Background
Many portable electronic devices, such as mobile cellular telephones, include a digital camera. The lenses for such cameras must be compact to fit within the case of the portable electronic device. At the same time there is a desire to provide an increasingly high quality camera function in these devices. To provide a higher quality image, some cameras found in portable electronic devices provide an autofocus feature and/or an adjustable iris to control exposure.
An image sensor, lens, and actuators for the lens are typically assembled into a camera module. The lens may be mounted in a actuator that moves the lens along its optical axis to change the distance between the lens and the image sensor. This changes the focal distance of the camera and allows a sharper image to be obtained for subjects over a greater range of distances from the camera. One such lens moving mechanism for moving a lens is a voice coil motor. Voice coil motors are relatively complex assemblies with a number of parts. Voice coil motors also consume a significant amount of power. The addition of an adjustable iris further increases mechanical complexity and power consumption in the camera module.
It would be desirable to provide a camera module that provides a focus actuator and adjustable iris with a structure that reduces mechanical complexity and power consumption.
SUMMARY
An embodiment of the invention described here is an artificial muscle or EAP actuator that also provides a variable aperture, for use with moveable camera imaging optics. An electrode arrangement is formed in an EAP structure that may achieve both camera optics displacement (actuation) and variable aperture functions.
The above summary does not include an exhaustive list of all aspects of the present invention. It is contemplated that the invention includes all systems and methods that can be practiced from all suitable combinations of the various aspects summarized above, as well as those disclosed in the Detailed Description below and particularly pointed out in the claims filed with the application. Such combinations have particular advantages not specifically recited in the above summary.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described with reference to the drawings summarized below. The embodiments of the invention are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to “an” or “one” embodiment of the invention in this disclosure are not necessarily to the same embodiment, and they mean at least one.
FIG. 1 is a pictorial view of a camera module that embodies the invention.
FIG. 2 is an exploded view of the camera module of FIG. 1 , showing the sub-assemblies of the module.
FIG. 3 is a cross-section view of the camera module taken along section line 3 - 3 in FIG. 1 .
FIG. 4 is an exploded pictorial view of an exemplary artificial muscle actuator structure.
FIG. 5 is a bottom view of the exemplary artificial muscle actuator structure looking from the image sensor toward the lens.
FIG. 6 is a plan view of the top side of a signal terminal ring.
FIG. 7 is a plan view of the bottom side of the signal terminal ring shown bonded to the artificial muscle actuator.
FIG. 8 is a further exploded view of the camera module of FIG. 2 , showing component parts of the sub-assemblies.
FIG. 9 is a plan view of the top side of the assembly focus ring.
FIG. 10 is a plan view of the bottom side of the assembly focus ring.
FIG. 11 is a plan view of the top side of the base assembly.
FIG. 12 is a side view of the assembly focus ring on the threaded portion of the base assembly.
DETAILED DESCRIPTION
Several embodiments of the invention with reference to the appended drawings are now explained. Whenever the shapes, relative positions, and other aspects of the parts described in the embodiments are not clearly defined, the scope of the invention is not limited only to the parts shown, which are meant merely for the purpose of illustration. Also, while numerous details are set forth, it is understood that some embodiments of the invention may be practiced without these details. In other instances, well-known circuits, structures, and techniques have not been shown in detail so as not to obscure the understanding of this description.
In the following description, reference is made to the accompanying drawings, which illustrate several embodiments of the present invention. It is understood that other embodiments may be utilized, and mechanical compositional, structural, electrical, and operational changes may be made without departing from the spirit and scope of the present disclosure. The following detailed description is not to be taken in a limiting sense, and the scope of the embodiments of the present invention is defined only by the claims of the issued patent.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. Spatially relative terms, such as “beneath”, “below”, “lower”, “above”, “upper”, and the like may be used herein for ease of description to describe one element's or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the exemplary term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
As used herein, the singular forms “a”, “an”, and “the” are intended to include the plural forms as well, unless the context indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising” specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.
FIG. 1 is a pictorial view of a camera module 100 that embodies the invention. FIG. 2 is an exploded view of the camera module 100 , showing the sub-assemblies of the module. A base assembly 220 supports an optical assembly 210 that is covered by a shield 200 . The base assembly 220 provides a threaded portion 222 to mate with a corresponding threaded portion of an assembly focus ring 212 of the optical assembly 210 . The threaded connection between the base assembly 220 and the optical assembly 210 allows the optical assembly to be focused on an image sensor in the base assembly during the manufacturing process as will be further described below.
FIG. 3 is a cross-section view of the camera module 100 , taken along section line 3 - 3 in FIG. 1 . The base assembly 220 may include a substrate 316 (e.g., a printed circuit carrier such as a flex circuit) that supports an image sensor 318 and a cover glass 314 , which may be an infrared cut filter that reduces the amount of infrared light that reaches the image sensor. A base frame 312 may be assembled to the substrate 316 to provide the aforementioned threaded portion 222 and electrical tracks as will be further described below. The base frame 312 may include an opening that allows light from a scene to reach the active pixel area of the image sensor 318 . The base frame 312 may be made of an electric insulator material such as plastic. If the base frame 312 is made of a sufficiently clear light transparent material, then the physical opening shown in FIG. 3 may not be needed.
The optical assembly 210 includes a lens assembly 306 that provides the imaging optics for the camera module 100 . The lens assembly 306 is supported by springs 308 that are supported in turn by the assembly focus ring 212 . The lens assembly 306 is held against the springs 308 by the artificial muscle actuator 300 that provides lens displacement for focusing as well as the variable aperture. The artificial muscle actuator 300 may be part of an autofocus lens subsystem, for example. The artificial muscle is an electroactive polymer (EAP) that exhibits a change in size or shape when stimulated by an electric field. A common terminal ring 302 and a signal terminal ring 304 provide electrical connections to the artificial muscle actuator 300 as will be further described below.
FIG. 4 is an exploded pictorial view of an exemplary artificial muscle actuator 300 structure. FIG. 5 is a bottom view of the exemplary artificial muscle actuator 300 structure looking from the image sensor 318 toward the lens 306 . In this case, the muscle structure is generally frusto-conical, and as seen in FIG. 2 , its larger lower base is attached to the assembly focus ring 212 (e.g., via a clamping mechanism). The smaller upper base of the frusto-conical structure (or frustum) has a central, generally circular opening 324 that serves as a variable aperture.
The artificial muscle may have a structure of one or more layers of silicon based polymers that react to a differential of potential between two electrodes that cover the polymer layers. This potential differential creates a sufficient electric field that activates the conductive particles of the polymer material, and creates a significant amount of force through the material to provide elongation. As a result, the structure may strain along its length proportionally to the square of the voltage input.
The strain in the artificial muscle actuator 300 is used here for at least two different purposes. An electrode arrangement is formed on the artificial muscle structure (EAP structure) that may achieve both camera lens displacement actuation and variable aperture functions.
For lens focus actuation, the artificial muscle can move a lens or other optics forward and backward (or up and down) along the imaging axis of the lens. This may yield significant cost reduction versus a voice coil actuator (VCM). The artificial muscle actuator may support large optics with improved system integration due to its generally frusto-conical shape. Power consumption may be minimal.
As a variable aperture element, the actuator may be able to change an aperture diameter of the optics in smaller f-number increments, and it can support relatively large aperture diameters thereby yielding fast optics and better low light performance. To combine lens focus actuation and variable aperture features, a “focus actuation electrode” of the muscle is separated (electrically isolated) from an “aperture electrode” that is used to provide the variable aperture.
An electroactive polymer (EAP) 402 is between positive and negative electrodes that create an electrical potential across the EAP. The muscle 402 is activated (deforms) when a sufficient electric field is created through and across the artificial muscle structure, due to sufficient voltage being applied to the opposing or complementary electrodes (formed on opposite faces of the muscle). These so-called positive and negative electrodes may be screen-printed onto the rear and front surfaces, respectively, of the EAP material, in such a way that the positive and negative electrodes substantially overlap each other to increase the electric field strength that is created between them. In one embodiment, to enable displacement of optics, the driver circuit may need to deliver around 500V to 1000V potential to the electrode, through its respective terminal, relative to ground. In one embodiment, the negative electrode of the actuator is also connected to ground.
In this example, the forward surface 404 , which is adjacent the shield 200 , is the common, negative electrode. The shield 200 is connected to ground to provide some immunity from electromagnetic interference. As best seen in bottom view of FIG. 5 , the positive focus actuation electrode has two segments 406 , 408 , each segment covering a little less than one half of the entire side surface area of the rear side of the EAP frustum 402 closest to the image sensor 318 . A “gap” 510 is formed between the two segments that may extend from one edge of the base, up to the tip and then down to an opposite edge of the base, as shown in the bottom view of FIG. 5 .
The positive aperture electrode 410 , which in this case has a single segment, lies in the gap 510 . In this example, the positive aperture electrode 410 has two arms that extend down from the tip of the frustum on opposite sides, to opposing edges of the base of the frustum. As also seen in FIG. 5 , the positive aperture electrode 410 covers essentially the entire surface area of the tip (with the central opening therein that serves as the variable aperture). Note however that the particular arrangement of the electrodes shown in FIGS. 4 and 5 is just one example of how the positive electrode (actuation and aperture portions) can be formed on the inner or rear face of a frusto-conical muscle. Other electrode patterns are possible.
A focusing force F 1 may be produced by the actuator 300 in its non-energized state, where F 1 may be substantially along the imaging axis in a so-called rearward direction that moves the lens assembly 306 toward the image sensor 318 . An opposing force F 2 is produced by the spring 308 that urges the lens assembly 306 away from the image sensor 318 . When the actuator 300 deforms in response to a potential difference between the common, negative electrode 404 and the positive focus actuation electrode 406 , 408 , the focusing force F 1 is reduced allowing the opposing force F 2 produced by the spring 308 to move the lens assembly 306 away from the image sensor 318 . The forces act upon the lens assembly 306 , in which the lenses may be rigidly fixed, to move the lens assembly forward and backward as necessary for focusing an image on the image sensor 318 .
A variable aperture function may be produced by the actuator 300 deforming in response to a potential difference between the common, negative electrode 404 and the positive aperture electrode 410 . As the annular portion at the tip of the EAP frustrum deforms in response to an increasing potential difference delta P as distributed to the aperture electrodes, the circular opening 324 decreases in diameter, providing a higher f-number for the variable aperture.
FIG. 3 depicts an example of the infinity lens position that can be obtained from the actuator when not energized. In this case, the artificial muscle is under pre-tension (material elasticity in the side surface of the frustum in the longitudinal direction or along a length direction of the frustum), when it is not active. In this state, this pre-tension is compressing the spring mechanism (spring loading). Now, when the potential difference delta P as distributed to the actuator electrodes has been increased sufficiently, the pre-tension of the muscle releases, thereby allowing the lens barrel to be pushed up away from the image sensor under the spring loading. The shield 200 may provide a hard stop that defines the maximum actuator stroke possible.
The infinity lens position obtained from the actuator when not energized is typically set when the camera module is assembled. This may be accomplished by rotating the assembly focus ring 212 at the lower end of the artificial muscle actuator 300 to adjust the distance between the optical assembly 210 and the image sensor 318 by the screw action between the threaded portion of the assembly focus ring 212 with the corresponding threaded portion 222 of the base 312 .
The near end of the artificial muscle actuator 300 may be fixed against the assembly focus ring 212 by capturing the near end between the common terminal ring 302 and the signal terminal ring 304 . The terminal rings are, in turn, attached to the assembly focus ring 212 . The assembly focus ring 212 is coupled to the base 312 by engaging the threaded portion of the assembly focus ring 212 with the corresponding threaded portion 222 of the base.
FIG. 6 is a plan view of the top side of the signal terminal ring 304 , which may be bonded to the artificial muscle actuator 300 by a conductive adhesive such as epoxy or tape. The signal terminal ring body 600 may be made of a non-conductive material such as a glass fiber and epoxy composite. The signal terminal ring body 600 may include features such as tabs 602 to facilitate orienting and holding the signal terminal ring during assembly.
A number of conductive pads are provided on the top side of the signal terminal ring 304 to provide electrical connections to the positive focus electrodes on the lower surface of the artificial muscle actuator 300 . The exemplary signal terminal ring 304 provides two upper conductive pads 604 to be coupled to the two segments 406 , 408 of the positive focus actuation electrode. The exemplary signal terminal ring 304 also provides two upper conductive pads 606 to be coupled to the two ends 310 of the positive aperture electrode 410 .
FIG. 7 is a plan view of the bottom side of the signal terminal ring 304 shown bonded to the artificial muscle actuator 300 . A number of conductive pads are provided on the bottom side of the signal terminal ring 304 to provide electrical connections from the positive focus electrodes on the lower surface of the artificial muscle actuator 300 to the exemplary signal terminal ring 304 . The terminal ring provides four lower conductive pads 704 to be coupled to the two segments 406 , 408 of the positive focus actuation electrode. The exemplary signal terminal ring 304 also provides two lower conductive pads 706 to be coupled to the two ends of the positive aperture electrode 410 . The upper and lower conductive pads are electrically coupled, such as by vias 710 , that provide an electrical path across the signal terminal ring body 600 .
The signal terminal ring 304 is mechanically and electrically coupled to the assembly focus ring 212 .
It will be seen in the exemplary signal terminal ring 304 that the lower conductive pads on the bottom side of the signal terminal ring are smaller and more widely separated than the corresponding upper conductive pads on the top side of the signal terminal ring. This may facilitate making electrical connections to the assembly focus ring 212 .
The lower conductive pads are arranged to cooperate with conductive pads on the base 312 so that at least one lower conductive pad is aligned with a corresponding base conductive pad for each of the positive electrodes regardless of the angular position of the signal terminal ring 304 .
FIG. 8 is a further exploded view of the camera module 100 , showing component parts of the sub-assemblies. The base assembly 220 may include the substrate 316 (e.g., a printed circuit carrier such as a flex circuit) that supports the image sensor 318 and the cover glass 314 , which may be an infrared cut filter that reduces the amount of infrared light that reaches the image sensor. The base frame 312 may be assembled to the substrate 316 to provide the threaded portion 222 and electrical tracks as will be further described below. The base frame 312 may include an opening or be made of a sufficiently clear light transparent material to allow light from a scene to reach the active pixel area of the image sensor 318 .
The optical assembly 210 includes the lens assembly 306 that provides the imaging optics for the camera module 100 . The lens assembly 306 is supported by springs 308 that are supported in turn by the assembly focus ring 212 . The lens assembly 306 is held against the springs 308 by an artificial muscle actuator 300 that provides lens displacement for focusing as well as a variable aperture. The artificial muscle actuator 300 may be part of an autofocus lens subsystem, for example. The artificial muscle is an electroactive polymer (EAP) that exhibits a change in size or shape when stimulated by an electric field. A common terminal ring 302 and a signal terminal ring 304 provide electrical connections to the artificial muscle actuator 300 .
The camera module 100 is assembled by assembling the component parts into the sub-assemblies of the base assembly 220 , the optical assembly 210 , and the shield 200 , which may be a single component. The optical assembly 210 is first coupled to the base assembly 220 . The optical assembly 210 is coupled to the base assembly 220 by the threaded connection between the assembly focus ring 212 and the threaded portion 222 of the base assembly. The threaded connection allows the lens assembly 306 to be focused on the image sensor 318 during the assembly process to provide a reference focal position for the autofocus system. The shield 200 is then coupled to the base assembly 220 to enclose the optical assembly 210 and form the camera module 100 .
It is also necessary to electrically couple the optical assembly 210 to the base assembly 220 to provide the electrical signals that actuate the artificial muscle actuator 300 . At least two terminals 820 , 822 are formed on the base frame 312 , to bring a differential of potential up to the electrodes 406 , 408 , 410 of the artificial muscle actuator 300 . One terminal 820 may be connected to the focus actuation electrode 406 , 408 . Another terminal 822 may be connected to the aperture electrode 410 . The two terminals 820 , 822 may be driven by separately controllable driver circuits. Each terminal may be electrically connected to a driver circuit (not shown) through conductive traces or routes (not shown) in the substrate 316 , which produces sufficient voltage needed for the desired deformation of the artificial muscle actuator 300 .
FIG. 9 is a plan view of the top side of the assembly focus ring 212 . The top side of the assembly focus ring is immediately adjacent the bottom side of the signal terminal ring 304 as seen in FIG. 7 . The signal terminal ring 600 may be mechanically aligned to the assembly focus ring 212 by engaging features on the signal terminal ring, such as tabs 602 , with mating features on the assembly focus ring, such as notches 902 . This may hold the signal terminal ring 304 in the proper orientation on the assembly focus ring 212 during assembly. The conductive pads 704 , 706 on the signal terminal ring 304 face corresponding conductive pads 904 , 906 on the assembly focus ring 212 . The corresponding conductive pads are mechanically and electrically coupled such as by soldering or by a conductive adhesive such as epoxy or tape.
There are at least two conductive pads 904 , 906 on the assembly focus ring 212 , at least one of which is coupled to the focus actuation electrode 406 , 408 and at least one other of which is coupled to the aperture electrode 410 . If there are two or more conductive pads on the assembly focus ring 212 that are coupled to the same electrode on the artificial muscle actuator 300 , the conductive pads on the assembly focus ring may be electrically coupled by an electrical path 905 on the assembly focus ring.
FIG. 10 is a plan view of the bottom side of the assembly focus ring 212 . The bottom side of the assembly focus ring is immediately adjacent the base assembly 220 . The conductive pads 904 , 906 on the assembly focus ring 212 extend onto the bottom side of the assembly focus ring. The conductive pads 904 , 906 may be on a beveled outside surface of the bottom side of the assembly focus ring as best seen in FIG. 3 . The conductive pads 904 , 906 on the bottom side of the assembly focus ring 212 are arranged to cover a majority of the circumference of the assembly focus ring. The conductive pads 904 , 906 on the bottom side of the assembly focus ring 212 are further arranged such that each of the at least two conductive pads 904 , 906 on the assembly focus ring 212 covers more than 90 degrees of total arc on the circumference of the assembly focus ring.
FIG. 11 is a plan view of the top side of the base assembly 220 . The top side of the base assembly is immediately adjacent the bottom side of the assembly focus ring 212 as seen in FIG. 10 . The optical assembly 210 is mechanically coupled to the base assembly 220 by the threaded engagement of the assembly focus ring 212 on the threaded portion 222 of the base assembly. The optical assembly 210 is rotated relative to the base assembly 220 to adjust the initial focus of the camera module 100 during the assembly process.
At least two terminals 820 , 822 are formed on the base frame 312 , to bring a differential of potential up to the electrodes 406 , 408 , 410 of the artificial muscle actuator 300 . As seen in FIG. 11 , the terminals 820 , 822 are distributed on the base frame 312 such that each of the two terminals is provided at multiple points around the circumference. For example, in the embodiment illustrated, each of the two terminals is provided at six places around the circumference of the threaded portion 222 of the base assembly 312 . The terminals may be advantageously arranged to lie in the four corner regions of a generally square base frame 312 .
The arrangement of the conductive pads 904 , 906 on the bottom side of the assembly focus ring 212 and the arrangement of the terminals 820 , 822 on the base frame 312 are such that at least one of the conductive pads on the bottom side of the assembly focus ring will be adjacent at least one corresponding terminal on the base frame regardless of the relative orientation of the optical assembly 210 to the base assembly 220 . When the optical assembly 210 is correctly focused, at least one of the conductive pads on the bottom side of the assembly focus ring is mechanically and electrically coupled to an adjacent corresponding terminal on the base frame 312 for each of the two terminals on the base frame.
FIG. 12 is a side view of the 212 on the threaded portion 222 of the base assembly. The corresponding conductive pads and terminals are mechanically and electrically coupled 1104 such as by soldering or by an electrically conductive adhesive such as silver conductive epoxy. This coupling provides both an electrical path for the electrical signals that actuate the artificial muscle actuator 300 and a mechanical fixing of the assembly focus of the optical assembly 210 on the image sensor 318 in the base assembly 220 . It will be appreciated that beveling at least one of the corresponding conductive pads and terminals provides a V-shaped region, which may be advantageous for the coupling of the pads and terminals.
Assembly of the camera module 100 is completed by placing the shield assembly 200 over the optical assembly 210 . The shield assembly is mechanically and electrically coupled to the shield to terminals 224 on the base assembly 220 . The shield and terminals are mechanically and electrically coupled such as by soldering or by a conductive adhesive such as epoxy or tape. This coupling provides both an electrical path for the common electrical signal that actuates the artificial muscle actuator 300 and a mechanical fixing of the shield 200 to the base assembly 220 . The shielding structure 200 may be electrically grounded through the substrate 316 . The shielding structure 200 may provide shielding against electromagnetic interference.
For purposes of explanation, specific embodiments were described to provide a thorough understanding of the present invention. These should not be construed as limiting the scope of the invention but merely as illustrating different examples and aspects of the invention. It should be appreciated that the scope of the invention includes other embodiments not discussed in detail above. Various other modifications, changes, and variations which will be apparent to those skilled in the art may be made in the arrangement, operation, and details of the systems and methods of the present invention disclosed herein without departing from the spirit and scope of the invention as defined in the appended claims. Therefore, the scope of the invention should be determined by the claims and their legal equivalents. Such equivalents include both currently known equivalents as well as equivalents developed in the future, i.e. any elements developed that perform the same function, regardless of structure. Furthermore, no element, component, or method step is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims.
While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention is not limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those of ordinary skill in the art. The description is thus to be regarded as illustrative instead of limiting. | A camera module includes an image sensor having a first threaded portion. A lens assembly includes an electro-active polymer (EAP) structure having a frusto-conical shape with an opening formed in the tip. A lens is secured to a lens holder that is attached to the EAP structure surrounding the opening. A first electrode is attached to a rear face of the EAP structure and extends along a side. A second electrode is attached to the rear face of the EAP structure along the tip. A base frame is attached to the base of the EAP structure. The base frame includes a second threaded portion that engages the first threaded portion, joining the lens assembly to the image sensor assembly and allowing the lens assembly to be rotated relative to the image sensor to adjust the distance between the lens assembly and the image sensor to establish a default focal distance. | 7 |
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